Operations and Service Manual

LM45/55/75/90
Operations and Service

Manual
This page is intentionally blank.
Accumulators
IMPORTANT NOTE
• These two accumulators must be fitted to the Power Pack before

this drill is started.
• The 0.35L accumulator is connected to the pilot pressure line PP7.

It assists in maintaining a constant pilot pressure.
Accumulator 0.35L
• The 0.075L accumulator is fitted directly into the back of the M4 valve
bank. It screws into the MB port on the rotation section and is used
to assist in maintaining a constant rotation speed.
Accumulator 0.75L
Limited Warranty
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.
Capital Equipment. Boart Longyear warrants that the capital equipment

manufactured by it is free from defects in materials and workmanship for a period
equal to the lesser of (i) one (1) year after the date of shipment, or (ii) the initial
1,000 operating hours. Boart Longyear warrants for a period of six (6) months
after the performance of related services that such services are performed in a
professional and workmanlike manner.
General Terms. Boart Longyear further warrants that, to the extent applicable,
as of the date of shipment or performance, all goods manufactured by it and
services performed shall conform to the written specifications agreed between the
parties. THIS IS BOART LONGYEAR’S ONLY WARRANTY. BOART LONGYEAR
MAKES NO OTHER WARRANTY, INCLUDING WITHOUT LIMITATION, ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. As a condition to Boart Longyear’s warranty obligations, any goods
claimed to be defective under the foregoing warranty must be returned to the
facility designated by Boart Longyear, which return shall be made promptly upon
Purchaser’s discovery of the alleged defect. With respect to consumable products
purchased through an authorized Boart Longyear distributor, the party making the
warranty claim must also deliver to Boart Longyear reasonable evidence of the
date of purchase. Boart Longyear shall perform its examination of the goods so
returned by Purchaser and shall report the results of its examination to Purchaser
within thirty (30) days following its receipt of such goods from Purchaser, or, if
longer time is required to complete such examination, within such time as would
be required through the exercise of reasonable diligence. As a further condition
to Boart Longyear’s obligations hereunder for breach of warranty, Purchaser
shall offer its reasonable cooperation and assist Boart Longyear in the course of
Boart Longyear’s review of any warranty claim. If requested by Purchaser, Boart
Longyear will promptly repair or replace at Boart Longyear’s expense goods that
are non-conforming according to Boart Longyear’s warranty as set forth herein. All
removal and installation of goods shall be at Purchaser’s expense. Boart Longyear
reserves the right to reimburse Purchaser for an amount equal to the purchase
price of any defective goods in lieu of providing repaired or replacement goods.
Anything contained herein to the contrary notwithstanding, in no event shall Boart
Longyear be liable for breach of warranty or otherwise in any manner whatsoever
for: (i) normal wear and tear; (ii) corrosion, abrasion or erosion; (iii) any goods,
components, parts, software or services which, following delivery or performance
by Boart Longyear, has been subjected to accident, abuse, misapplication,
modification, improper repair, alteration, improper installation or maintenance,
neglect, or excessive operating conditions; (iv) defects resulting from Purchaser’s
specifications or designs or those of its contractors or subcontractors other than
Boart Longyear; (v) defects associated with consumable parts or materials, the
lifetime of which is shorter than the warranty period set forth in this Section; (vi)
defects associated with Purchaser’s specifications or designs or those of its
contractors or subcontractors other than Boart Longyear; (vii) defects resulting
from the manufacture, distribution, promotion or sale of Purchaser’s own products;
or (viii) accessories of any kind used by the Purchaser which are not manufactured
by or approved by Boart Longyear.
Sourced Goods. If the defective parts or components are not manufactured
by Boart Longyear, the guarantee of the manufacturer of those defective
parts or components is accepted by the Purchaser and is the only guarantee
given to the Purchaser in respect of the defective parts or components.
Boart Longyear agrees to assign to the Purchaser on request made by the
Purchaser the benefit of any warranty or entitlement to the defective parts or
components that the manufacturer has granted to Boart Longyear under any
contract or by implication or operation of law to the extent that the benefit of
any warranty or entitlement is assignable.
Boart Longyear Pty Ltd

919 Marion Road, Mitchell Park
South Australia 5043 Australia
Telephone +618 8375 8375
Fax +618 8377 0534
© Boart Longyear 2008

Ordering and Returning Parts
Ordering Parts
The following procedure will expedite the filling of your parts order, eliminate
delays and assure correct replacement parts:
1 List the model and serial number of the drill.

2 State exact quantity required.
3 Specify description and part number as shown in parts manual.
4 Specify method of shipment, i.e. Parcel Post, Express, Freight; and for
Overseas shipment, Air Freight, Air Parcel Post, or Ocean Freight.
All parts are priced F.O.B., our factory and separate charge will be made for
transportation and export packing.
Returning Parts
1 If you desire to return parts, whether for repairs, replacement or warranty,
an email or fax should first be sent to the Boart Longyear Sales Manager
in your region.
It should specify quantities and part numbers, and model and serial
number of the product, as well as the reason for requesting the return.
2 DO NOT ship parts until authorization and shipping instructions are
received.
3 All parts returned must be prepaid.
Recommended Tool Kit
In Hex Socket Set A94554
Allen Key Set - Metric A93765
Socket Extension Bar ½” Drive A56402
Offset Socket Handle ½” Drive A56403
Combination Ring and Open Ended Spanner 10AF A56404
13AF A56405
16AF A80857
17AF A56406
19AF A56407
24AF A80858
30AF A80859
36AF A80860
5/16”AF A56408
9/16”AF A56409
11/16”AF A56410
7/8”AF A56411
1”AF A56412
1 1/8”AF A56413
1 ¼”AF A56414
Allen Key ½”AF A56415
Double Open Ended Flare Nut Spanner 9/16”AF A56416
Tool Box A56417
Options
Gear Puller - HQ Rotation Unit A59484
Fitting Kit A56445
Flow Meter Kit - Hydraulic Commissioning A80594
Spring Pack Assembly Tool A94556
Front Oil Seal Installation Tool - HQ Rotation Unit A602025
Important Note
Do not start or operate the drill until you have read this manual and
understand its contents.
Hazard Signal Words

Hazard signal words are used throughout this manual. They appear in the
narrow left-hand column of numerous pages and, with their additional text
description, are intended to alert the reader to the existance and relative
degree of a hazard.
DANGER indicates an imminently hazardous situation which, if not avoided,

will result in serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided,

could result in serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided,

may result in minor or moderate injury.
BOART LONGYEAR
TABLE of CONTENTS
Section 1 Drill Introduction and Operation
1-2 The Power Pack
1-4 The Electric Starter
1-6 The Control Panel
1-9 Operating the Diesel Power Pack
1-11 Operating the Electric Power Pack
1-13 Operating Both Power Packs
1-17 Rod Handling
1-23 Drilling Operations
Section 2 Commissioning Procedure

2-2 Hydraulic Hose Connections
2-3 Prestart Checks
2-6 Start Up
2-7 Purging (Flushing) and Pilot Bleeding
2-12 Function Tests
Section 3 Servicing the Hydraulic System

3-2 Hydraulic Reservoir
3-3 Oil Selection Chart
3-4 Hydraulic Filters
3-5 Filter Hints
Section 4 BQ Rod Clamp

4-2 Introduction
4-3 Rod Clamp Jaw Replacement
4-4 Rod Clamp Guide Bushing Replacement
4-5 Spring Pack Replacement
4-7 Rod Clamp Hydraulic Piston
4-8 Rod Clamp Troubleshooting
Section 4 HQ Mk2 Rod Holder

4-2 Introduction
4-3 Rod Holder Jaw Replacement
4-4 Rod Holder Guide Bush Replacement
4-7 Rod Holder Hydraulic Piston
4-8 Rod Holder Troubleshooting
Section 4 PQ Rod Holder

4-2 Introduction
4-4 Rod Holder Guide Bushing Replacement
4-5 Spring Pack Inspection/Replacement
BOART LONGYEAR Table of Contents (cont’d)
Section 5 BQ Rotation Unit and Chuck

5-2 Introduction
5-3 Gearbox Lubrication and Maintenance
5-4 Chuck Jaw Replacement
5-5 Guide Bushing Replacement – Front
5-6 Guide Bushing Replacement – Rear
5-7 Gear Set Replacement in Rotation Unit
5-9 Gear Replacement on Hydraulic Motor
5-10 Chuck Disassembly
5-13 Rotation Unit Disassembly
5-15 Rotation Unit Preassembly Checks
5-16 Rotation Unit Reassembly
5-18 Important Note for Rotary Seal
Rotation Unit Rotary Seal Test
5-21 Break Out Device Operation
5-22 Break Out Device Disassembly
5-23 Setting Sequence Valve Pressure
5-24 Rotation Unit Troubleshooting
Section 5 HQ Mk2 Rotation Unit and Chuck

5-2 Introduction
5-5 Guide Bush Replacement
5-7 Oil Seal Replacement
5-14 Gear Replacement in Hydraulic Motor
5-15 Chuck Cylinder Overhauling
5-19 Breakout Device Servicing
5-27 Rotation Unit Maintenance
5-33 Rotation Unit Rotary Seal Test
Section 6 400 Series (Direct Coupled) Feed Frame

6-2 Introduction
6-3 Assembling the Feed Frame
6-4 Feed Frame Maintenance
6-5 Adjusting the Carriage
6-7 Replacing the Carriage Wear Strips
6-9 Carriage Side Plate Disassembly
6-10 Removing the Feed Cylinder
6-11 Removing the Cylinder Trunnions
6-12 Replacing the Feed Cylinder
6-13 Feed Cylinder Disassembly
6-16 Cylinder Reassembly
BOART LONGYEAR Table of Contents (cont’d)
Section 6 700 Series (Direct Coupled) Feed Frame

6-2 Introduction
6-10 Load Transfer Direct Linkage Disassembly
6-12 Replacing the Cylinder Support Wear Strips
6-19 Bit Weight Chart
Section 6 700 Series (Chain Coupled) Feed Frame

6-2 Introduction
Carriage Side Plate Disassembly
6-7 Carriage Side Plate Reassembly
6-8 Adjusting the Feed Chains
6-10 Chain Sheave Removal and Disassembly
Section 6 1300 Series Feed Frame

6-2 Introduction
6-3 The Cylinder Cover
6-5 The Telescopic Rod Slide
6-11 Changing the Feed Frame Push and Pull Forces
6-19 The Feed Cylinder
6-24 Feed Cylinder Reassembly
6-25 Bit Weight Charts
BOART LONGYEAR Table of Contents
Section 7 The Power Pack

7-2 Introduction
7-3 The Main Pump
7-9 Heat Exchanger
7-10 Swagelok Connections
7-12 Power Pack Troubleshooting
Section 8 The Control Panel

8-2 Introduction
8-3 Pilot Oil Unit
8-5 Directional Controls
8-6 Fine Feed Valve
Section 9 Options
9-2 Wireline Hoist
9-6 Feed Frame Positioner (FFP)
9-10 Air Blast Cooler
9-12 Water Pump
9-14 Transportation
9-16 Cuddy Sizes
9-17 Lanyard
9-18 Feed Frame Guard
9-19 Accumulator (Pilot Pressure)
Section 10 Hydrostatic Explanation

10-2 Introduction
10-2 The Main Pump
10-3 The Recirculation Pump
10-4 Main Valve Bank
10-7 Valve Manifold Blocks
10-11 Valve Module Schematic
10-12 Check Valves
10-14 Setting Valve Pressures
10-19 Setting Flow Rates
Section 11 Troubleshooting the Hydraulic System

11-2 Explanation of Inbuilt Checking System
11-4 LM45/55/75 Design Circuit Pressures and Amperes
11-5 LM45/55/75 Circuit Test Chart
11-6 LM90 Design Circuit Pressures and Amperes
11-7 LM90 Circuit Test Chart
11-8 Hydraulic Circuit Diagrams
Section 12 Drill Rig Service Schedule

12-2 Service Schedule
SECTION 1
DRILL INTRODUCTION and OPERATION

1-2 The Power Pack
1-4 The Electric Starter — Diesel Motor
1-5 The Electric Starter — Electric Motor
1-6 The Control Panel
1-9 Operating the Diesel Power Pack
Cooling Water
Control Positioning
Starting the Diesel Power Pack
Stopping the Diesel Power Pack
1-11 Operating the Electric Power Pack

Cooling Water
Control Positioning
Starting the Electric Power Pack
Stopping the Electric Power Pack
1-13 Operating Both Power Packs

Adjusting and Setting Motor Displacement
Rod Holder Calibration
Thread Making
Head Float Calibration
1-17 Rod Handling

Inserting the Core Barrel
Running Rods into the Hole
Rod Pulling
Drilling
Rechucking
Calculating Bit Weight
1-23 Drilling Operations

Down Hole Drilling
Up Hole Drilling
Horizontal Drilling
Weight: Electric Power Pack 1190 Kg

Diesel Power Pack 1800 Kg
Chapter Reference: LM55 Stub Shaft Assembly p/n 602380
LM75 Stub Shaft Assembly p/n 602031
LM90 Stub Shaft Assembly p/n 3002778
LM75D Stub Shaft Assembly p/n 30002918

PRINTED IN AUSTRALIA
© 2003 Boart Longyear Pty Ltd Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
Drill Introduction and Operations 1-
The Power Pack

1 OIL REPLENISHMENT PUMP — this hand pump pumps hydraulic fluid
into the reservoir through an inlet filter. The handle folds away when not
in use.
2 HAND PUMP FILTER — filters all inlet oil to 10 microns before entering
the hydraulic reservoir.
3 HYDRAULIC MODULE — contains the main hydraulic directional control
valves and circuitry.
4 CIRCUIT TESTING — Integrated monitoring system checks individual
main, pilot and charge pressures at any time while the machine is
running.
Note: The reservoir can be filled 5 TOW BAR SOCKET — permits a Tow Bar to be fitted to either end of
with a wide range of oils. Power Pack to allow towing from either end.
See the Oil Selection Chart on 6 HYDRAULIC RESERVOIR — has a total oil capacity of 66 litres, and is
page 3-3 to determine the oil most fitted with an indicator to show hydraulic oil level and temperature.
suited to your conditions.
7 SHACKLE HOLES — assist with slinging the Power Pack.
8 HEAT EXCHANGER — provides cooling of hydraulic oil whenever water
flow is present across Heat Exchanger.
9 FORKLIFT POCKETS — provide access for forklift blades to assist when
moving the Power Pack.
10 MAIN HYDRAULIC FILTER — maintains continual particle filtration through
a 10 micron, beta-rated element. A visual clogging indicator is fitted, which
changes colour to warn of an element servicing requirement.
11 ELECTRIC STARTER — refer to pages 1-4 and 1-5 for further details of
the electric starter fitted to the diesel motor and the electric motor in the
relevant Power Packs.
12 FUEL TANK (Diesel Power Pack only) — has a capacity of 120 litres, and
is fitted with a fuel guage on the Starter panel. The tank can be filled via
a filler port on the front right-hand side of the Power Pack.
13 DIESEL ENGINE THROTTLE (Diesel Power Pack only) — controls the
RPM of the diesel engine.
1 2 10 3 8 13
Diesel Power Pack

— Service Side
9 11 4 7
Diesel Power Pack

— Diagnostic Side
4
12
Diesel Power Pack

Weight: 1800 kg (3960 lb)
1 2 10 3 11
Electric Power Pack

(approx.) without hoses
Electric Power Pack

— Service Side
8 9 5
4 7
Electric Power Pack

— Diagnostic Side
The Electric Starter — Diesel Motor

Starter specifications, features and appearances may vary.
A typical starter fitted to a Diesel Power Pack supplied by Boart Longyear
may include the following features:
1) Fuel level guage — indicates the fuel level in the tank. It is also fitted
with a ‘Low Fuel Level’ cut-out.
2) Hour Meter — shows the total hours of engine operation. The meter
should be used to measure the time between scheduled maintenance
intervals.
3) Low Oil Level (red) — indicates that the pre-set level of the sensor in
the hydraulic tank has been activated.
4) High Oil Termerature (red) — indicates that the pre-set level of the
sensor on the hydraulic oil tank has been activated.
5) Voltage Warning lamp (red) — indicates when the alternator is
charging.
6) Fault light (red) — indicates when a fault has been detected on the
drill.
7) ON/OFF/START switch — rotating the switch clockwise will start the
diesel engine. Hold the ‘Press During Starting’ button until the red ‘Fault’
and ‘Alternator’ light go out. The switch is spring centred and will return
to the ‘On’ position when released after the engine has started. Turn
anticlockwise to stop the engine.
8) PRESS DURING STARTING button — energises the protection
ccircuits whilst starting. Release when both red ‘Fault’ and ‘Alternator’
lights go out.
9) EMERGENCY STOP button — when pressed, will immediately shut
down the drill.
10) RESET button — in the event that the ‘Emergency Stop’ button is
pressed, the ‘Reset’ button will activate the electrics and allow the
engine to start once more.
6
Diesel Starter
control panel 9
10
8
The Electric Starter — Electric Motor

A typical starter for an Electric Power Pack supplied by Boart Longyear may
include the following features:
• Main Isolator switch (on front panel) disconnects the Starter Unit from
incoming power.
• Start/Run switch initiates a Start cycle and illuminates a green lamp when
in Run mode.
• Main Stop switch — push to stop (Locks in this position — twist to
release).
• Main Display Panel for EOCR-FDM microprocessor.
In addition, six coloured lights indicate the following:
1) Under/Over Voltage; (red) indicates status of incoming power and
monitors if voltage is above or below preset level (push to reset).
Note: Factory preset maximum 2) Oil Temp High (red) indicates that the pre-set level of the sensor on
temperature is 65°C to 70°C. hydraulic tank has been activated.
Note: Factory preset level is the 3) Low Oil Level (red) indicates the pre-set level of the sensor in the
‘Low Level’ mark on the Level/ hydraulic tank has been activated.
Temp gauge on the hydraulic 4) Fault (red) indicates that a fault
tank. has been detected; check the
EOCR-FDM display for status.
5) Start/Run (green) indicates that
a Start sequence has been
initiated, or the drill has been
started and is in Run mode.
6) Full Load (orange) indicates
the electric motor is running at
full load capacity. (The EOCR-
FDM makes many calculations.
This lamp lights at 90% load,
depending on actual conditions
of the electric motor.) EOCR-FDM display
Earth Leakage Test (CONTROL) circuit tests the front panel 110 volt control
circuit is protected for Earth Leakage, and the circuit is working correctly.
Earth Leakage Test (POWER) circuit tests the Earth Leakage protection in
the power circuit is working correctly.
Pilot Break Test circuit tests incoming ‘trailing power cable’ for pilot wire
continuity.
Pilot Short Test circuit tests incoming ‘trailing power cable’ for pilot wire
continuity.
Stop switch (red) stops motor only (non-locking).
Emergency Stop stops ALL controls, and if a pilot is connected will also drop
out Main Breaker.
Note: Correct rotation of the The EOCR-FDM motor system protection unit is designed to protect electric
electrical motor is CLOCKWISE motors and connected loads accurately. This device monitors thermal
when looking at the fan end of the overload, electrical fault conditions, and incoming voltage lines continuously
electric motor. during operation for a user friendly control and protection of the electrical
system.
The EOCR-FDM digital display constantly monitors numerous readings and
settings. Consult the EOCR-FDM Manual for complete details.
The Control Panel

1 ROTATION DIRECTION CONTROL — Controls clockwise or anti-
clockwise rotation of the Chuck. Moved into the fully-forward position,
Rotation occurs when lever is when in Drilling mode, will provide maximum chuck rpm. A neutral interlock
moved. Potential for personnel
prevents unintentional operation if the drill is started in an actuated
to be trapped in rotating
mode.
equipment — ensure area is
kept clear around Rotation Unit. 2 FEED DIRECTION CONTROL — Controls forward and reverse traverse
Feed occurs when lever is for Rotation Unit Carriage. When tripping rods, the Carriage Speed
moved. Potential for personnel is proportional to the lever movement. A neutral interlock prevents
to be trapped between moving unintentional operation if the drill is started in an actuated mode.
parts — keep area clear around Actual feed rate is controlled with the feed flow control valve and the feed
Feed Frame. pressure control valve. Fast pull-back is available in the drilling mode
simply by moving the feed lever rearwards.
3 FEED SEQUENCE CONTROL — Set to either Rod Feeding or Rod Pulling
it controls the correct clamping sequence of the Chuck and Rod Clamp
when tripping rods.
4 ROD HANDLING/DRILLING CONTROL — Set to Rod Handling when
rod tripping or rechucking. In the Drilling position, closes the Chuck and
opens the Rod Clamp and converts the feed system to fine feeding for
drilling mode. It is safety interlocked with the Feed Frame Guard.
5 FEED PRESSURE CONTROL VALVE — Controls the pressure at which
the oil is fed into the Feed Cylinder whilst drilling.
6 ROD CLAMP ISOLATING VALVE — Used to isolate the Rod Clamp from
the hydraulic circuit and keep the Clamp either open or closed independent
Ensure the isolation valve is
of any other drill operation.
in ‘automatic’ at all times. It
must only be isolated ‘open’ 7 CIRCUIT PRESSURE GAUGE — Displays the pressure from a pre-
when inserting the core barrel selected circuit pressure tapping. Monitors rotation circuit pressure or
between the Chuck and Rod torque whilst drilling.
Holder to allow rods to pass
through the Rod Holder. 8 FEED PRESSURE GAUGE — Displays the pressure in the Feed Cylinder
which is controlled by the Feed Pressure Control Valve.
9 WATER PRESSURE GAUGE — Connected to the Flush Pump discharge,
will indicate the pressure at which the flushing fluid is being pumped into
the hole.
10 FEED FLOW CONTROL VALVE — Meters the oil flow returning from
the Feed Cylinder to the Reservoir. Used in conjunction with the Feed
Pressure Control Valve to set penetration rate of drill bit and to hold back
when drilling deep down holes.
11 HOLD BACK PRESSURE GAUGE — Displays the hold back pressure
in the Feed Cylinder when using the Feed Flow Control Valve.
12 WIRELINE HOIST CONTROL — Controls the hoisting or lowering
operation of the Wireline Hoist. Speed range in both directions is variable
and depends on control lever movement. Braking of the Hoist is achieved
by returning the control lever to neutral. A ‘Lift to Operate’ interlock is fitted
to the control lever and prevents accidental operation of the lever.
13 FLUSH PUMP CONTROL — Regulates the flush pump hydraulic motor
Water pump hose can ‘whip’ speed through a three-way selector, which allows the operator to select
when commencing full pump
a Metered Control Position or Full Pump Flow Position, and an Off
flow — ensure hose is firmly
Position.
restrained.
12 13a 17 7 11 8
6 9 1 2 3 4
Control Panel (fully optioned)

(approx.) with hoses
50 kg (110 lb)
(approx.) without hoses
15 16 13b 18 10 5 14
under
Control Panel cover
PP7
WL2 PP2 FC3 FC2 FC1 PP3 PP9
PT Gauge WL1 PP1 WP1 FC4 PP4 PP5 T WP

Gauge
RC0 RC1 PPX
Bulkhead — Underside View
FITTING SPANNER
SIZE
1 1/16” JIC 1 1/4” AF

Important
Always cap Hoses and fittings 7/8” JIC 1” AF
after removing hoses 3/4” JIC 7/8” AF
9/16” JIC 11/16” AF
14 ROTATION SPEED CONTROL — Used to adjust the displacement of

the Rotation Unit hydraulic motor. Turned clockwise will increase chuck
rpm and reduce torque output, whilst turning it anticlockwise will decrease
rpm and increase torque (see ‘Operating the Diesel Power Pack’ on page
1-9 or ‘Operating the Electric Power Pack’ on page 1-11 for more detailed
information).
Options
15 ROD HOLDER LOCKOUT — provides a mechanical lockout of the Rod
Holder when in ‘Automatic’ mode. On Up-holes the Rod Holder can be
Rod drop hazard if the drill
locked in ‘Automatic’ mode so as to prevent rods dropping if power fails.
shuts down and the Rod Holder
is isolated ‘open’. 16 HOSE BURST PROTECTION — in the event of a hose failure, the
Always have selector valve in
sheathes prevent oil from being sprayed onto the operator and also restrict
‘Automatic’. any moving hoses.
Be aware at all times of of 17 EMERGENCY STOP BUTTON — push to STOP. The switch locks in this
hazards associated with oil position and the diesel engine shuts down. (Twist to release.)
under pressure and moving
18 LIMIT SWITCHES — are fitted as interlocks to ensure the levers are in
hoses.
the neutral position before starting is permitted.
Operating the Diesel Power Pack

Cooling Water
A cooling water flow of 20–30 lpm must be circulated through the oil cooler.
Either connection can be used for the water inlet.
The water flow must be controlled by throttling the ingoing water supply.
The flow must not be controlled by restricting the outlet water flow as the
water pressure limit in the water tube may be exceeded. The maximum
allowable pressure in the tubes is 10 bar.
Control Positioning
1 The Rotation and Feed control levers must be in the neutral position.
Limit switches will not allow the 2 The wireline hoist control lever (if fitted) must be in neutral. The
Power Pack to start unless the water pump speed control (if fitted) must be wound fully out (anti-
controls are in neutral. clockwise) to the zero speed position, with the three position selector
in the middle or Off position.
3 The Drilling/Rod Handling selector lever must be in the Rod Handling
position.
4 The Rod Pulling/Rod Feeding selector lever may be in either position.
Starting the Diesel Power Pack

Wear the correct Personal Starter specifications, features and appearances may vary.
Protective Equipment during
this operation. 1 Check that the oil level in the hydraulic reservoir is up to the top of the
sight glass. If necessary, use the replenishment pump to add more oil.
2 Check the engine oil dipstick and, if required, top-up using the correct
grade of oil.
3 Check the Fuel level gauge and add fuel if required.
4 Check the radiator level and add more coolant if required.
Fire Hazard — refer to 5 Ensure the throttle cable is set to ‘idle’ speed.
site-specific procedures 6 Push the ‘PRESS DURING STARTING’ button on the Starter control
for engine refuelling. panel.
Refer to the site-specific
7 Turn the ignition key to the ‘ON’ position, and then continue turning to
‘Pre Start’ procedure prior to
‘crank’ the engine.
starting the Power Pack.
Before starting the equipment

8 Once the engine fires, keep the ‘PRESS DURING STARTING’ button
ensure that nobody is standing depressed until the Red ‘FAULT’ light and Red ‘ALTERNATOR’ light go
in the immediate vicinity of the out.
engine or the drill assembly. 9 Release the ‘PRESS DURING STARTING’ button and the protection
circuits are now active.
Drill Introduction and Operations 1-10
PT Pressure Gauges
10 Monitor the charge pressure and allow the power unit to run only if the
charge pressure (PT7) reaches 1–2 bar.
11 Monitor the pilot pressure gauge (PT6) and ensure the main pump stand-
by pressure is 35–40 bar.
Ensure PTI reads 35–40 bar, and PT2, PT3, PT4, and PT5 all read
zero.
12 Allow the unit to run for approximately 10 minutes and note the operating
level in the oil reservoir.
Add oil if required.
Stopping the Diesel Power Pack

1 Return all control levers to neutral and return the Rod Handling/Drilling
selector valve to the Rod Handling position.
2 Ensure engine speed is set to ‘idle’.
3 Turn the ignition key clockwise to stop the engine.
4 The diesel engine can also be stopped by pressing the Emergency Stop
on the Starter control panel or the Emergency Stop button on the main
Control Panel.
Operating the Electric Power Pack

Cooling Water
A cooling water flow of 20–30 lpm must be circulated through the oil cooler.
Either connection can be used for the water inlet.
The water flow must be controlled by throttling the ingoing water supply.
The flow must not be controlled by restricting the outlet water flow as the
water pressure limit in the water tube may be exceeded. The maximum
allowable pressure in the tubes is 10 bar.
Control Positioning
1 The Rotation and Feed control levers must be in the neutral position.
Limit switches will not allow the

2 The wireline hoist control lever (if fitted) must be in neutral. The
Power Pack to start unless the water pump speed control (if fitted) must be wound fully out (anti-
controls are in neutral. clockwise) to the zero speed position, with the three position selector
in the middle or Off position.
3 The Drilling/Rod Handling selector lever must be in the Rod Handling
position.
4 The Rod Pulling/Rod Feeding selector lever may be in either position.
Starting the Electric Power Pack

1 Check that the oil level in the hydraulic reservoir is up to the top of the
sight glass. If necessary, use the replenishment pump to add more oil.
Wear the correct Personal
Protective Equipment during 2 Turn the Main Isolator on:
this operation. a) EOCR-FDM display will activate, and readings may be accessed at
this time.
b) Under/Over Voltage light will come on for one second while the system
is checking status.
c) Full Load light and Fault light will come on for approx. 5 seconds while
the system checks and cycles through the total system protection. The
above two lights will go off when the system is ready to start.
d) Check the Stop button is in the released position (twist to release)
If any fault or condition arises that is out of preset limits, the fault lights or
the EOCR-FDM display will indicate the cause of the problem.
The EOCR-FDM and internal control circuit are protected with circuit
breakers inside the front panel of the Starter Unit.
3 Observe the fan attached to the electric motor.
Press the start button and immediately press the stop button. Failure to
start may be indicated by the phase reversal alarm which prevents the
Refer to the site-specific motor from running in the wrong direction. Phase reversal of the incoming
‘Pre Start’ procedure prior to
electrical supply is then required before starting is re-attempted.
starting the Power Pack.
4 Press the green Start button to start the Power Pack. There may be a
Before starting the equipment small delay before all three motor phases “kick in”, which is normal.
ensure that nobody is standing If the fault light and/or EOCR-FDM display indicates a Phase Reversal,
in the immediate vicinity of the
the incoming power supply has been incorrectly connected and must be
engine or the drill assembly.
reconnected correctly.
The electric motor must not be 5 When the motor starts, confirm that the direction of rotation is CLOCKWISE
run in the wrong direction. when looking at the motor fan.
IMMEDIATELY SHUT-DOWN
When the motor and starter combination is started for the FIRST
if the direction of rotation is
TIME, incorrect motor rotation MAY occur even though the phase
incorrect.
reversal alarm light is not illuminated. If this occurs, phase reversal
is required at the electric motor or phase detector after which the
motor direction and alarm system are synchronised and the phase
alarm is then ‘calibrated’ for correct motor rotation.
PT Pressure Gauges
6 Monitor the charge pressure and allow the power unit to run only if the
charge pressure (PT7) reaches 1–2 bar.
7 Monitor the pilot pressure gauge (PT6) and ensure the main pump stand-
by pressure is 35–40 bar.
Ensure PTI reads 35 –40 bar, and PT2, PT3, PT4, and PT5 all read
zero.
8 Allow the unit to run for approximately 10 minutes and note the operating
level in the oil reservoir. Add oil if required.
Stopping the Electric Power Pack

1 Return all control levers to neutral and return the Rod Handling/Drilling
selector valve to the Rod Handling position.
2 Press the red Stop button on the Power Pack.
Switch Main Isolating Switch to OFF before attempting any electrical
repairs.
Operating Both Power Packs

Adjusting and Setting Motor Displacement
The LM Drill Control Panel has a rotation speed control which permits the
maximum available chuck speed to be selected and set. Always use this
control for limiting chuck speed and not the rotation directional control
since this lever must be left in the fully-forward position to ensure full power
availability.
The hydraulic motor on the Rotation Unit also has a load sensing feature
which comes into effect once full power is being developed. This load sensing
provides for a constant speed/torque relationship irrespective of the setting
on the rotation speed control which only governs free running speed under
minimal load conditions.
Motor adjustment point

Rod Holder Calibration

Adjustment may be required to ensure that during rod handling, the chuck is
holding the drill rod before the rod clamp releases.
Valve V13 (located in the hydraulic module) allows this adjustment. Screwing
this valve inward will increase the delay time.
Rods may drop if the correct

adjustment is not maintained.
Adjust as soon as the need

becomes evident.
Rod Holder calibration adjustment

Thread Making
Different diameter rods will require differing speed to make up the rod thread.
Valve V12 (located on the bulkhead) allows this speed to be adjusted when
in rod handling. Inward adjustment will increase thread “make-up” speed.
Tighten lock nut after making any adjustments.
Thread ‘’make-up” speed adjustment

Head Float Calibration

Wear the correct Personal During the thread making and thread breaking modes, reduced system
Protective Equipment for pressure is automatically applied to the appropriate side of the feed cylinder.
this operation. This causes the rotation unit carriage to move either forwards or rearwards
in sequence to the thread pitch on the drill rods.
To adjust the speed at which the carriage floats, take the following steps:
1 Located in the power pack hydraulic module are valves V20 and V21.
Screw both of these valves fully anticlockwise to close off the flow to the
cylinder completely.
2 Select Rod Handling mode and full forward rotation. Adjust V21 (bottom)
so that the carriage moves forward approximately synchronised to the rod
Ensure area is clear when head thread pitch.
is rotating and feeding.
3 Select Rod Handling mode and full rearward rotation. Adjust V20 (top) so
that the carriage moves rearward approximately synchronised to the rod
thread pitch.
Adjustment may also be necessary when changing between upholes
and downholes.
Rod threads must always be engaged and disengaged at least half a
turn by hand to prevent cross threading.
V20
V21
Rod Handling
Inserting the Core Barrel
Use the correct Personal 1 Place the Rotation and Feed control levers in neutral and ensure the
Protective Equipment for interlocked guard is fitted.
this operation.
2 Push the Rod Handling/Drilling selector lever into the Drilling position.
3 Place the Rod Clamp isolating lever into the manual over-ride position.
4 Return the Rod Handling/Drilling selector lever to the Rod Handling

position. The Rod Clamp and Chuck will now both be open and the guard
Core barrel may fall if power can now be removed.
is lost when isolated ‘open’.
5 Insert the core barrel through the Chuck and Rod Clamp.
Possibility of core barrel falling

— use the correct manual
handling procedures.
6 With the core barrel positioned so that the core bit and reamer shell are
clear of the Rod Clamp, move the Rod Clamp isolating lever to Automatic.
The Rod Clamp will grip the core barrel.
Do not grip on core bit or reamer shell.
Running Rods into the Hole

1 Place Rotation and Carriage feed levers in neutral.
2 Push the Rod Pulling/Rod Feeding lever to Rod Feeding.
3 Pull the Drilling/Rod Handling lever to Rod Handling.
Use the correct manual 4 Manually thread additional drill rod.

handling procedures and
Personal Protective Equipment
for this operation.
5 Move Carriage Feed lever rearward and position the Chuck so the rod
joint is between the Chuck and the Rod Clamp.
Ensure area is clear of
personnel before moving 6 Return the Feed lever to neutral.
carriage or rotating head.
7 Move the Rotation lever forward and hold until the thread joint shoulders
butt.
Do not make joints up too fast as it will make them too tight.
8 Move Carriage Feed lever forward at which time the Chuck will close, the
Rod Clamp will open and the rods will be fed into the hole.
9 Pull the Feed lever to bring the Carriage rearward. The Rod Clamp will
close, the Chuck will open and the Carriage will move rearward.
personnel before moving 10 You are now ready for another feed cycle.
carriage or rotating head.
Rod Pulling
Use the correct Personal 1 Place the Rotation and Carriage Feed levers in neutral.
Protective Equipment for
2 Pull the Rod Pulling/Feeding lever to Rod Pulling.
this operation.
3 Pull the Drilling/Rod Handling lever to Rod Handling.

4 Move the Carriage Feed lever rearward at which time the Chuck will close,
personnel before moving the Rod Clamp will open and the rods will be withdrawn from the hole.
carriage or rotating head. 5 Position the rod joint between the Rod Clamp and the Chuck, but far enough
out of the Rod Clamp so that the Chuck can pass over the exposed section
of the next rod held in the Clamp.
Also ensure a minimum stroke of 75 mm remains behind the Rotation
Unit carriage. This allows the Carriage to float rearwards as the rod joint
is unscrewed.
75 mm
L L
6 Return the Feed lever to neutral.

7 Move the Rotation lever rearward to break and partially unscrew the rod
joint.
Do not completely separate the rods.
DO NOT completely separate
the rods on angled holes as the 8 Return the Rotation lever to neutral.
rods will fall through the Chuck
— manually unscrew the rod.
9 Move the Carriage Feed lever forward until the Rotation Unit passes over
the rod joint.
10 Return the Feed lever to neutral.
Use the correct manual

11 Manually unscrew and remove the rod.
handling procedures for
this operation.
Drilling
1 Place the Rotation and Carriage Feed levers in neutral.
2 Push the Rod Pulling/Feeding lever to Rod Feeding.
3 Pull the Rod Handling/Drilling lever to Rod Handling.

4 Move the Feed lever rearward and move the Carriage to the rear end of
the Feed Frame.
5 Return the Feed lever to neutral and ensure the safety guard has been
fitted.
Use correct manual handling
procedures for guard. 6 Push Rod Handling/Drilling selector to Drilling.
7 Start up Flushing Fluid circulation by winding in the Pump control valve
on the Control Panel, then move the three position selector forward to the
Regulated position. Adjust the required flow via the control valve.
8 Close the Feed Flow Control Valve on the Control Panel by winding fully
inwards.
9 Move the Rotation lever forward until desired rod string RPM is achieved.
Lock the lever in position by moving the lever at right angles.
Beware of rotating drill string
— ensure all personnel are 10 If necessary, adjust the Rotation Speed Control to reset the free running
cleared from immediate area speed of the Chuck to suit the drill rod size being used.
before starting. 11 Move the Carriage Feed lever forward and lock in position.
Note: If thin kerf core barrels are 12 Wind in the Feed Pressure Control on the Control Panel until the pressure
used, ensure that recommended reading on the Feed Pressure Gauge indicates a suitable pressure for the
maximum bit weights are not formation being drilled.
exceeded.
13 Adjust the Feed Flow Control Valve by turning it counter-clockwise and

let the core bit come into contact with the rock face. There will be a small
Be aware of moving hoses
delay after opening the Valve before feeding commences, due to hydraulic
and rotating rods during
hose expansion.
fast pullback.
Note: Always ensure that the

14 Adjust the Feed Flow Control Valve further open to select the penetration
Feed Pressure Control valve is rate best suited for the conditions.
screwed in far enough to provide 15 If a core blockage occurs, move the Carriage Feed lever rearwards for
sufficient pressure to penetrate fast pull-back off bottom.
the formation being drilled.
Rechucking
1 Move the Carriage Feed lever to neutral.
2 Move the Rotation lever to neutral.
3 Pull the Rod Handling/Drilling lever to Rod Handling.
4 Move the Carriage Feed lever rearward and position the Chuck in the
required position.
Be aware of moving carriage

and hoses — clear immediate
area before this operation.
5 Push the Rod Handling/Drilling lever to Drilling.

You are now ready to drill again.
Calculating Bit Weight

The Drill’s Control Panel contains two control valves which together or
individually are utilised to control the fine feeding operation. The feed pressure
control valve regulates the amount of oil pressure being directed into the feed
cylinder. The feed flow control regulates the oil flow exiting the cylinder.
The feed pressure gauge (P1) and the hold back pressure gauge (P2) do not
display actual weight on the drilling bit. Actual weight needs to be calculated
from the Bit Weight Chart which can be found in the Feed Frame chapter.
Hold Back pressure Feed pressure


The method explained on pages 1-23 to 1-26 uses the change in hold back
pressure which occurs when the feed flow control is adjusted, for determining
the load on the bit. A slightly different technique is required for uphole drilling
to down hole drilling but the principle remains the same.
Drilling Operations
Down Hole Drilling
1 With the rod string gripped in the Chuck and the drilling bit approximately
150 mm off the bottom, close the feed flow control valve fully.
2 Rotate the drill string and then increase the setting of the feed pressure
control valve to a level sufficient for drilling. The amount of pressure
required will vary significantly due to types of rock and drilling bits used.
Also as hole depth increases, the feed pressure requirement is potentially
less due to greater rod weight acting on the face of the bit.
P2 Hold Back pressure will rise

in accordance with amount of rod
weight and feed pressure.
P1 Feed pressure will rise in

proportion to setting of feed
pressure control.
3 To commence feeding, gradually open the feed flow control which will be
accompanied by a drop in the hold back pressure on the gauge.
P2 Hold Back pressure falls.
P1 Feed pressure remains

constant.
4 In a true vertical hole the level of visible drop may be minimal.

5 Register the indicator reading on the hold back pressure gauge at this
point while the bit is advancing downward but not yet contacting the hole
bottom.
6 As the drilling bit touches the bottom of the hole, a further reduction in the
hold back pressure will be noted. The change in hold back pressure from
the point in para 4, to the pressure indication now is the amount of weight
being applied onto the bit. (lined area on P2)
7 If the indicator on P2 drops to zero, it is likely that there is insufficient

feed pressure to provide sufficient bit force. To counteract this, the feed
pressure setting should be increased.
8 To approximate the bit weight, first determine the change in MPa on P2
in para 6. For example, if the drop off is 6 MPa, locate 6 MPa on the bit
weight chart in the Feed Frame chapter and its corresponding bit weight
value in kN or lbf.
Up Hole Drilling
500 mm off hole bottom, set the feed pressure control to zero and open
the feed flow control valve.
2 Rotate the rod string, move the carriage control lever forward and then
adjust the feed pressure control so that the rod string slowly moves upward
into the hole.
3 Note the indicator reading on the feed pressure gauge which approximates
the weight of the rod string and drill head. The deeper the hole, the higher
the pressure will be.
4 Close the feed flow control valve and then increase the feed pressure
further to supply sufficient cutting force onto the bit to suit the type of rock
being cut.
5 Slowly open the Feed Flow Control to commence fine feeding. The resultant
change in hold back pressure from the point in para 4, to the pressure
indication now is the amount of weight being applied onto the bit (lined
area on P2).
6 If the indicator on P2 drops to zero it is likely that there is insufficient feed

pressure to provide sufficient bit force. Feed pressure will need to be
periodically increased to compensate for the additional rod weight as the
hole depth increases.
value in kN or lbf.
Horizontal Drilling
500 mm off hole bottom, set the feed pressure control to zero and open
the feed flow control valve.
2 Rotate the rod string, move the carriage control lever forwards and then
adjust the feed pressure control so that the rod string slowly moves into
the hole.
3 Note the indicator reading on the feed pressure gauge, which is the
pressure required to overcome the friction of the rods lying in a flat hole.
4 Close the feed flow control valve and then increase the feed pressure
further to supply sufficient cutting force onto the bit to suit the type of rock
being cut. Rod weight will have no influence in horizontal holes.
5 Slowly open the feed flow control to commence fine feeding. The resultant
change in hold back pressure from the point in para 4, to the pressure
indication now is the amount of weight being applied onto the bit (the lined
area on P2).
6 If the indicator on P2 drops to zero, it is likely that there is insufficient bit

force. Increase the value of P1 by increasing the fine feed pressure to
remedy this.

value in kN or lbf.
SECTION 2
COMMISSIONING PROCEDURE
2-2 Hydraulic Hose Connections
2-3 Prestart Checks
Power Unit
Control Panel
Drill Head
Wireline Hoist
2-6 Start Up
Diesel Power Pack
Electric Power Pack
2-7 Purging (Flushing) and Pilot Bleeding

Chuck Circuit Purging
Rod Holder Circuit / PP9 Bleeding
Rotation (Hydraulic Motor) Circuit / PP1 & PP2 Bleeding
Feed Cylinder Circuit / PP4, PP5, & PP6 Bleeding
Fine Feed Circuit
Wireline Hoist Circuit
Water Pump Circuit
2-12 Function Tests

Chuck / Rod Clamp
Rotation Direction
Feed Frame
Drill Head – Alignment Check
Drill Head – Thread Making / Breaking
Rod Handling
Wireline Hoist
Water Pump
Commissioning Procedure 2-
Hydraulic Hose Connections

Prestart Checks
This checklist is intended to assist the setting up of the drill for either
demonstration purposes or for actual drilling. It ensures that the factory
Use the correct Personal settings of the hydraulic components are correct, and that all hoses are
Protective Equipment when properly connected and purged.
handling hydraulic oil.
Power Unit
1 Connect the oil level switch to the electric starter prior to filling the oil
reservoir. Check that the low oil level alarm light illuminates when the
power supply is turned on.
2 Connect the oil temperature switch to the electric starter and ensure switch
is set to 65–70 degrees C.
DO NOT start the Power Unit
during this operation. 3 Ensure that the correct grade of hydraulic oil has been selected for the
Important environment in which the drill will be operating. Refer to the Oil Selection
Chart on page 3-3 for the suitable oil grades.
4 Fill the oil reservoir with the correct grade of oil using the hand pump
replenishment filter to filter the oil entering the tank.
— ELECTRIC Power Pack
The electric motor must be
5 Ensure the low level alarm light extinguishes when the oil level approaches
wired for the correct direction the bottom of the sight glass.
of rotation. Do not test the motor direction of rotation unless the oil reservoir had
This direction is CLOCKWISE been filled or the pump case has been filled with oil.
when looking at the motor
cooling fan, i.e. Anticlockwise 6 Ensure a cooling water supply of 20–30 lpm is available.
when looking at end of the
motor shaft.
 Oil Temperature Switch

Control Panel
Use the correct Personal 1 Connect the hoses from the control panel to the power unit taking particular
Protective Equipment and care to ensure that no contamination is introduced into the system.
tools for this operation.
Store the JIC caps and plugs in a clean location for future use.
2 Check that all hose terminations are correct. The hose cover may then
be used to bundle these hoses together.
3 Connect the rod holder hose from the power unit to the isolating valve on
the control panel. This is a 3/4” JIC hose end.
Drill Head
1 Before the drill head is set up, the oil level in the rotation unit gearbox
should be checked. This is most conveniently done when the rotation unit
is horizontal.

Use the correct Personal

Protective Equipment when
handling hydraulic oil.
Fill to halfway point of sight glass
2 Set up the portable low voltage lighting system (if supplied).

3 Ensure that the front of the feed frame is firmly anchored and that the rear
of the frame is not free to move. When anchoring the rear of the frame,
Refer to Section 9 for details of take particular care to ensure that the front anchoring system is free to
how to anchor the Feed Frame pivot so as to allow the feed frame to be correctly aligned without twist or
Positioner.
distortion.
4 Connect the two 1/2” hoses from the power unit to the connections on the
Feed Frame.
5 Connect the rod holder hose from the isolating valve on the control panel
to the rod holder using the quick-release coupling.
6 When connecting the following hoses, ensure that no contamination is
introduced and store the JIC plugs and caps in a clean location for future
use.
a) Connect the chuck supply hose between the power unit and the rotation
unit (this is a 3/4” JIC hose end).
b) Connect the rotation unit drain hose between the power unit and the
rotation unit (this is a 7/8“ JIC hose end).
c) Connect the two motor hoses between hydraulic motor ports and
connections on the power unit, (these hoses have 1 1/16“ JIC hose
Use the correct Personal ends).
Protective Equipment and
Ensure A & B ports are correctly connected.
d) Connect the breakout device hose between the BOD connection on
Dispose of any waste oil in an
the power unit, to the connection on the rotation unit (this is a 7/16“ JIC
environmentally responsible
hose end).
manner.
e) Connect the motor pilot speed control between the PPX motor
connection on the Power Unit to the same connection on the Rotation
Unit (this is a 9/16” JIC hose end).
f) Connect the motor drain hose between the Power Unit and the Rotation
Unit (this is a 7/8” JIC hose end).
Wireline Hoist
1 If a wireline hoist is not connected ensure that:
a) The wireline hoist pilot signal connections, WL1 and WL2, at the power
unit and control panel are looped.
b) The wireline hoist A and B ports and the drain port on the power unit
are capped.
2 If a wireline hoist is required, connect the A and B hoses and the wireline
motor drain hose, between the power unit and the hoist motor.
3 Connect the WL1 and WL2 pilot hoses between the power unit and the
control panel.
Water Pump
1 If a water pump is not connected ensure that:
a) The water pump pilot signal connection, WP1, at the power unit and
control panel is capped.
b) The water pump A and B ports on the power unit are bridged.
2 If a water pump is required, connect the A and B hoses between the power
unit and the pump motor.
Some water pumps may require a drain hose connection between the
water pump motor and the power unit.
3 Connect the WP1 pilot hose between the power unit and the control
panel.
Start Up
Diesel Power Pack
Refer to pages 1-9 to 1-10 (‘Operating the Diesel Power Pack’) for a description
of the required procedures for:
• Control Positioning
• Starting, and
• Stopping the Diesel Power Pack.
Electric Power Pack

Refer to pages 1-11 to 1-12 (‘Operating the Electric Power Pack’) for a
description of the required procedures for:
• Control Positioning
• Starting, and
• Stopping the Electric Power Pack.
Purging (Flushing) and Pilot Bleeding

Before operating the drill, perform the complete purging procedure if:
a) The drill has been delivered by sea freight or has been exposed to the
Use the correct Personal weather for more than 1 week.
Protective Equipment
at all times. b) The drill has been idle for more than 4 weeks.
c) The drill has suffered a pump, motor or valve failure.
d) The drill may have been subjected to contamination in any part of the
hydraulic circuit.
Whenever a hose is replaced, the relevant part of the purging procedure must
be carried out, e.g. a chuck hose replacement requires the chuck circuit to
be purged.
Chuck Circuit
1 Disconnect both the chuck supply hose and the chuck drain hose from the
rotation unit. Cap the open 3/4” JIC connection but do not cap the open
7/8” JIC drain connection. Leave this connection open.
Possibility of hydraulic oil
under pressure — vent hose 2 Join the two hose ends together using nipple 7/8” JIC male x 3/4” JIC male.
by cracking the fitting, slowly This allows the chuck oil supply to return directly to the drain manifold
bleeding oil into a suitable thereby purging the chuck circuit.
container, and then disposing
3 Ensure the Safety Guard pressure switch is activated, if fitted.
of in an environmentally
responsible manner. 4 Start the power unit and, after starting, place the Drilling/Rod Handling
Use the correct tools for this selector in the Drilling mode.
operation. Allow the hoses to purge for at least 5 minutes.
5 Return the selector to the Rod Handling position and stop the power
unit.
Disconnect the two hoses and plug the chuck supply hose.
Rod Holder Circuit / PP9 Bleeding

1 Disconnect the hose from the rod holder and using a 3/4” JIC male x 7/8”
JIC male nipple, connect the hose end to the chuck drain hose. This allows
Possibility of hydraulic oil the rod holder oil supply to return directly to the drain manifold thereby
under pressure — vent hose
priming and purging the rod holder circuit.
by cracking the fitting, slowly
bleeding oil into a suitable 2 Ensure the rod holder isolating valve on the control panel is in the forward
container, and then disposing (Automatic) position.
of in an environmentally
responsible manner.
Use the correct tools for this 4 Start the power unit and, then place the Drilling/Rod Handling selector in
operation. the Drilling mode.
Allow the hoses to purge for at least 5 minutes.
5 While purging, bleed the PP9 pilot system by partially unscrewing the tube
connections at valve V10 and Valve V8 and allowing oil to vent. Ensure all
air is removed. Repeated movement of the Drilling/Rod Handling selector
will help to bleed the PP9 lines.
6 Return the selector to the Rod Handling position and stop the power
unit.
7 Reconnect the rod holder hose and the chuck drain hose to their correct
fittings.
Rotation (Hydraulic Motor) Circuit / PP1 & PP2 Bleeding

1 Disconnect both A and B motor hoses from the hydraulic motor. Place
caps on the open connections and join the two hose ends together using
Possibility of hydraulic oil nipple 1 1/16” JIC male x 1 1/16” JIC male. This allows oil to by-pass the
under pressure — vent hose motor and purge the rotation circuit.
by cycling the Rotation control
lever on the Control Panel. 2 Start the power unit and slowly move the rotation control lever fully
forwards. Check that the clogging indicator on the filter assembly is not in
the raised position if the oil is warm.
tools for this operation. A false clogging indication may occur if the oil is cold.
Ensure the charge pressure (PT7) is 1–2bar.
3 While purging, bleed the PP1 pilot system by partially unscrewing the PP1
pilot hose connection at valve V2 (second from right) and allow venting
Capture the bled oil in a until clear oil is obtained. Move the rotation control lever fully rearwards
suitable container and and allow the hoses to purge for at least 5 minutes.
then dispose of in an
environmentally responsible 4 While purging, bleed the PP2 pilot system by partially unscrewing the
manner. PP2 pilot hose connection at valve V2 and allow venting until clear oil
is obtained. Return the control lever to neutral and stop the power unit.
Reconnect the rotation unit motor hoses.


Feed Cylinder Circuit / PP4, PP5, & PP6 Bleeding

1 Disconnect the two feed cylinder hoses from the cylinder connections and
join the ends together via a 1 1/16” JIC male x 1 1/16” male nipple.
Protective Equipment and 2 Start the power unit and ensure the Rod Pulling/Rod Feeding selector
tools for this operation. lever is in the Rod Pulling mode. The Drilling/Rod Handling selector lever
must be in the Rod Handling position.
under pressure — vent hose by Slowly move the carriage control lever fully forwards, then check the
cycling the Feed control lever clogging indicator.
on the Control Panel. Ensure the charge pressure (PT7) is 1–2 bar, and allow the hoses to purge
for at least 5 minutes.
3 While purging, bleed the PP6 pilot system by partially unscrewing the PP6
pilot connection at valve V3 (second from left) and allow venting until clear
Capture the bled oil in a oil is obtained.
suitable container and
then dispose of in an 4 Return the carriage control lever to neutral and place the Rod Pulling/Rod
environmentally responsible Feeding selector in the Rod Feeding mode.
manner. Move the carriage control lever fully rearwards and allow the hoses to
purge for at least 5 minutes.
5 While purging, bleed the PP4 pilot system by partially unscrewing the
PP4 pilot hose connection at valve V3 and allow venting until clear oil is
obtained.
6 With the Rod Pulling/Rod Feeding selector in the Rod Feeding mode,
move the carriage control lever fully forwards.
Check that PT4 reads 140 bar.
7 Bleed the PP5 pilot hose by partially unscrewing the tube connection at
valve V10 and allow venting until clear oil is obtained.
Return the carriage control lever to neutral.


Commissioning Procedure 2-10
Fine Feed Circuit

1 Fully close the feed flow control valve on the control panel.
2 Place the Drilling/Rod Handling selector in the Drilling mode and lock the
carriage control lever in the fully forward position. Slowly wind inwards the
feed pressure control valve on the control panel and note the reading on
the feed pressure guage and the hold back pressure guage.
These two pressures should be within 1 MPa of each other at each pressure
increment up to 14 MPa.

Care is required in reading
gauges due to the different

graduations used on the
gauges.
3 Reduce the feed pressure to zero by fully winding out the feed pressure
control valve. Ensure the pressure on the right-hand side gauge follows
the reducing pressure on the left-hand side gauge down to zero.
Return the carriage control lever to neutral and return the selector to the
Rod Handling position.
4 Stop the power unit and reconnect the feed cylinder hoses.
Wireline Hoist Circuit

1 Disconnect the A and B hoses at the wireline hoist and join the ends
together using nipple 1/2” JIC male x 1/2” JIC male.
2 Ensure the Drilling/Rod Handling selector is in the Rod Handling
tools for this operation. position.
Start the power unit and move the wireline hoist control lever fully forwards.
by cycling the Wireline control 3 While purging, bleed the WL2 pilot system by partially unscrewing the WL2
lever on the Control Panel. pilot hose connection at valve V1 (right-hand side) and allow venting until
Capture the bled oil in a clear oil is obtained.
suitable container and

then dispose of in an
manner.

4 Move the wireline hoist control lever fully rearwards and allow the hoses
to purge for 5 minutes.
While purging, bleed the WL1 pilot system by partially unscrewing the
WL1 pilot hose connection at valve V1.
5 Stop the power unit and re-connect the wireline hoist hoses.
Water Pump Circuit

1 Disconnect the A & B hoses at the water pump motor and join the ends
together using nipple 1/2”JIC male x 1/2” JIC male. Ensure the Drilling/Rod
Possibility of hydraulic oil Handling selector is in the Rod Handling position.
by cracking the fitting, slowly 2 Start the power unit and engage the three position water pump selector
bleeding oil out into a suitable in the Regulated position, then wind fully inwards (clockwise) the water
container, and then disposing pump speed control valve on the control panel.
of it in an environmentally Allow the hoses to purge for at least 5 minutes.
responsible manner.
3 While purging, bleed the WP1 pilot system by partially unscrewing the
WP1 pilot hose connection at the bottom of valve V4 (left hand side) and
allow venting until clear oil is obtained.
Wind out the speed control valve, return the three position selector to the
Off position, and stop the power unit.
4 Re-connect the water pump hoses.

Function Tests
Chuck/Rod Clamp
1 Ensure the rod holder isolating valve on the control panel is in the
AUTOMATIC position and the Safety Guard pressure switch is activated,
Use the correct Personal if fitted.
tools for this operation. 2 Start the power unit and place the Drilling/Rod Handling selector lever in
the Drilling position.
Check that the chuck closes and the rod holder opens. Ensure PT4 reads
140 bar
3 Bleed the rod holder hose at the rod holder end using the bleed nipple.
Ensure all trapped air is removed.
under pressure — open the 4 Move the Drilling/Rod Handling selector to the Rod Handling position and
bleed screw slowly, collect confirm PT4 reads 5–6 bar.
any waste oil in a suitable When moving the selector from Drilling to Rod Handling the PT4
container, and dispose pressure should decrease from 140 bar to 5-6 bar with no more than
of it in an environmentally a half second delay.
responsible manner.
If the delay is greater than half a second, further bleeding of the PP9 pilot
lines may be required. (Refer page 2-8.)
Rotation Direction
2 With the Drilling/Rod Handling selector in the Drilling mode, slowly move
the rotation control lever forwards and ensure that the direction of rotation
Rotating parts — is in the drilling sense.
ensure work area is clear.
Allow chuck to rotate slowly for approx. 5 minutes.
3 Increase the speed to maximum and ensure the speed is within ±50 rpm
of the specified limit.
This should be checked with the speed control adjustment on the Control
Panel, adjusted fully clockwise.
Rotation Free Running
Unit Speed (rpm)
BQ45 2625
HQ45 1650
HQ55 1650
HQ55 H/T 1150
HQ75 1650
HQ75 H/T 1300
Feed Frame
1 With the Drilling/Rod Handling selector in the Rod Handling mode, ensure
that rapid cylinder movement occurs in both directions.
Check the cushioning at each end of the feed cylinder.
2 Hold the cylinder at each end of its stroke and ensure that maximum amps
are not achieved.
Excessive amperage, i.e., close to the red line on the ampmeter, may be
caused by either of the secondary relief valves on the main valve bank
venting prematurely. Check that PT4 reads 285 bar.
3 Place the Drilling/Rod Handling selector in the Drilling mode and move
the carriage control lever forwards.
4 Wind inwards (clockwise) the feed pressure control valve until feed
pressure of approximately 140 bar is obtained. Adjust the carriage speed
Use the correct Personal using the feed flow control valve and ensure that the carriage movement
Protective Equipment when can be stopped by closing the feed flow control valve. (Slight movement
handling rods.
due to spool leakage may still occur.)
5 Allow the fine feeding to proceed until the carriage reaches the end of its
stroke and confirm that the Hold Back Pressure as shown on the left hand
pressure gauge then decreases to zero.
6 Whilst feeding in mid-stroke, move the carriage control lever rearwards and
ensure that the carriage fast pull-back system operates satisfactorily.
Hoses moving rearwards
quickly — keep area clear.
Drill Head — Alignment Check
1 Install a straight drill rod in the chuck with approximately 150 mm protruding
forward of the chuck.
Protruding rods —
ensure the area is clear. 2 Place the Drilling/Rod Handling selector in the Drilling mode and move
the carriage control lever forwards.
3 Using the feed flow control valve, allow the carriage to move slowly
forwards until the drill rod approaches the guide bushes in the rod holder.
Forward feed can be stopped immediately by returning the carriage control
lever to neutral.
4 Check that the drill rod is free to pass through the guide bushes. Alignment
adjustments may be required on the carriage to ensure the drill rod
passes through the guide bushes freely. If the alignment is unsatisfactory,
excessive wear will occur to the two guide bushes in the rod holder.
The drill rod may be slowly rotated during this test to check that the
chuck run-out is satisfactory and is not causing mis-alignment.
Drill Head — Thread Making / Breaking

1 Place the drill rod through the chuck and the rod holder then close the rod
holder.
Protruding rods and rotating
head when threadmaking and 2 With the Drilling/Rod Handling selector in the Rod Handling mode, stall
breaking — no safety guard the chuck in the forward and reverse directions. In each case, ensure that
fitted — ensure area is clear. PT4 reads 285 bar.
3 Install two rods through the chuck and rod holder with the thread joint in
between.
4 Check that the cylinder float mode operates during thread making and
breaking.
Rod Handling
If there is sufficient rod handling space in front of the feed frame, feed the
Moving Feed Frame, rods, and
hoses — ensure area is clear
rods backwards and forwards in the Rod Handling mode, noting any delay
before starting Rod Handling. in the operation of the chuck or rod holder. This is indicated by the rod not
being gripped immediately the carriage control lever is moved for a ‘working’
stroke.
A working stroke is defined as the stroke that requires the chuck to move the
rod string and it occurs when:
a) The carriage control lever is moved forward in Rod Feeding mode,
Rotating drum — b) The carriage control lever is moved rearward in Rod Pulling mode.
keep area clear whilst turning.
Note any delay of the chuck or rod holder and bleed the PP5 line if necessary.
Refer to page 2-10.
Wireline Hoist
position.
Start the power unit.
for this operation. 2 Lift the Safety Lock, slowly move the hoist control lever forwards and
note the direction of drum rotation. This should be in the wireline lowering
sense.
3 Move the control lever fully forwards and ensure the maximum speed is
180 rpm ±20 rpm.
4 Lift the Safety Lock, move the control lever fully rearwards and ensure the
drum speed is the same as the maximum forward speed.
Note and record pressure PT4.
5 Move the control lever fully forwards and ensure the PT4 reading is
10-20 bar higher than the value obtained for PT4 in the previous step. This
ensures that the hoist counter-balance valve is correctly set.
Water Pump
1 Ensure the water pump suction is connected to a water supply.
position.
Maximum speed of the water Start the power unit.
pump control may cause the 3 Engage the three position selector in the Regulated position, slowly wind
discharge hose to ‘whip’,
inwards (clockwise) the pump speed control, and check the direction of
possibly causing injury.
pump rotation.
Ensure the hose is firmly fixed Ensure the pump has primed and is pumping correctly.
to avoid this occurrence.
4 Wind the speed control fully inwards and ensure the maximum speed is
satisfactory. For most pump types this will be approximately 600 rpm.
5 Set the water pump relief valve as required.
SECTION 3
SERVICING the HYDRAULIC SYSTEM

3-2 Hydraulic Reservoir
Hydraulic Oil Hints
3-3 Oil Selection Chart

3-4 Hydraulic Filters
Hand Pump Filter
Main Return Filter
Chuck Filter
3-5 Filter Hints

Hydac Filters
Servicing the Hydraulic System 3-
Hydraulic Reservoir
The capacity of the oil reservoir is 66 litres when the oil level is at the maximum
sight-glass indication.
Refer to the Oil Selection Chart to select an oil suitable for your conditions.
The reservoir is fitted with an air breather, oil temperature switch and oil level
switch. These switches should be connected into the control circuit of the
electric starter.
The bottom of the reservoir is sloped to allow easy drainage through the
drain plug.
Always use the hand pump for replenishing the hydraulic reservoir. This will
ensure that only clean, filtered oil is added.
Every 12 months remove the reservoir from the Power Pack and clean
internally. Do this in a clean, dust-free environment.
The oil temperature switch is factory set at 65 to 70°C. Do not alter this setting
as the drill should normally not run hotter than this if the incoming cooling
water is correctly set.
Stop the drill and locate the source of the problem.
Always try to keep the oil level to the top of the sight glass.
Hydraulic Oil Hints

Do not mix types or brands of fluid.
Do not use oil of uncertain origin or type or from containers that have
been left open.
The Hydraulic Reservoir should be drained and refilled at intervals no greater
than 1000 hours.
Always wear the correct
Regularly check all hoses, fittings, drain plugs etc. for indications of oil leakage.
Personal Protection Equipment
when handling hydraulic fluid.
Correct as required.
Keep hydraulic oil clean. Use oil from unopened 20 litre containers and dispose
Always use the correct tools
of any half-filled drums.
for the application.
Oil level
switch
Main pump
case drain
Breather
Inlet Oil from

hand pump

Sight glass
thermometer
Oil temp
switch
Hydraulic Reservoir

Drain Plug
Oil Selection Chart
AMBIENT OPERATING TEMPERATURE
BELOW 5°C 5-15°C 15-25°C 25-35°C ABOVE 35°C

BRAND & GRADE
Below 41°F 41-59°F 59-77°F 77-95°F Above 95°F
BP BARTRAR H V 1 H V 3 H V H V 8 H V 100
CASTROL HYSPIN AWS 22 AWH 32 AWH 46 AWH 68 AWS 100
CHEVRON EP HYDR OIL 3 H V 8 H V 100
ESSO NUTO H22 UNIVIS J32 UNIVIS N56 UNIVIS N56 NUTO H100
FINA HYDRAN H V 3 H V H V 8 100
OPTIMOL HYDO 5025 MV 5035 MV 5045 MV 5065 5095
MOBIL D TE 1 7
SHELL TELLUS OIL 22 T 32 T 46 T 68 100
TEXACO RANDO OIL HD A- HD AZ-3 HD CZ-8 HD E-100
This recommendation does not include all oil types
OIL TANK CAPACITIES and LUBRICANT TYPES
TANK CAPACITY LUBRICANT TYPE
LM DRILL OIL TANK L
BQ ROTATION UNIT 1.0 L (¼ U.S. gallon) MOBILGEAR SHC 320 (or equivalent)
HQ Mk ROTATION UNIT 0. L (1/7 U.S. gallon) MOBILGEAR SHC 30 (or equivalent)
W11 WATER PUMP 3.7 L (4 U.S. quarts) S A E 30
L09 WATER PUMP L (¼ U.S. quarts) SAE 30

Hydraulic Filters
1 Hand Pump Filter
10 micron spin-on type installed in the oil replenishment line.
Does not have a clogging indicator but should be changed whenever
Always wear correct
resistance is felt when filling the oil reservoir.
when replacing filter element Longyear Part Number: 82915
Vendor Part Number: MP Filtri CS50P10A
2 Main Return Filter

10 micron beta-rated filter with clogging indicator.
Longyear Part Number: 602518
Always wear correct
Vendor Part Number: HYDAC 00660D010BN3/HC2
when replacing filter element.
1 2
3 Chuck Filter
10 micron beta-rated filter with clogging indicator mounted on Rotation
Unit.
Always wear correct
Longyear Part Number: 56156
when replacing filter element Vendor Part Number: HYDAC 060D010BNHC

Filter Hints
All clogging indicators should be checked every drilling shift.
Check clogging indicators only whilst Drill is actually drilling otherwise a false
reading may occur.
Replace elements when the indicators warn of a blockage or else at 500
hour intervals, whichever occurs first. All elements are of non-washable type
Always wear correct and must be discarded and replaced with new ones each time the filters are
Personal Protective Equipment serviced.
when replacing filter elements.

Hydac Filters
The Hydac Filters are fitted with indicators which progressively change colour
as the elements become blocked. When the element is new, the indicator
should be a predominant green band, slowly turning to red as the filter starts
to block.
The element must be replaced when the colour of the band turns completely
red.
This page is intentionally blank

BOART LONGYEAR SECTION 4
BQ ROD CLAMP
4-2 Introduction
Rod Clamp Specifications
4-3 Rod Clamp Jaw Replacement

4-4 Rod Clamp Guide Bushing Replacement
4-7 Rod Clamp Hydraulic Piston
4-8 Rod Clamp Troubleshooting
Weight: BQ Rod Clamp assembly 33 Kg (73 lb)
Chapter Reference: BQ Rod Clamp: P/N 58235

BOART LONGYEAR BQ Rod Clamp 4-2
Introduction
Attached to a bracket on the front of the Feed Frame, the Rod Clamp can be
removed without disturbing the face mounting of the Drill.
DO NOT reuse worn rod holder
The Rod Clamp has two jaws which are held in the gripping position by a
components when carrying out
spring pack. Hydraulic pressure is required to open the jaws, and both jaws
repairs and general service
retract radially away from the rod to a position where both jaws are protected
work.
from contact with the rod by means of two guide bushings.
DO NOT use an LM drill with
The Outer Sleeve of the Rod Clamp is reversible for extended life. An
missing or badly worn rod
assembly tool is available which enables the spring pack to be easily serviced.
holder guide bushes that allow
the drill rods to rotate against The Rod Clamp will allow the passage of all reamer shell sizes up to and
the inner slide. including BQ.
DO NOT attempt to weld or
repair worn or cracked sections
on the inner slide — replace the Rod Clamp Specifications
damaged item with a new part.
Maximum Opening 60 mm (2.36 in)
Rated Axial Holding Capacity (max.)
— Forward and Reverse rotation 60 kN (13,300 lbf)
Rated Static Torsional Holding Capacity
(max.) 1670 Nm (1,230 lbft)
Weight: Rod Clamp Assembly 33 Kg (73 lb)
Inner Slide Assembly 29 Kg (64 lb)
Rod Clamp Jaw Replacement

1 Remove the two spring clips and withdraw the pins.
Beware of potential hazard 2 Remove the inner slide assembly from the outer face clamp. Wear strips
when removing the inner slide may fall out if they are not held as the inner slide assembly is being
due to an unbalanced load withdrawn.
(29 Kg).
3 Slide rod clamp jaws out of wear strip opening.
Use correct lifting equipment
and Personal Protective
Equipment for this application.
Beware of pinch point hazards

when removing the inner slide
assembly.
Reassembly
Use the correct Personal 4 Inspect assembly and ensure the tee bolt is tight.
handling and using cleaning
5 Clean and lightly grease all sliding surfaces.
fluids. 6 Slide in new jaws so the slot engages the tee bolts.
Beware of pinch point hazards 7 Smear grease on wear strips, hold in position and slide inner slide assembly
when reassembling. into the outer sleeve.
Use the correct lifting
The Outer Sleeve is reversible for extended use.
equipment for this operation.
Rod Clamp Guide Bushing Replacement

Front and rear guide bushings can be replaced on the Rod Clamp without
removing the assembly from the Feed Frame.
Protective Equipment and 1 Remove the four socket capscrews from the guide bushing clamp using a
tools for this application. 6 mm Allen key.
2 Remove guide bushing clamp.
3 Remove guide bushing.
Reassembly
4 Insert guide bushing into the recess with the longer sleeve side facing
outward.
5 Place guide bushing clamp in position and retain with the four socket
capscrews.
Spring Pack Replacement

1 Disconnect the hydraulic hose to the Rod Clamp at the JIC fitting. Use
caps to cover ends.
Beware of potential hazard
due to oil under pressure 2 Remove the spring pins from the retaining pins and withdraw them.
— bleed off slowly. 3 Slide the Rod Clamp inner slide assembly from the outer Clamp housing.
Potential hazard when
4 Insert the Spring Pack assembly tool into the guide sleeve and tighten
removing inner slide due to
firmly. Alternatively, a hydraulic press can be used in place of the Spring
unbalanced load (29 Kg) —
Pack assembly tool to retain spring tension.
use correct lifting equipment.
The extra long socket head capscrews surrounding the flange allow the
spring plate tension to be released evenly and safely.
5 Undo the six M10 socket head screws and locknuts and remove the disc
Spring Pack assembly housing.
6 Slowly undo the Spring Pack assembly tool until the spring pressure is
fully released.
Potential hazard
— spring pack under load. 7 Stand the housing upright with the tool at the top. Withdraw the tool and
the housing leaving the retaining plate, disc springs, guide sleeve actuating
Beware of potential pinch point
plate, and plug.
hazards when removing inner
slide assembly. 8 Slide all of the components from the guide sleeve. Clean and inspect
them for wear and damage.
Protective Equipment and 9 Check rear of the cylinder for signs of oil leakage or damage to the circlip.
tools for this application. Refer to the Rod Clamp Hydraulic Piston section if leaks are found.
Beware of potential pinch point If one or more of the disc springs are broken, all of the springs must
hazard when removing springs.
be replaced.
Reassembly
Beware of potential pinch point 10 Stand the guide sleeve upright with the disc spring actuating plate in
hazards when refitting springs. position at the bottom.
Use the correct Personal 11 Cover the disc springs individually with liberal amounts of Molybdenum
Protective Equipment and Disulphide grease.
tools for this application.
The springs must be assembled with the first spring disc facing down,
the second facing up, the third down, and so on, alternating until all
twenty four are in place.
12 Fit the Spring Pack housing over disc spring assembly.
Potential hazard
13 Insert the Spring Pack assembly tool into guide sleeve and tighten until
— spring pack under load. the Spring Pack is compressed, or use the long bolts to evenly tighten the
spring pack.
14 Attach the Spring Pack to the piston assembly with the six M10 socket
heads screws tightened to 55 Nm (40 ft lb) torque, then fit the six lock
nuts.
15 Remove the Spring Pack assembly tool.
16 Grease the inner slide where it fits into the rod clamp outer housing and
During reassembly beware of assemble, ensuring that the two jaw wear strips are correctly positioned.
pinch point hazard between
inner and outer slide assembly. 17 Fit the two retaining pins and secure with spring pins.
18 Check that the jaws retract behind the inner diameter of the guide bushings
when the Clamp is open.
Rod Clamp Hydraulic Piston

1 Withdraw the Clamp Assembly from the Feed Frame and disassemble
the Spring Pack from the Piston assembly, as described in the previous
section.
2 Clean around the Piston retaining circlip then remove it.
Circlip may come off

3 Withdraw the Piston in the same direction as the circlip.
pliers when compressed 4 Using a suitable tool, remove the piston rod seal and rod wiper located in
— cover when removing. the cylinder housing and the piston seal located in the Piston.
Use the correct Personal 5 Clean all parts and replace any worn or damaged items.
cleaning.
Reassembly
Use the correct tools for this
operation. 6 Dip all seals in clean hydraulic oil.
7 Fit the piston rod wiper with the lip facing away from the Piston.
8 Insert the piston rod seal with the lip facing towards the piston.
9 Fit the piston seal into the Piston with the lip facing toward the piston rod.
Check that all seals are correctly seated and that none are damaged.
Circlip may come off 10 Lubricate the piston rod and the cylinder bore with clean hydraulic fluid
pliers when compressed and then gently feed the Piston into the cylinder.
— cover when fitting.
11 Fit a new circlip and ensure that it is correctly seated.
12 Reassemble the Spring Pack to the Piston assembly and replace the
entire Rod Clamp assembly into the outer bracket.
Potential hazard
— spring pack under load.
Hydraulic Rod Clamp Piston Assembly

Rod Clamp Troubleshooting

Whenever troubleshooting the Rod Clamp, always remember that the
operation requires hydraulic pressure to open the Clamp and spring tension
to close the Clamp.
1 If the Rod Clamp will not grip the rods properly, check for:
• Worn jaw bodies and/or worn T.C. jaw inserts.
• Broken spring(s) in spring pack.
• Inner slide assembly seized into outer housing.
• Worn drill rods.
2 If Rod Clamp fails to open, check for:

• Rod Holder solenoid valve not energised.
• Rod Holder solenoid valve faulty.
• Low hydraulic pressure in rod holder pressure reducing valve.
Refer to Input/Output test charts in Section 12 for the required lights to

be ON.
SECTION 4
HQ Mk2 ROD HOLDER

4-2 Introduction
Reassembly
4-4 Rod Holder Guide Bush Replacement

Reassembly

Reassembly
4-7 Rod Holder Hydraulic Piston

Reassembly
Weight: Rod Holder 50 Kg (without brackets)
Chapter Reference: HQ Mk2 Rod Holder p/n 3000352 / (Hinged) 3000965

(with 700 Series feed frames)
HQ Mk2 Rod Holder p/n 3000357

(with 400 Series feed frames)
HQ Mk2 Rod Clamp: p/n 600781

p/nRINTED IN AUSTRALIA
HQ Mk2 Rod Holder 4-
Introduction
The rod holder operates on the principle of hydraulic pressure to open the jaws,
and spring pressure to close the jaws. When hydraulic pressure is applied,
DO NOT reuse worn rod holder both jaws move radially away from the drill rod to a position where the jaws
components when carrying are protected from touching the drill rod by the guide bushings.
out repairs and general service
work.
It is therefore important that the guide bushes are always in good condition
for maintaining optimum rod holder jaw life. Continuing to use the drill with
DO NOT use an LM drill with worn bushes will cause premature wear of the gripper points in the jaws, also
missing or badly worn rod resulting in the rod holder slipping when rod handling.
holder guide bushes that will
allow the drill rods to rotate
The rod holder can be readily serviced in the field and this is made easier
against the inner slide
through the use of an assembly tool which is available for dismantling the
spring pack. The spring pack is held under constant tension and care must
DO NOT attempt to weld or be taken when servicing this component.
repair worn or cracked sections
on the inner slide. Replace the
damaged item with a new part. Weight: Rod Holder 50 Kg (without brackets)
Retaining ring
on spring cap
Wiper to prevent Increased thickness New outer sleeve
contamination ingress of side plates
Larger diameter
piston
Rod Holder for 400 Series Feed Frames
Single piece construction

Retaining ring outer sleeve / rod holder
on spring cap mounting bracket
Wiper to prevent Lifting point Increased thickness
contamination ingress of side plates
Larger diameter
piston
Easier guide bush servicing
Rod Holder for 700 Series Feed Frames

Rod Holder Jaw Replacement

1 Remove the two R clips and withdraw the pins.

2 Remove the inner slide assembly from the rod holder bracket using
when removing inner slide due appropriate lifting device. Hold the wear strips in place as the inner slide
to unbalanced load (46 Kg). assembly is withdrawn to prevent them dropping out of position.
Use the correct Personal 3 Slide the two jaws out of the recess in the inner slide.
Protective Equipment for The jaws can only be removed from one side only, dependent on the
this application.
orientation of the tee slot in the back of the jaw.
Beware of Pinch Points when
removing inner slide assembly.
Rod Holder Jaw replacement
Reassembly
1 Carefully inspect the inner slide for defects prior to fitting the new jaws.
2 Check that the tee bolt in the bottom end of the inner slide is present and
is sufficiently tight .
3 Smear a coating of grease on the sides of the new jaws and slide them
into position on the tee bolts.
4 Apply a coating of grease to one side of each of the wear strips and place
this side against the jaws. Ensure that the wear strips are installed with
the large chamfer as per the illustration.
The wear strips are not required when fitting jaws for HQ size drill
rod.
5 Locate the inner slide assembly back into the rod holder bracket ensuring
that it is orientated so that the hydraulic connection is on the side facing
Beware of Pinch Points
when reassembling.
the chuck.
6 Refit the two pins and R clips.
7 Using a grease gun, apply clean EP grease to both the top and bottom
grease nipples.
Rod Holder Guide Bush Replacement

Both guide bushes can be replaced without needing to remove the inner slide
assembly from the rod holder.
1 Remove the four socket head capscrews from the guide bush retaining
clamp using a 6 mm Allen key.
Use the correct tools and
Personal Protective Equipment 2 Remove the clamp from its location.
for this application. 3 Remove the guide bush from its location.
4 Remove the remaining guide bush in the same way.
Reassembly
1 Insert the new guide bush into location so that the short spigot section is
pressed into the bracket.
2 Place the clamp over the guide bush and fasten into location using the
four socket head capscrews.
Rod Holder Guide Bush replacement

Spring Pack Replacement

If the rod holder is not holding the rod string as well as usual and the two jaws
have been inspected and are in good condition, it is likely that one or more
Beware of potential hazard springs in the rod holder have fatigued excessively and must be replaced.
due to oil under pressure. The rod holder contains 30 springs and it is recommended that all springs
Bleed off slowly.
are replaced at the same time to prevent recurrent failure.
when removing inner slide 1 Disconnect the hydraulic hose going to the rod holder. Plug the end of the
due to unbalanced load (50 Kg). hose and cap the open fitting on the rod holder connection.
Beware of potential pinch 2 Remove an R clip from each of the pins and remove the two pins from the
points when removing rod holder.
inner slide assembly.
3 Carefully withdraw the inner slide assembly from the rod holder bracket
Use the correct tools and and relocate it to a work bench where it can be worked on.
for this application. 4 The extra long socket head capscrews surrounding the flange allow the
spring pack tension to be released evenly and safely.
5 Loosen and remove the twelve M10x75 socket head capscrews surrounding
the flange on the inner slide and remove the disc spring housing and the
Beware of potential hazard retaining flange.
when removing the disc spring
housing — springs under load.
The bolts should be removed in the sequence as shown in the
Loosening and Torquing Sequence diagram on page 4-6.
6 Remove the spring pack assembly and relocate to a workbench where it
can be worked on.
7 Slide all components from the guide sleeve, then clean and inspect them
for wear and damage.
Beware of potential Pinch
If one or more of the disc springs are broken, all 30 of the springs should
Hazard when removing springs
be replaced.
8 Check the rear of the cylinder assembly for signs of oil leakage or damage
to the circlip. Refer to the rod clamp cylinder section if further dismantling
is required.
Spring Pack replacement

Reassembly
1 Refit the threaded plug to the bottom of the guide sleeve.
2 Stand the guide sleeve upright and then fit the disc spring actuating plate
into location first.
3 Cover each of the new disc springs with a good quantity of grease, then
insert them onto the guide sleeve as per the illustration.
Beware of potential pinch
hazard when refitting springs.
The springs must be assembled with the first facing down, the second
facing up, the third down and so on until all 30 springs are in place.
4 Fit a new rod wiper to the disc spring retaining plate, then fit the plate into
Protective Equipment and tools
for this application.
location on top of the guide sleeve.
5 Fit the spring pack housing and the retaining flange over the spring pack,
ensuring the lifting eye is in the vertical position.
6 Fit the correct length M10x75 socket head capscrews through the retaining
flange, into the cylinder assembly and tighten.
Potential Hazard
— spring pack under load. 7 Evenly tighten the twelve M10 socket head capscrews, safety washers
and torque to 65 Nm (48 ft/lb).
Refer to the diagram (below) for the correct torquing sequence.
8 Reassemble the jaws and wear strips into the inner slide assembly and
then insert it into the rod holder bracket.
During reassembly, beware
of pinch hazard between 9 Fit the two retaining pins through the holes in the bracket and secure with
inner and outer slide assembly. the R clips.
10 Using a grease gun, apply clean EP grease to both the top and bottom
grease nipples.
Loosening and Torquing Sequence

Rod Holder Hydraulic Piston

1 Remove the inner slide assembly from the feed frame and disassemble
the spring pack from the cylinder assembly as described in the previous
section.
2 Clean around the top of the piston and then remove the circlip.
Circlip may come off pliers

3 Remove the piston by pushing on it from the jaw end.
when compressed. 4 Using a small lever, prise the two seal out of location in the cylinder.
Cover when removing. Likewise remove the seal from the outside of the piston.
5 Clean and inspect all parts. Replace any worn or damaged items.
cleaning.

application.
Rod Holder Hydraulic Piston
Reassembly
When following this 1 Dip all new seals in clean hydraulic oil prior to installation.
reassembly procedure,
ensure that the hands
2 Fit the rod wiper into the cylinder housing with the lip facing the jaw end.
and face are kept well clear. See illustration.
3 Fit the rod seal into the cylinder housing with its lip facing towards the
piston cavity. See illustration.
4 Install the piston seal onto the piston with lip side facing the rod end of the
piston. See illustration.
Check that all seals are correctly installed and that none have been
damaged on assembly.
5 Lubricate the piston rod and the cylinder bore with clean hydraulic oil and
then carefully install the piston into the cylinder.
6 Carefully tap the piston below the circlip groove and then fit the circlip into
location ensuring that it snaps fully into the groove.
Circlip may come off
pliers when compressed. 7 Reassemble the spring pack to the cylinder assembly following the
Cover when fitting. procedure described in the previous section.
8 The rod holder should be bled of air once reinstalled onto the drill. This
is done by selecting drilling mode and then releasing the bleed screw on
Oil under pressure. the rod holder cylinder.
Open bleed screw slowly.
Rod Holder Troubleshooting

Whenever troubleshooting the Rod Holder, always remember that the
operation is hydraulic pressure to open the Holder and spring tension to
close the Holder.
Symptom Action
1 Rod Holder will not grip Check for:

the rods properly • Worn jaw bodies and/or T.C. jaw inserts.
• Spring or springs in springpack broken.
• Inner slide assembly seized into outer
housing.
• Worn drill rods.
2 Rod Holder fails to open Check for:

• Hose connections not fitted correctly.
• Isolator valve on Control Panel closed.
• Low hydraulic pressure at PT3.
SECTION 4
PQ ROD HOLDER
4-2 Introduction
Disassembly
Inspection and Reassembly
4-4 Rod Holder Guide Bushing Replacement

Replacing Guide Bushes up to HQ size
Replacing PQ/HW Guide Bushes
Reassembly
4-5 Spring Pack Inspection/Replacement

Spring Pack Removal
Spring Pack Disassembly
Spring Pack Reassembly
Rod Holder Reassembly
Weight: PQ Rod Holder 155 Kg (340 lb)
Chapter Reference: PQ75 Rod Holder: p/n 88708

PQ Rod Holder 4-
Introduction
The PQ rod holder is attached to a mounting bracket which is located on the
front of the LM75 feed frame. It can be interchanged to the opposite end of
All procedures detailed within the feed frame when increasing pushing force for uphole drilling.
Section 4 assume that no
items are left gripped in the rod
The rod holder has three jaws which are each acted upon individually by a
holder prior to commencing
disc spring pack for closing and providing holding force. The drill’s power
any work. pack provides an hydraulic oil supply which is used to open the rod holder
during the drilling and rod handling operations.
Remove any drill rods, etc.,
In the event of a break in the power supply or the rupturing of the hydraulic
to a safe storage location
before proceeding.
supply hose, the rod holder will close and retain the rod string in the hole.
Jaws and guide bushings can be readily serviced without the need for
disturbing any sealed hydraulic components.
The rod holder will allow the passage of all reamer shell sizes up to and
including PQ.
If the rod holder assembly Weight: PQ Rod Holder 155 Kg (340 lb)
has to be removed ensure
the correct lifting equipment PQ Rod Holder
is used.
PQ Rod Holder 4-
Rod Holder Jaw Replacement

Note: The guide bush can be left Disassembly
in location during this operation.
1 Remove the twelve M12 socket capscrews which fasten the front cover
plate to the rod holder and remove the cover plate.
2 Slide the three jaws and jaw adaptors from their location within the rod
holder.
If these are difficult to remove it is because sludge and corrosion has
Protective Equipment for and
accumulated on the sides of the jaws.
tools this application.
If necessary use tool p/n 600265.
3 Remove the jaws from their respective adaptors by unscrewing the four
M8 socket capscrews found at the rear of the adaptors.
Inspection and Reassembly

1 Inspect all components for defects prior to reassembly.
Use the correct Personal 2 Clean and lightly grease all sliding surfaces.
Protective Equipment when 3 Attach the jaw to the jaw adaptor and fit the four M8 socket capscrews
cleaning components. which can then be uniformly tightened to 45 Nm (33 lb ft).
Note: Jaw adapters are not
4 Slide the assembled jaws into the recesses in the rod holder, ensuring
required when using PQ size
that the tee slots in the back of the jaw adaptors are correctly engaged.
jaws.
5 Refit the front cover plate and twelve M12 socket capscrews.
Beware of pinch points when
reassembling. 6 Start the drill and repeatedly move the rod handling/drilling selector from
Ensure area around the rod drilling to rod handling, ensuring that all three jaws move radially away
holder is clear of personnel then close simultaneously.
before starting the drill.
Torque to 45 Nm (33 lbft)
Jaw Adapter
Disassembly Tool
Jaw
Front Cover Plate
Torque to 160 Nm (117 lbft)
Chuck jaw replacement using disassembly tool (p/n 600265)

PQ Rod Holder 4-
Rod Holder Guide Bushing Replacement

The rod holder contains two guide bushing adaptors which permit the use of
standard size guide bushes (as used in the chuck) to be used. These adaptors
Use the correct Personal are removed only if PQ/HW size bushings are to be installed.
The procedure for changing the front and rear guide bushings is the same.
Replacing Bushes up to HQ size

1 Remove the four M8 socket capscrews from the inner guide bush clamp
using a 6mm Allen key.
2 Remove the guide bushing clamp.
Replacing PQ/HW Guide Bushes

1 Remove the four M8 socket capscrews from the outer guide bush
clamp.
2 Remove the guide bushing clamp.
Reassembly
1 Insert guide bushing into recess with the longer sleeve side facing
outward.
2 Re-install the correct guide bushing clamp and fasten into position with
the four M8 socket capscrews.
Clamp
Guide Bushing
PQ/HW Guide bushing reassembly

PQ Rod Holder 4-
Spring Pack Inspection/Replacement

Spring Pack Removal
Due to the weight of the The three spring packs can then be transferred to a convenient workshop
complete rod holder assembly, location.
it may be more convenient
to remove the spring pack 1 Disconnect the hydraulic hose to the rod holder at the rod holder end. Fit
assemblies whilst the rod a 3/4” JIC cap to the open fitting on the rod holder and also plug the open
holder is still attached to the hose end.
feed frame.
2 Carefully loosen the tube fittings on the hydraulic tubes and remove the
Beware of potential hazard due tubes completely. Store these in a clean location for reassembly.
to oil under pressure — bleed
off slowly and dispose of 3 Remove all three jaws following the procedure detailed on page 4-3.
spent oil in an environmentally 4 Loosen and remove the six M12 socket capscrews around the flange on
responsible manner.
each of the spring pack assemblies using a 10 mm Allen key.
Note: All 3 spring packs are
5 The spring pack assembly should now be free to be removed by hand and
identical.
transferred to a new location.
PQ Rod Holder 4-
Spring Pack Disassembly

The rod into which the
1 The spring pack is disassembled by first removing the M20 socket
capscrew is screwed must be capscrew which is located at the upper end.
restrained from turning. 2 Clamp one of the jaw adaptors firmly into a vice using soft jaws to prevent
Use the correct manual damage to the sides of the adaptor. Lift the spring pack and position it
handling procedures when onto the jaw adaptor, aligning the tee section on the end of the rod into
lifting the spring pack. the slot in the adaptor.
3 Use an M17 inhex socket and wrench to loosen and remove the M20
capscrew.
4 Grasp the disc spring housing and carefully remove it by lifting it upwards.
The spring pack will remain on the rod whilst the housing can be relocated
Potential hazard — spring pack to a bench.
under load.
5 Using circlip pliers, remove the circlip from the top of the spring
Circlip may come off housing.
pliers when compressed
— cover when removing. 6 Turn the spring housing onto its upper end to remove the components
from the inside of it.
7 Dismantle all parts and clean them for inspection prior to reassembly.
Spring Pack Reassembly

1 Fit a new rod wiper into the lower groove of the cylinder with the lip on the
wiper facing downwards.
tools for this operation. 2 Fit a new rod seal into the upper groove of the cylinder with the lip on the
Note: Dip all oil seals in clean seal facing upwards.
hydraulic oil to enable easier 3 Fit a new oil seal to the groove in the piston with the lip on the seal facing
assembly.
downwards.
4 Lubricate the bore of the cylinder with clean hydraulic oil and carefully
assemble piston into it.
5 Fit a new oil seal into the groove in the end cap with the lip on the seal
facing upwards.
6 Smear clean hydraulic oil around the upper section of the piston and
replace the end cap into location.
7 Re-fit the circlip ensuring that it is correctly seated in its groove.
Circlip may come off 8 Before re-assembling the spring pack, inspect each spring carefully for
pliers when compressed any signs of breakage.
— cover when removing.
If one or more of the disc springs is broken, it is strongly recommended
that all springs are replaced.
9 Cover the disc springs individually with liberal amounts of molybdenum
disulphide grease.
10 The spring pack is assembled with the first spring facing downward,
the second facing up, the third down and so on until all 17 are in
Beware of pinch hazard
place.
when refitting springs.
11 Lift the spring housing and carefully lower it into position over the spring
pack.
PQ Rod Holder 4-
12 Apply thread lubricant such as Never-Seez to the thread of the M20 socket
capscrew and reassemble the capscrew.
Potential hazard — spring pack
under load. 13 Correct bolt pretorque is very important to ensure correct reassembly
and trouble free operation of this component. Use a torque wrench
and M17 in hex socket and torque the socket capscrews to 700Nm
(520 lb ft).
14 The spring pack assembly is now ready for re-installing on the remainder
of the rod holder.
M20 socket
capscrew
torque to
700 Nm
(520 lbft)
Circlip
Oil Seal
Spring
Housing End Cap
Oil Seal
Piston
Disc
Springs
Rod Seal
Cylinder
Rod
Rod Wiper
PQ Rod Holder 4-
Rod Holder Reassembly

See illustration on page 4-7. 1 Thoroughly clean the bore of the jaw housing in the vicinity of the oil
seal and fit a new seal into the groove with the lip on the seal facing
downwards.
2 Lower the spring pack assembly into location and orientate it so that the
flats on the tee section of the rod are as parallel as possible to the sides
of the jaw housing.
tools for this operation. 3 Rotate the spring pack to the closest bolt hole alignment and refit the six
M12 socket capscrews.
handling procedures when Incrementally tighten these to 135Nm (100 lb ft).
lifting the spring packs.
4 Replace the remaining two spring packs in the same manner.
5 Refit the four steel tubes into their correct locations and tighten the tube
fittings firmly.
6 Replace the jaw and jaw adaptors into position in the rod holder. It may
be necessary to rotate the tee section on the rod a small amount to allow
the installation of the jaw adaptor.
This is done using the M17 in hex socket and wrench and by rotating
the rod in a clockwise direction only. Turning anti-clockwise could
release the pre-torque on the socket capscrew.
7 Replace the front cover plate and fasten it into position with the twelve
M12 socket capscrews.
PQ Rod Holder 4-
Rod Holder Troubleshooting

Use the correct Personal Protective Equipment at all times.
Refer to appropriate sections of the manual for a detailed description
of repair requirements.
Symptom and Cause Action
1 Rod Holder will not open:

Isolator valve on control panel closed Move valve handle to automatic position.
Low hydraulic pressure on PT3. Adjust V7 until PT3 reaches 140–150 bar.
Jaws or jaw adaptors jamming in housing. Remove and repair or replace jaws.
Insufficient jaw travel. Check M20 capscrews are pretorqued to
700Nm.
2 Rod Holder will not hold drill rods:

Worn carbide inserts in jaws. Replace jaw set.
Worn jaw blocks. Renew jaw set.
Jaws are not fully closing. Remove jaw set and clean off sludge
build up.
Grease sides of jaws and adaptors when
replacing.
Broken disc springs in spring pack. Remove and overhaul rod holder.
Worn drill rods. Becomes worse as rod weight increases.
Replace rod string.
3 Rod Holder Jaws wearing quickly:

Missing or worn guide bushings. Replace guide bushes.
Loose or missing rod holder mounting bolts. Replace missing bolts and retighten.
Vibration in hole. Alter drilling parameters to minimise
vibration.
Secure front of feed frame to rock face.
Ensure guide bushes are in good condition.
PQ Rod Holder 4-10

BQ ROTATION UNIT and CHUCK

5-2 Introduction
Chuck
Drill Head Specifications
Rotation Unit

5-5 Guide Bushing Replacement – Front
5-6 Guide Bushing Replacement – Rear
5-7 Gear Set Replacement in Rotation Unit
5-9 Gear Replacement on Hydraulic Motor
5-10 Chuck Disassembly
Cylinder Disassembly
Cylinder Reassembly
Chuck Reassembly
5-13 Rotation Unit Disassembly

5-15 Rotation Unit Preassembly Checks
5-16 Rotation Unit Reassembly
5-18 Important Note for Rotary Seal
Requirements
Before Testing
Testing Method
5-21 Break Out Device Operation

5-22 Break Out Device Disassembly
5-23 Setting Sequence Valve Pressure
BOD Malfunction Checks
BOD Specification Table
Weight: Rotation Unit and Chuck 160 Kg (352 lb)
Chapter Reference: BQ Rotation Unit: P/N 602184 BQ Chuck: P/N 602170

BOART LONGYEAR BQ Rotation Unit and Chuck 5-2
Introduction
Chuck
The Chuck is comprised of three jaws which hydraulically close to grip the
drill rods or casing, and are released by spring packs. The Chuck allows
reamer shell sizes up to and including BQ to pass through. The Chuck jaws
may also be changed readily without disturbing any hydraulic components.
Drill Head Specifications

Maximum Opening 60 mm (2.36 in)
Maximum Operating Speed
Forward 0–2000 rpm
Reverse 0–500 rpm
Forward Torque
at 1500 rpm 35 Nm (26 lbft)
at 500 rpm 275 Nm (203 lbft)
Rearward Torque
at 28.5 MPa (4132 psi) 1350 Nm (995 lbft)
Rotation Unit
The Rotation Unit is fitted with a variable displacement hydraulic motor which
drives a hollow spindle via a helical reduction gear set. The gears are
contained in a separate gear case and are lubricated by a gear oil bath.
The variable displacement motor provides both manual and automatic speed
adjustment so that the maximum hydraulic power may be used over a wide
speed range. The barrel of the Rotation Unit contains a rotary seal which
allows high pressure oil to pass to the Chuck via passages in the spindle.
The seal allows a small amount of leakage oil to cool the lip seals and
bearings in the Rotation Unit before returning to the Hydraulic Reservoir.
All Rotation Units are factory tested at full load on a dynamometer to ensure
that each unit delivers the rated power. The hydraulic motor automatic stroke
control is adjusted and set at this time and no further adjustment should be
attempted. Field adjustment will result in an incorrect speed/torque
relationship. The Rotation Unit is equipped with a rod break out device that
produces greatly increased torque when uncoupling rods.
Weight: Rotation Unit (c/w Chuck) 160 Kg (352 lb)

Gearbox Lubrication and Maintenance

1 Stop motor before checking or adding oil.
Use the correct Personal 2 Clean around the oil filler before removing to add oil.
Protective Equipment 3 It is recommended that the lubricating oil be changed after the first
for this operation. 100 hours of service.
Thereafter, and under average operating conditions, it is recommended
that the oil be changed at intervals no longer than 200 hours.
4 Drain oil while the unit is still warm, examining for contamination or metal
particles.
Drain waste oil into a
suitable container and dispose 5 Use only clean oil that has been stored in clean containers.
of it in an environmentally 6 Do not overfill. This will result in overheating and possible malfunction of
responsible manner. the unit.
Lubricant Type:
7 Fill with Mobilgear SHC 320 (or equivalent) lubricant.
Mobilgear SHC 320
Oil Capacity:
1.0 litre (¼ U.S. gallon)
À
Â
Gearbox Service locations:
1. Oil fill/breather
2. Oil level sight glass
3. Drain plug.
Chuck Jaw Replacement

Note: The guide bush and guide 1 Remove the three hex. head bolts (M8 x 1.25 x 25 mm long) from the
bush retaining plate do not need chuck hood using a 13 mm spanner and remove the hood.
to be removed unless different
sized jaws are being fitted. 2 Remove the nine hex. head bolts (M8 x 1.25 x 20 mm long) and lock
washers from the front retaining plate, using a 13 mm spanner.
3 The jaws and jaw return springs can now be withdrawn
Reassembly
1 Clean and lightly grease all moving surfaces.
2 Insert the jaws and jaw return springs into the recess in the cylinder
assembly.
3 Replace the front retaining plate and finger tighten the nine 20 mm hex.
head bolts.
4 Slide the chuck hood back into place and finger tighten into position with
the three 25 mm hex. head bolts.
Tighten all bolts to 22 Nm (16 ft lb) torque.
Torquing
Sequence
Guide Bushing Replacement - Front

1 Remove the three socket head setscrews on the guide bushing retaining
plate using a 6 mm Allen key and remove.
Protective Equipment and 2 Remove the guide bushing.
Reassembly
1 Fit the guide bushing into the recess with the longer sleeve side facing
outward.
2 Place the guide bushing retaining plate into position and retain with the
three socket head setscrews.
Guide Bushing Replacement - Rear

1 Remove the four socket head capscrews on the guide bush retaining
plate using a 6 mm Allen key and remove.
Protective Equipment and 2 Remove the guide bushing.
tools for this operation. 3 If changing to a different size guide bush, also remove the tapered sleeve
which is located beneath the guide bush.
Use a tapered sleeve for all drill rod sizes below BQ to prevent the guide
bush assembly being knocked from the end of the spindle. (This can occur
when the head moves over a drill rod.)
Reassembly
1 Cover with grease and fit the tapered insert into the rear of the spindle.
(See para 3 above.)
2 Fit the guide bushing into the recess with the longer sleeve side facing
outward.
3 Place the guide bushing retaining plate into position and retain with the
Tapered sleeve
Guide bush
Bush retaining plate
Gear Set Replacement in Rotation Unit

1 Drain the oil from the gear case.
2 Using a 6 mm Allen key, remove the three socket head setscrews that
Dispose of spent oil in an
retain the guide bushing retaining sleeve. Remove the sleeve assembly.
manner.

Retaining sleeve
Guide bush assembly
3 Loosen the hose fittings on the motor manifold and undo the hoses
completely at the Rotation Unit.
Possible crush hazard when
removing the motor — use
4 Using a 19 mm spanner, remove the four bolts that hold the hydraulic
correct lifting equipment. motor to the gear case and remove the motor and gear attached to the
shaft.
Hydraulic motor removed
5 Remove the end cover off the gear case by taking out the sixteen socket
head setscrews, using a 6 mm Allen key. Jack off the cover using the
threaded ports supplied.
6 Remove the M75-2 Lock Nut and Lock Washer.
7 Using the gear puller (Part No. 94637), withdraw the gear from the shaft.
Do not lose the two keys which fit into the shaft. Ensure the oil seal
which fits onto the gear is not worn or damaged. If necessary, replace.
Ensure the ‘O’ ring under the gear is not damaged. Replace if necessary.
Reassembly
1 Fit the gear to the shaft, lining up the keyways and keys, and ensuring the
‘O’ ring under the gear does not fall out.
2 Replace tab washer and locknut. Tighten nut firmly and bend over tab.
3 Clean off old gasket cement from mating faces of the gear case and cover.
Apply new gasket cement.
4 Fit cover and tighten the sixteen capscrews evenly.
5 Clean off old gasket cement from motor face of the gear case cover and
the hydraulic motor mounting face. Apply new gasket cement.
6 Fit the motor (complete with gear) to gear case, and tighten the four bolts
to 130 Nm (98 ft lb) torque.
7 Reconnect the hydraulic hoses and tighten firmly at either end.
refitting the motor — use
correct lifting equipment. 8 Refit the guide bushing retaining sleeve and tighten the three socket head
setscrews.
9 Refill gear case with 1 litre (¼ U.S. gallon) of Mobilgear SHC 320 (or
equivalent) gear oil.
Rear cover removed

Gear Replacement on Hydraulic Motor

1 Using a 19 mm spanner, remove the bolt, washer, and safety washer off
the motor shaft .
Protective Equipment and 2 The Gear can be withdrawn by hand off the motor shaft spline.
Reassembly
3 Press the drive gear onto motor shaft spline by hand.
4 Fit retaining washer, safety washer, and bolt. Use Locktite 242 (or similar)
and tighten to 77 Nm (57 lb).
Chuck Disassembly
1 Undo the three hex. head bolts which fasten the chuck hood to the Chuck
and remove the hood.
Protective Equipment and 2 Undo the remaining nine hex. head bolts in the front retaining plate and
tools for this operation. remove the retaining plate. The guide bushing and guide bushing clamp
will still be connected to the retaining plate.
3 Slide out the three chuck jaws complete with the two jaw return springs.
4 Remove the nine socket head capscrews that attach the rear chuck
subplate to the retaining plate attached to the main shaft. Three capscrews
Possible crush hazard when are located between each chuck cylinder. The Chuck is now free to be
removing Chuck from Rotation removed from the Rotation Unit.
Unit — use the correct lifting
equipment. Take care to retain the three ‘O’ rings on the rear of the chuck plate.
5 Each of the three cylinder assemblies are held to the rear subplate by
Undo the twelve screws and remove the cylinder assemblies.
6 Locate and retain the three small ‘O’ rings from the front face of the rear
subplate.
Cylinder Disassembly
1 Clean the area around the face of the cylinder assembly.
2 Place the cylinder assembly under a press and, using a mandril that will
fit over the piston shaft, apply pressure to the end cap to push the piston
below the level of the cir-clip.
3 Using cir-clip pliers remove the cir-clip from the assembly and slowly
Compression hazard
release the press.
from cir-clip — cover
when removing. 4 The piston, return springs and end cap are now able to be removed from
Compression hazard
the cylinder body. The piston may be removed by holding the cylinder
from chuck springs body with piston end facing down and tap the back of the cylinder body
— slowly release press. with a soft hammer.
Dowel Retaining
pin Plate
‘O’ ring Cylinder assembly Jaws Front retaining plate Hood
‘O’ ring
Chuck sub plate Chuck cylinders
BQ chuck assembly
BQ chuck cylinder assembly

Cylinder Reassembly
Use the correct Personal 1 Clean all parts thoroughly and check the cylinder bore for score marks or
Protective Equipment and excessive corrosion. Replace if necessary.
If only a small amount of corrosion is present the bore can be cleaned by
rubbing with a fine grade of ‘wet and dry’ paper.
2 Inspect the piston seals for wear or damage and replace them if necessary.
3 Check the small diameter of the piston for excessive scoring or corrosion.
Light damage can be cleaned using ‘wet and dry’ paper. Replace the
piston if necessary.
4 Inspect the rod wipers in the end caps for wear or damage, and replace if
necessary.
5 Inspect the return springs for breakage or damage. If one or more are
faulty then all eight must be replaced.
6 Apply a generous coating of hydraulic oil to the cylinder bore, piston and
piston seal.
7 Tap the piston into the cylinder bore using a soft hammer. Care must be
taken not to damage the top of the piston.
8 Apply liberal amounts of Molybdenum Disulphide grease to the return
springs and place them around the piston starting with the first spring
facing up, the second down and so on (refer to diagram).
9 Fit a new ‘O’ ring to the outside diameter of the end cap and replace.
10 Place the assembly under a press and, using a suitable mandril, press
Compression hazard from
the end cap down until a new cir-clip can be placed in the groove. Release
cir-clip — cover when fitting. the press.
Compression hazard from Ensure that the cir-clip is fitted with the tangs located under the high
chuck springs. side of the cylinder body.
BQ cylinder assembly
Chuck Reassembly
Use the correct Personal 1 Fit a new ‘O’ ring into the chuck subplate ‘O’ ring groove of each cylinder
Protective Equipment and body and hold in place with grease.
Fit the three chuck cylinders individually into position, replacing each set
of four socket head capscrews, and torque to 45 Nm (33 ft lb).
2 Place the Chuck assembly on its face and insert new ‘O’ rings into the
‘O’ ring groove, holding in place with grease.
3 Ensure the surface between the chuck subplate and retaining plate is
free from defects.
4 Fit the Chuck assembly to the Rotation Unit, ensuring the pressure ports
and ‘O’ rings line up.
refitting Chuck to Rotation Unit 5 Fit the nine socket head capscrews and tighten them uniformly. Torque to
— use the correct lifting 45 Nm (33 ft lb).
equipment.
6 Check that the chuck jaws slide freely in the chuck jaw recesses.
7 Lightly grease the ends and sides of the chuck jaws, then fit the jaws and
the jaw return springs as an assembly into the Chuck.
8 Fit the front retaining plate to the Chuck and tighten the nine hex. head
bolts to a seating torque of 22 Nm (16 ft lb).
9 Slide the Chuck hood into position and attach it in place with the three
hex. head bolts.
Dowel Retaining
pin Plate
‘O’ ring Cylinder assembly Jaws Front retaining plate Hood
‘O’ ring
Chuck sub plate Chuck cylinders
BQ chuck assembly
BQ chuck cylinder assembly

Rotation Unit Disassembly

1 Clean the hose fittings where they join to the Rotation Unit fittings.
Use the correct Personal 2 Disconnect rotation ports A and B hoses and fit the correct plugs and
Protective Equipment and caps to hoses and fittings.
tools for this operation. 3 Disconnect the BOD, drain and chuck lines and fit the correct plugs and
caps to the hoses and fittings.
4 Undo the rotation unit latch bolts and swing them free. Undo the hexagon
nut and withdraw the rotation unit connecting bolt. Lift the Rotation Unit
Beware of potential hazard from the carriage.
when removing the Rotation
Unit due to its weight — use Before disassembly clean all external surfaces of the Rotation Unit.
the correct lifting equipment. 5 Undo the three hex. head bolts which attach the hood to the Chuck and
remove the hood.
6 Undo the nine hex. head bolts in the retaining plate and remove the
retaining plate. The guide bushing and bushing clamp will still be connected
to the retaining plate.
7 Slide out the three chuck jaws complete with the two jaw return springs.
8 Remove the nine socket head capscrews that attach the rear chuck
subplate to the retaining plate attached to the main shaft. Three capscrews
are located between each chuck cylinder.
9 Remove the Chuck from the Rotation Unit.
10 Disconnect the five hydraulic hoses from hydraulic motor to the rotation
Potential crush hazard when
removing the Motor and Chuck
unit body at the rotation unit end.
from Rotation Unit due to their 11 Undo the four hex. head bolts retaining the hydraulic motor to the gear
weight — use the correct lifting case end cover and remove the hydraulic motor.
equipment.
12 Undo the three socket head grub screws in the guide bushing collar and
remove the collar, complete with the bushing and retaining ring.
13 Undo the sixteen socket head bolts and remove the end cover from the
gear case by inserting two of the socket head bolts into the tapped holes
Dispose of spent oil in an in either end of the cover and tightening them evenly.
14 Knock down the tab on the lock washer, undo the lock nut and remove the
manner.
lock washer and lock nut.
15 Remove the main gear from the spindle using the special gear puller
supplied.
Do not lose the two keys that fit onto the shaft or the ‘O’ ring that is located
beneath the gear.
16 Undo the six socket head bolts and remove the oil seal adaptor plate by
fitting two of the bolts in the tapped hole and tightening evenly.
17 Undo the six socket head bolts which fasten the rear of the gear case to
the Rotation Unit body and remove the case.
Disconnect and remove the hydraulic hose between the chuck filter and
the main housing.
18 Press the spindle from the main housing using a press. Press from the
chuck end toward the motor end.
19 Remove the cir-clip retaining the rotary seal assembly and remove the
rotary seal components from the housing.
Compression hazard
from cir-clip — cover 20 Remove the front end oil seal cir-clip. The front end oil seal and bearing
when removing. can now be pressed out of the housing.
When handling the rotary seal components and the main spindle use
extreme care so as not to damage the sealing surfaces.
21 Clean and inspect all components and replace any worn or damaged
items. Pay particular care to the two rotary seals and sealing faces, and
Use the correct Personal the area on the main spindle where the seals operate.
If the seals or spindle have to be replaced, a matched set must be fitted.
fluids.
Rear gear cover
Gear housing
Adapter plate
Main housing
Rotation Unit
driven gear
Keys
Intermediate seal
Rotation Unit assembly

Rotation Unit Preassembly Checks

Before commencing the reassembly of the Rotation Unit, the following
procedure must be observed.
Protective Equipment 1 The main housing has a longitudinal oil drain hole which breaks out from
for this operation. the bearing recess area and is then connected by a groove to the inside
diameter at the main housing. Ensure that this groove has no sharp edges
which may damage the ‘O’ ring during assembly.
Rotary shaft
Main housing
2 Ensure the shaft has no defects (i.e. scratches or burrs) on the diameter
on which the rotary seal is located (i.e. in the vicinity of the three radial oil
holes), or on the diameter on which the rear lip seal bears.
3 Ensure that the rotary seal has no defects in the bore or on the end faces.
4 Check that the shaft and the rotary seal are a matched set. Replacement
shaft and seal sets supplied from Boart Longyear come as a matched
set. The components are not available individually.
5 Before fitting the ‘O’ rings and back-up washers to the rotary seal, slide
the seal into the main housing. Fit the cir-clip and ensure that the rotary
Compression Hazard from seal is free to move laterally in the main housing.
cir-clip — cover when refitting.
Rotation Unit Reassembly

1 Clean all the components carefully and use compressed air to blow out
the three oil passages in the shaft and the oil passage in the main housing.
Protective Equipment when 2 Dip the ‘O’ rings and back-up washers in clean hydraulic oil and fit them to
working with compressed air. the rotary seal as shown in the diagram.
for this operation.
3 Stand the Rotation Unit main body on its front bearing end.
Important 4 Smear the inside bore of the main housing with hydraulic fluid then carefully
Be careful that the ‘O’ rings do not push the rotary seal assembly into place.
get pinched on the cir-clip groove. Fit the cir-clip snuggly into its groove.
5 Wipe hydraulic oil in the bearing recess area in the front of the main housing
and press the front bearing into position.
cir-clip — cover when refitting. 6 Smear hydraulic oil on the bearing area on the main shaft and press the
rear bearing onto the spindle.
7 Carefully feed the shaft (with the rear bearing fitted), through the rotary
seal assembly and press it into place, while supporting the front bearing
in its correct position.
8 Slide the ‘O’ ring over the rear bearing until it fits against the shoulder of
the main housing.
9 Fit the rear housing onto the rear bearing and tighten the six socket head
bolts evenly around the diameter. Torque them to 90 Nm (66 ft lb).
Possible falling hazard due to
gearbox weight and shape. 10 Fit the oil seal to the front of the main housing so that the seal opening is
facing toward the bearing. Grease should be lightly applied to the seal lip
surfaces.
11 Insert the cir-clip correctly into its groove.
12 Press the intermediate oil seal into the intermediate oil seal adaptor so
that the oil seal opening faces towards the rear bearing.
13 Insert the ‘O’ ring into the oil seal adaptor and attach the adaptor by means
of the socket head bolts to the rear housing.
14 Ensure that the two keys are located correctly in the keyways of the main
shaft and fit gear to the shaft, making sure the ‘O’ ring under the gear
does not fall out.
15 Position the lock washer in its locating groove and then tighten the locknut
against it securely.
16 Bend over a tab on the lock washer to lock into the nut.
Use the correct Personal 17 Press the rear oil seal into the end cover.
Protective Equipment 18 Apply sealant to the mating faces and attach the end cover to the rear
for this operation. housing. Tighten the sixteen socket head bolts evenly.
19 Fit the guide bushing retaining sleeve to the end of the shaft and fasten in
position with the three socket head grub screws.
20 Using four socket head bolts, fit the guide bushing and retaining plate to
the retaining sleeve.
21 Apply sealant to the hydraulic motor mounting face and the mating surface
on the end cover.
With the gear already fitted, attach the motor to the end cover using the
refitting motor — use the
correct lifting equipment.
four bolts.
22 Reconnect the five hydraulic hoses to the Rotation Unit body.
23 Place the chuck retaining plate on its face and insert a new ‘O’ ring into
the groove in the rear retaining plate and smear it with hydraulic oil.
24 Fit the three small ‘O’ rings into the recess in the rear of the retaining plate
and hold them into position with a little petroleum jelly.
Ensure that the surface on the rear retaining plate where the oil seal
contacts is free of any defects.
25 Fit the retaining plate to the Rotation Unit aligning the dowel pin with the
dowel hole.
26 Fit the six socket head bolts and tighten them uniformly to pull the Chuck
up snug to the shaft. Apply 45 Nm (33 ft lb) torque.
27 Place the Chuck assembly on its face and insert new ‘O’ rings into the
‘O’ ring groove, holding in place with grease.
28 Ensure the surface between the chuck subplate and retaining plate is
free from defects.
29 Fit the Chuck assembly to the Rotation Unit, ensuring the pressure ports
and ‘O’ rings line up.
refitting Chuck to Rotation Unit
30 Fit the nine socket head capscrews and tighten them uniformly. Torque to
— use the correct lifting 45 Nm (33 ft lb).
equipment. Check that the chuck jaws slide freely in the chuck jaw recesses.
31 Lightly grease the ends and sides of the chuck jaws then fit the three
chuck jaws and jaw return springs as an assembly into the Chuck.
32 Fit the front retaining plate to the Chuck and tighten the nine hex. head
bolts to a seating torque of 22 Nm (16 ft lb).
33 Slide the chuck hood into position being careful to align the slot with the
grease nipple in the rear retaining plate.
Fix the hood in position with the three hex. head bolts. Add E.P. grease to
the grease nipple until it is evident around the rear retaining plate.
34 Refill the gear case with 1 litre (¼ U.S. gallon) of Mobilgear SHC 320 (or
Beware of potential hazard equivalent grade) gear oil.
when refitting Rotation Unit to
Carriage due to its weight — 35 Refit the Rotation Unit to the Drill.
Important Note For Rotary Seal

Fill the rotary seal housing with hydraulic oil after completing any work on the
Rotation Unit.
To ensure that the housing is filled with oil:
1 Ensure that the Rotation lever is in neutral then start the Power Pack.
2 Turn the Drilling/Standby/Rod Handling selector switch to DRILLING.
3 Allow the oil to circulate for at least five minutes.
Potential crush hazard between 4 Move the lever from DRILLING to ROD HANDLING several times.
the Chuck and the Carriage
when head rotating slowly 5 Rotate the Chuck by hand with the Chuck closed. If it is free to rotate then
— keep hands clear at all times. the Unit is correctly primed and can be put into service.

The primary objective of this test is to measure the combined leakage past
the rotary seal and to ensure that the leakage rate falls within the specified
limits.
The testing method detailed here is for an on-site check only, and will give a
reasonably accurate indication of the condition of the Rotation Unit.
This may need to be done for any of the following reasons:
a) The Rotation Unit is considered faulty if it is repeatedly blowing the front

and/or intermediate oil seals.
b) The Drill is requiring higher than normal amperage while drilling.
c) The Rotation Unit has been overhauled and a new matched rotary shaft
and seal set is fitted. (This is not a necessity as shaft and seal sets have
their leakage rates checked at the Boart Longyear factory before despatch.)
d) Demonstration and training purposes.
Requirements
The Drill must be set up on-site or in a workshop as for normal operation.
The only extra items required for this test are a graduated container, a stop
watch (or wrist watch), and a magnetic thermometer.
The graduated container should be approx. 20 litre capacity and be graduated
in one litre increments.
The magnetic thermometer can be used in conjunction with and as a check
against the sight glass thermometer in the hydraulic reservoir of the Power
Pack. If a magnetic thermometer is not available, the thermometer in the
sight glass will suffice.
The stop watch (or wrist watch) is required to time the one minute testing
cycle.
Before Testing
The leakage rate is determined by measuring the amount of oil deposited
into the graduated container whilst the Chuck is pressurised for one minute.
This rate should be between 1.5 and 10 Lpm.
Important Ensure that the hydraulic reservoir is filled with an oil grade suitable for the
Refer to the Oil Selection Chart operating ambient temperature.
on page 3-2. The leakage rate is very temperature dependent, so the drill must be
brought up to its normal operating temperature before commencing the
test.
(Depending on the ambient temperature, this is normally between 35 and
55 degrees C on the sight glass thermometer.)
Testing Method
Use the correct Personal 1 Ensure that the Control Panel valves are in the following position and
Protective Equipment start the Skid Steer.
for this operation.
a) The Drilling/Standby/Rod Handling selector is in ROD HANDLING.
b) The Fine Feed valve is wound right out.
c) The Rod Feeding/Rod Pulling selector may be in either position.
d) The Carriage lever is in neutral.
e) The Rotation lever is in neutral.
2 Switch the Drilling/Standby/Rod Handling selector to the DRILLING
position. This pressurises and closes the Chuck.
3 Confirm that the reading on the circuit pressure gauge is 60–70 bar.
The Chuck must now be free to be turned by hand.
4 Return the Drilling/Standby/Rod Handling selector to the ROD HANDLING
position.
5 Disconnect the rotation drain hose at the Power Pack and place the end
of the hose into the graduated container. Cap the open fitting on the Power
Pack.
6 Confirm that the hydraulic oil is still at its normal operating temperature
and simultaneously:
a) Move the Drilling/Standby/Rod Handling selector to the DRILLING position
b) Begin timing with the stop watch (or wrist watch) a time span of one minute
c) Monitor the oil flow coming out of the rotation drain hose into the graduated
container.
7 After one minute return the Drilling/Standby/Rod Handling selector to the
ROD HANDLING position. This will stop the oil flow out of the rotation
drain hose.
8 Check the quantity of drain oil in the graduated container. This then
becomes the leakage rate in litres per minute (Lpm), e.g. if there is five
litres of oil in the graduated container, the leakage rate is 5 Lpm.
9 Repeat steps 6, 7, and 8 three times to ensure that the correct leakage
rate is determined.
10 If the leakage rate does not fall between 1.5 and 10 Lpm consult your
nearest Boart Longyear Service Centre.
11 Connect the rotation drain hose back to the Power Pack and then switch
off the Skid Steer.
12 This completes the Rotation Unit Rotary Seal test.
Rotary seal testing

Break Out Device Operation

The Break Out Device is a hydraulically activated, automatic engaging rack
gear. It provides additional torque to the Chuck (rod joint) in reverse rotation,
enabling easier uncoupling of tight joints.
Oil flow to the rack mechanism is controlled by the opening of a sequence
valve. The setting of the valve determines the pressure at which the rack
gear will engage. Pressure from the Chuck circuit is combined during this
operation to assist the rack gear complete its cycle.
F E
C
A
BOD Nomenclature
A. Rack engaging connection E. Rotation speed poppet
B. Rack pressure connection F. Sequence valve
C. Chuck pressure connection G. Inspection plug
D. Rack return (pilot) connection
Break Out Device Disassembly

1 Follow steps 1 through 7 in the ‘Gear Set Replacement’ section starting
on page 5-7 to remove the rear cover.
Protective Equipment for this 2 Loosen and remove the two hex. head plugs located at the ends of the
operation. main and return cylinders. Carefully remove the two pistons.
3 Loosen and remove the two cap nuts located side by side on the side of
the housing.
4 Remove the two socket head shoulder bolts and springs located behind
the removed cap nuts.
5 The rack gear and rack carrier should now be free to be removed from
the inside of the gear case.
6 The small rack engaging piston and its cylinder can be pressed from the
casing by pressing from the outside inwards.
7 The two larger opposing piston cylinders can also be removed from the
casing by pressing from the outside inwards. On BQ45 and HQ45/55
versions, the driven gear requires prior removal.
8 Clean and inspect all items carefully and replace any worn or damaged
components, paying careful attention to the teeth on the rack and the
Note: Ensure the main and return sliding surfaces of the pistons.
piston are correctly installed. Rack
gear must be installed with tooth
Reassembly
orientation in line with the driven
gear and a large, flat surface Reassembly of the break out device is performed in a reversal of its
against the return cylinder. disassembly.
Ensure the ‘Tee’ fitting connected It is recommended that new ‘O’ rings and seals are used in all locations and
to the main piston is fitted with a that a liberal amount of clean hydraulic oil is used to lubricate the ‘O’ rings
0.8 mm orifice. and also on all sliding surfaces.
Setting Sequence Valve Pressure

1 Disconnect the hose at point ‘B’ and place into a container. An increased
oil flow from the hose will occur when the sequence valve opens. Cap the
Use the correct Personal open ‘T’ fitting.
for this operation. 2 Ensure that reverse rotation flow has been adjusted as per the table below.
3 Place a drill rod through the Chuck and Rod Clamp ensuring the Rod
Clamp is gripping the rod.
4 Connect a test gauge into the circuit pressure port (located under the
Control Panel). Gradually pull the Rotation control lever rearward which
Hose may ‘kick’ when sequence will increase the pressure on the circuit pressure gauge. Oil will flow from
valve opens — hold hose firmly the hose when the sequence valve ‘F’ opens. Adjust to the setting as
and point open end into a
specified in the table below.
bucket.
5 The correct setting of the valve is a commencement of oil flow from the
hose. Adjusting the valve clockwise will increase its cracking pressure.
manner. 6 Refit hose to fitting ‘B’ and test the operation of the rack assembly while
viewing through the inspection plug ‘G’.
7 Remove the drill rod and rapidly move the Rotation control lever from
neutral into reverse. Ensure that the circuit pressure gauge does not
register a pressure spike exceeding 180 bar.
If the pressure exceeds 180 bar, complete the BOD malfunction checks.
BOD Malfunction Checks

1. Check for blockage in orifice ‘B’.
2. Check fitting ‘C’ is clear.
3. Check size of the orifice in the poppet at ‘E’ is correct.
4. Reconfirm sequence valve setting ‘F’.
5. Check reverse rotation oil flow.
6. Check return (pilot) pressure ‘D’.
7. Check main pump compensator setting.
Break Out Device Specification Table

R otati on Uni t Typ e
Comp onent
H Q55/75 H /T H Q45/55/75 B Q45
Mai n Pi ston Leng th (mm) 123 129 113

R eturn Pi ston (mm) 117 117 113
Seq uence Valve Setti ng (b ar) 2 2 0 -2 3 0 2 2 0 -2 3 0 2 2 0 -2 3 0
R everse R otati on Pressure (b ar) * 1 3 0 -1 5 0 1 3 0 -1 5 0 1 3 0 -1 5 0
Ori fi ce Tee Pi ece (mm) 0.8 0.8 0.8
Ori fi ce Si ze Pop p et (mm) 2.2 2.2 2.2
* Approximately 30 Lpm oil flow is required in reverse rotation to hold circuit

pressure below sequence valve “F” setting, when rotating without load.
During factory commissioning the reverse flow is set to achieve a pressure
on the circuit gauge of 13–15 MPa. The reverse flow is adjusted up or down
from 20 Lpm to achieve this.
Rotation Unit Troubleshooting

Refer to the appropriate sections of the manual for detailed
descriptions of repair requirements.
Symptom Action
1 Chuck Slippage while Drilling or Rod Handling
Mechanical Fault
1 Tungsten Carbide grippers on chuck jaws worn. 1 Replace with chuck jaws with new grippers.
Hydraulic Fault
1 Low Pressure in chuck circuit. Should read 1 Adjust pressure in the chuck circuit if
70 bar whilst drilling. necessary. If pressure is O.K. then the drilling
bit may be polished and will not penetrate.
Take corrective action, such as changing to a
freer cutting bit.
2 Rotation Unit will not break Rod Joint

Mechanical Fault
1 Rod joint torqued up tighter than breakout 1 Break joint with stillson — do not overtorque
capacity of drill. joints on make up of threads.
2 Rod joints tightening up down the hole 2 Break joint with stillson — take steps to condition
due to vibration. the hole or alter drilling parameters to reduce
vibration.
3. Break Out Device not functioning correctly. 3. Perform checks shown on page 5-23.
Hydraulic Fault
1 Refer to Pressure Checking Table, Section 11. 1 A low pressure in the circuit gauge will cause a
loss of breaking capacity. Check main relief valve
or hydraulic pump.
3 Chuck Jaws not retracting fully

1 Chuck jaws are jamming in cylinders. 1 Remove the jaws. Remove any build-up of scale.
Apply a coating of grease and replace the jaws.
2 Worn or broken springs in the cylinder 2 Disassemble the cylinder assembly and if one
assembly. or more springs are broken replace all the
springs. Check all seals and wipers for damage
or wear and replace if necessary.
3 Seized piston in the cylinder assembly. 3 Disassemble the cylinder assembly and repair
as necessary.
4 Back pressure in the chuck hose caused by 4 Replace the chuck filter element.
a clogged chuck filter.
4 Rotation Unit leaking oil from behind the Chuck

1 Front Oil Seal blown. 1 Remove the chuck and rear retaining plate and
fit a new oil seal.
2 If the rotation unit blows the front oil seal
repeatedly then the rotary seal may be worn or
damaged. To test this, perform the rotary seal
test to check the leakage rate as detailed earlier
in this section.
Symptom Action
5 Rotation Unit Gear Case Filling-Up with Hydraulic Oil

1 Intermediate oil seal worn or damaged. 1 Remove the hydraulic motor, rear gear housing
cover, gear, and adaptor plate. Fit a new oil
seal.
2 Seal running surface on driven gear 2 Replace the driven gear.
excessively worn.
3 O-ring on front face of driven gear missing 3 Fit a new O-ring to driven gear and hold it in
or damaged. position with a smear of grease when reinstalling
gear on the shaft.
4 Hydraulic motor leaking oil through front 4 Remove and repair the motor.
shaft seal.
5 Seal(s) in Breakout Device leaking. 5 Dismantle and replace seals.
6 Rotation Unit leaking Gear Oil from Rear Oil Seal

1 Rear oil seal worn or damaged. 1 Remove rear gear housing cover and fit a new
oil seal. Check that the gear case breather is
properly installed and functioning.
7 Rotation Unit Overheating

1 Oil level in gear housing low. 1 Add oil to level of sight glass or drain and add
1 litre (1/4 U.S. gallon) of new oil.
2 Oil level in gear housing too high. 2 Check oil level and drain to correct level.
8 Rotation Unit lacks RPM while Drilling

1 Broken ground, hole deflection or in-hole 1 Ensure that the Rotation lever is fully forward.
vibration could cause loss of RPM. This would Condition hole to reduce torque and vibration,
be indicated by a circuit pressure of 240–250 or slow drilling speed, if necessary.
bar as the RPM starts to fall. This is the normal
circuit operating range of the drill and indicates
the drill is developing full power.
2 Hydraulic motor control has stroked the motor 2 Adjust the motor stroke control screw carefully
prematurely. This would be indicated by a outwards using a 3 mm Allen key.
circuit pressure of less than 240 bar as the The adjustment is very sensitive.
RPM starts to fall. Test the drilling function and note the circuit
pressure at which the RPM starts to fall as the
drill is placed under load. Repeat the
adjustment until the speed starts to fall when
circuit pressure lies between 240 and 250 bar.
3 Main hydraulic pump is worn. 3 Refer to Service Guides for action appropriate
to Main Pump.
4 Speed adjustment valve on control panel is 4 Increase chuck rpm by winding in the setting of
incorrectly set for operating conditions. the speed control valve.
Symptom Action
9 Rotation Unit lacks Torque whilst Drilling

1 Hydraulic motor control has not stroked. 1 Adjust the motor stroke control screw carefully
This would be indicated by a circuit pressure inwards using a 3 mm Allen key.
of 285 bar as the Chuck stalls. The adjustment is very sensitive.
There will be no steady decrease in RPM, Test the drilling function and note the circuit
rather the Chuck will go from max. RPM to stall. pressure at which the RPM starts to fall as the
drill is placed under load. Repeat the
adjustment until the speed starts to fall when
circuit pressure lies between 240 and 250 bar
for LM30/45/55/75.
This adjustment is factory set, and should
not require resetting on site.
Start of motor stroke

control adjustment
240 – 250 bar
Start of displacement
adjustment
4 – 14 bar
2 Hydraulic motor has excessive internal wear, 2 Confirm by checking motor case leakage
indicated by difficulty in maintaining full drilling when under load. This should be no more than
circuit pressure when the oil is warm. five percent of the rotation circuit oil flow.
10 Inability to alter RPM while Drilling

1. Incorrect setting of Start of Displacement 1 Reset adjustment screw by teeing a pressure
Adjustment. gauge into the PPX connection on the motor.
Adjustment must be made so that rpm control
occurs at between 4 and 14 bar when
resetting the speed control on the control
panel.
HQ Mk2 Rotation Unit and Chuck SECTION
5-15
HQ Mk2 ROTATION UNIT and CHUCK

5-2 Introduction
Chuck
Rotation Unit
Chuck Jaw Removal
5-5 Guide Bush Replacement
Front Guide Bush
Rear Guide Bush
5-7 Oil Seal Replacement
Rear Oil Seal
Intermediate Oil Seal
Front OIl Seal
5-14 Gear Replacement in Hydraulic Motor
5-15 Chuck Cylinder Overhauling
Chuck Removal and Disassembly
Chuck Cylinder Disassembly
Inspection and Replacement of Parts
5-19 Breakout Device Servicing
Breakout Device Main Cylinder
Breakout Device Return Cylinder
Cylinder Rack Engaging
Rack Gear
Breakout Device Disassembly and Reassembly
Breakout Device Operation
Breakout Device Malfunction Checks
Breakout Device Specification Table
5-27 Rotation Unit Maintenance
Disassembly
Preassembly Checks
5-33 Rotation Unit Rotary Seal Test
Requirements
Important Note
Testing Method
Weight: Rotation Unit and Chuck 235 Kg
Chapter Reference: HQ Rotation Unit p/n 602230, 602231

3000498, 3000500
HQ Chuck p/n 3001636
HQ Mk2 Rotation Unit and Chuck 5-
Introduction
Chuck
The Chuck:
 is comprised of three jaws and is hydraulically closed to grip the drill rods
or casing, and is released by spring packs.

 allows reamer shell sizes up to and including HQ to pass through.
 jaws may also be changed readily without disturbing any hydraulic
components.
Rotation Unit
The Rotation Unit is fitted with a variable displacement hydraulic motor
which drives a hollow spindle via a helical reduction gear set. The gears are
contained in a separate gear case and are lubricated by a gear oil bath.
The variable displacement motor provides a manual and an automatic speed
adjustment so that the maximum hydraulic power may be used over a wide
speed range. The barrel of the Rotation Unit contains a rotary seal which
allows high pressure oil to pass to the Chuck via passages in the spindle. The
seal allows a small amount of leakage oil to cool the lip seals and bearings
in the Rotation Unit before returning to the Hydraulic Reservoir.
All Rotation Units are factory tested at full load on a dynamometer to ensure
that each unit delivers the rated power. The hydraulic motor automatic stroke
control is adjusted and set at this time and no further adjustment should
be attempted. Field adjustment will result in an incorrect speed/torque
relationship. The Rotation Unit is equipped with a rod break out device that
produces greatly increased torque when uncoupling rods.
Weight: Rotation Unit and Chuck: 235 Kg

Gearbox Lubrication and Maintenance

 Stop motor before checking or adding oil.
 Clean around the oil filler before removing to add oil.
Protective Equipment  It is recommended that the lubricating oil be changed after the first
for this operation. 100 hours of service.

 Thereafter, and under average operating conditions, it is recommended
that the oil be changed at intervals no longer than 200 hours.

 Drain oil while the unit is still warm, examining for contamination or metal
particles.
Oil Capacity:  Use only clean oil which has been stored in clean containers.
0.6 litre (1/7 U.S. gallon)  Do not overfill. This will result in overheating and possible malfunction of
the unit.
Lubricant Type
Mobilgear SHC 320 or equivalent.  Fill with recommended lubricant.
Gearbox Service locations:

1. Oil fill/breather
2. Oil level sight glass
3. Drain plug.
Chuck Jaw Replacement

Note: The guide bush and guide Chuck Jaw Removal
bush retaining plate do not need
to be removed unless different 1 Remove the 12 socket head cap-screws (M10 x 1.5 x 55 lg) from the front of
size jaws are being fitted. the chuck using an 8 mm Allen key and remove the front retaining plate.
See below.
2 Slide the 3 chuck jaws from their recesses in the Chuck.
Important
If the chucks and jaws are Reassembly
incorrectly fitted, resultant
damage will occur to both 1 Clean and lightly grease all moving surfaces.
parts in operation.
2 Slide the 3 jaws into position in the Chuck, being careful to properly align
the tee-slot in the back of the jaws with the tee in the Chuck cylinders.
3 Replace the front retaining plate and alternatively tighten the 12 socket
Use the correct Personal capscrews to a torque of 90 Nm (66 ft lb).
Chuck jaws removed and retightening sequence

Guide Bush Replacement

Front Guide Bush
Use the correct Personal 1 Remove the 4 socket head capscrews (M8 x 1.25 x 25 lg) on the guide
Protective Equipment and bush retaining plate using a 6 mm Allen key and remove.
2 Remove guide bush.
Front Guide Bush removed

Rear Guide Bush

1 Remove the four M8 socket head capscrews in the guide bush retaining
plate and then remove the plate.
Protective Equipment and 2 Prise the guide bush retaining sleeve from the spindle which should also
tools for this procedure. release the guide bush.
3 Remove the guide bush from the retaining sleeve.
Note: A tapered sleeve is not 4 If changing to a different size guide bush, also remove the tapered sleeve
used when bushings for HQ size which is located in the inside end of the spindle.
rods are installed.
Use a tapered sleeve for all drill rod sizes below HQ to prevent the guide
bush assembly being knocked from the end of the spindle. This can occur
when the head moves over the end of a drill rod.
Rear Guide Bush removed
Reassembly
1 Fit a new tapered sleeve into the end of the spindle. See note above.
2 Fit a new guide bush into the retaining sleeve with the short spigot end into
the sleeve. Place this assembly into the end of the rotation unit spindle.
3 Place the guide bush retaining plate into location and retain with the four
M8 socket head capscrews.
Oil Seal Replacement

Rear Oil Seal Replacement
Use the correct Personal 1 Drain the oil from the gearbox by removing the most convenient drain plug.
Protective Equipment If the rotation unit is horizontal this will be the bottom plug.
when handling lubricants.
3 Prise the guide bush retaining sleeve from the spindle which should also
release the guide bush.
Protective Equipment and tools 4 Remove the guide bush from the retaining sleeve.
when removing the guide bush. 5 Remove the remaining section of the guide bush holder from the end of
the spindle. There are no fasteners holding this in position and it can be
removed by prising from the spindle.
6 Remove the seal housing from the gearbox by removing the ring of socket
head capscrews using a 5mm allen key.
7 Position the seal housing flat on a suitable work table and press the oil
seal from the housing.
Replacing the Rear Oil Seal
Reassembly
1 Clean out the seal recess in the housing and then carefully press a new oil
seal into location ensuring that the seal is pressed in square on entry.
2 Smear a good coating of grease to the oil seal lips where they will contact
the spindle.
Protective Equipment 3 Apply silicone gasket cement to the flange on the seal housing and its
when handling lubricants. mating face on the gearbox. When fitting the seal housing into place ensure
that the cut away section is positioned towards the hydraulic motor.
4 Refit the six M6 socket head capscrews and tighten them uniformly.
5 Replace the retaining ring into its groove in the end of the spindle. Slide the
rear section of the guide bush housing over the ring so it locates against
the seal housing.
6 If necessary, fit a new tapered sleeve into the end of the spindle.
7 Fit the guide bush into the retaining sleeve with the short spigot end into
9 Refill the gearbox using 1 litre (1/4 US gallon) of EP gear oil grade SHC
320 or equivalent.
Intermediate Oil Seal

1 Drain the oil from the gearbox by removing the most convenient drain
plug.
environmentally responsible 2 Remove the four M8 socket head capscrews in the guide bush retaining
manner. plate and then remove the plate.
Use the correct Personal 3 Prise the guide bush retaining sleeve from the spindle which should also
Protective Equipment and release the guide bush.
tooling for this operation.
5 Remove the remaining section of the guide bush holder from the end of
the spindle. There are no fasteners holding this in position and it can be
removed by levering from the spindle.
6 Disconnect the following hydraulic hoses from the hydraulic motor manifold
block to the rotation unit at the rotation unit end:
Oil under pressure
 lower breakout device connection
— undo slowly.
 upper breakout device connection
Wear the correct Personal
 chuck drain on top of gearbox
Protective Equipment.
 chuck filter.
7 Loosen and remove the four M12 bolts which fasten the hydraulic motor
to the gearbox. Carefully remove the motor from the gearbox and place
Possible crush injury to one side.
when removing motor.
8 Remove the rear cover from the gear box by firstly removing the M10
capscrews from around the circumference of the cover. Note the differing
equipment.
lengths of some of these capscrews for correct reassembly.
9 Using an 8mm allen key, remove the two special low head M10 capscrews
which hold the spindle nut locking ring to the gear. Remove the locking
ring and ensure that the screws are retained for reassembly.
10 Loosen the spindle lock nut and remove it from the spindle. This is a right
hand thread and is removed by rotating counter clockwise!
11 Using gear puller p/n 59484 withdraw the gear from the shaft.
Do not loose the four keys which fit into the shaft.
Removing Gear Case and Hydraulic Motor
Removing Driven Gear, Locknut, Lockwasher, and 4 keys
12 The six M6 socket capscrews in the intermediate oil seal adaptor plate
can now be removed using a 5mm allen key. Replace two of the removed
capscrews into the two tapped holes in the adaptor plate to jack the plate
out of the housing.
13 Relocate the adaptor plate to a suitable work area and press the oil seal
from the housing by tapping on its rear face.
HQ Mk2 Rotation Unit and Chuck 5-10
Removing Adaptor Plate, O-Ring, and Oil Seal
Reassembly
1 Clean out any debris from the recess in the seal adaptor plate and then
carefully press a new seal into location. Ensure that the seal is pressed
Use the correct Personal in square on entry and that it is pressed right to the bottom of the recess.
The seal must be installed with its opening facing the top of the recess
2 Carefully examine the O-ring that goes with the adaptor plate. If it shows
any signs of deterioration then replace it with a new one.
3 Refit the O-ring into the groove in the adaptor plate then locate the
plate into the gearbox housing. Secure in place with the six socket head
capscrews.
4 Carefully examine the O-ring that goes onto the end of the driven gear
and if it shows any signs of deterioration replace it with a new one.
5 Fit the O-ring to the end of the gear and hold in location with a smear of
grease. This will prevent the O-ring being dislodged on assembly of the
gear.
6 Check that all four drive keys are located correctly in the spindle and then
position the gear onto the spindle while aligning the keyways. Carefully
press the gear further onto the spindle until it seats all the way down
against the rear bearing.
7 Lubricate the thread where the spindle lock nut locates and then refit the
locknut with its taper facing away from the gear.
8 Tighten the locknut very firmly. It is important that all face to face clearance
between the locknut, the gear, and the bearing is removed.
9 Place the locking ring over the locknut and align two of the tapped holes
in the gear. Apply ‘Loctite 242’ (or similar) to the two special low head
capscrews then use these to fasten the locking ring into place.
10 Clean the mating faces of the two gearbox housings and then apply new
gasket sealant.
11 Assemble the gearbox rear cover to the rotation unit and refit the 16 M10
socket head capscrews. Tighten these uniformly and securely.
12 Apply gasket sealant to the hydraulic motor mounting face and the mating
surface on the gearbox housing then assemble the motor into location.
Lift motor into place using Refit the four M10 hexagon head bolts and tighten securely.
correct lifting equipment.
13 Reconnect the hydraulic hoses to their correct position on the rotation
unit.
the seal housing.
18 Refill the gearbox using 1 litre (1/4 US gallon) of EP gear oil grade SHC
320 or equivalent.
19 If applicable, reassemble the tacho proximity sensor into location on the
rotation unit.
Front Oil Seal Replacement

1 Remove the twelve socket head capscrews on the chuck front retaining
plate. Remove the plate together with the guide bushing.
2 Slide out the three chuck jaws.
Potential crush injury between 3 Slide off the chuck hood.

chuck and carriage when 4 Remove the six M12 socket head capscrews that attach the rear chuck
removing chuck.
sub plate to the spindle retaining plate and carefully remove the chuck.
Use correct lifting equipment.
5 Undo and remove the twelve M10 socket head capscrews holding the
retaining plate to the spindle and remove the plate.
6 Remove the circlip from its groove in the rotation unit housing.
Circlip under compression 7 The front oil seal is now free to be levered out of its location in the
— cover when removing. housing.
Reassembly
1 Before fitting a new front oil seal ensure that the oil seal spacer is in location
in the housing against the front bearing.
2 Carefully inspect the condition of the O-ring and backup ring located on
the end of the spindle and if necessary renew these items also.
3 Fit a new oil seal into the housing with the seal opening facing towards
the bearing. Apply a thin coating of grease to the lip cavity of the seal.
Installation can be made easier by using special installation tool
P/N 602025.
4 Insert the circlip into its groove and check that it is correctly seated.
Compression hazard from 5 Carefully inspect the condition of the O-ring and backup ring located in
circlip — cover until seated the bore of the spindle retaining plate. If necessary renew these items.
in its groove.
6 Apply clean hydraulic oil to the O-rings and back up rings on the end of
the spindle and in the retaining plate and then locate the retaining plate to
the spindle. Ensure that the tapped holes in the spindle are aligned with
the holes in the retaining plate.
7 Refit the twelve M10 socket head capscrews and tighten them uniformly
to 90Nm (60 ft/lb).
8 Fit three new O-rings into the back face of the chuck where it affixes to
the spindle retaining plate and hold in position using a small amount of
grease.
9 Being careful not to dislodge the O-rings, position the chuck onto the
spindle retaining plate. Hold the chuck in place while the first of the
Potential crush hazard capscrews are fitted.
between chuck and carriage.
10 Fit the six M12 socket head capscrews and tighten these uniformly to
160Nm (118 ft/lb).
when reassembling chuck
onto rotation unit. 11 Slide the chuck hood into place. A smear of grease inside the hood will
help it pass over the O-rings.
12 Grease the sides of the chuck jaws and then slide these into their locations
in the chuck.
13 Refit the front retaining plate and torque the twelve M10 socket head
capscrews to 90Nm (60 ft/lb).
Replacing the Front Oil Seal

Removing Rear Chuck Sub Plate
Removing Chuck Retaining Plate

Gear Replacement on Hydraulic Motor

Removal
1 Remove bolt, washer and safety washer off motor shaft using a 19 mm
spanner.
2 Gear can be withdrawn by hand off the motor shaft spline.
Reassembly
1 Press drive gear onto motor shaft by hand.
The machined area on the gear for the special retaining washer
should be facing out.
2 Fit retaining washer, safety washer and bolt. Use ‘Loctite 242’ (or similar)
and tighten to 77 Nm (57 lb).
Chuck Cylinder Overhauling

Chuck Removal and Disassembly
1 Remove the 12 socket head capscrews from the front of the Chuck and
remove the front retaining plate.
2 Slide out the three chuck jaws.
3 Slide off the chuck hood.
4 Remove the 6 socket head capscrews that attach the rear chuck sub-plate
to the retaining plate attached to the mainshaft. Two capscrews are located
between each chuck cylinder.
The chuck is now free to be removed from the Rotation Unit.
Potential crush hazard
when removing chuck Take care to retain the three small O-rings on the rear of the chuck
from rotation unit. plate.
The three cylinder assemblies are held to the rear sub plate by four socket
for this operation. head capscrews each.
5 Undo the screws and remove the cylinder assemblies.
6 Locate and retain in a safe place the three small O-rings from the front
face of the rear sub-plate.
Removing the Chuck Jaws

Chuck Cylinder Disassembly

Use correct Personal Protective 1 Clean the area around the face of the cylinder assembly.
Equipment and tooling for this
operation.
2 Place the cylinder assembly under a press and, using a mandril that will
fit over the piston shaft, apply pressure to the end cap to push the piston
below the level of the cir-clip.
Note: The piston may be 3 Using cir-clip pliers, remove the cir-clip from the assembly and slowly
removed by holding the cylinder release the press.
body with piston end facing down
and tap the back of the cylinder 4 The piston, return springs and end cap are now able to be removed from
body with a soft hammer. the cylinder body.
Inspection and Replacement of Parts

1 Clean all parts thoroughly and check the cylinder bore for score marks
or excessive corrosion. Replace if necessary. If only a small amount of
Compression hazard from corrosion is present the bore can be cleaned by rubbing with a fine grade
cir-clip— cover when removing.
of wet and dry paper.
2 Inspect the piston seals for wear or damage and replace them if
necessary.
3 Check the small diameter of the piston for excessive scoring or corrosion.
Light damage can be cleaned using wet and dry paper. Replace the piston
if necessary.
4 Inspect the rod wipers in the end caps for wear or damage and replace if
necessary.
5 Inspect return springs for breakage or damage and if one or more are
faulty then all must be replaced.
6 Apply a generous coating of hydraulic oil to the cylinder bore, piston and
piston seal.
Reassembly
1 Position the piston evenly into the cylinder bore and, using a suitable
mandril, press the piston into the cylinder bore.
Protective Equipment and 2 Apply liberal amounts of Molybdenum Disulphide grease to the return
tooling for this procedure. springs and position them around the piston.
3 Replace the end cap into the cylinder assembly.
4 Place the assembly under a press and, using a suitable mandril, press the
end cap down until a new cir-clip can be placed in the groove. Release
Compression hazard from the press.
cir-clip — cover when fitting.
It is important that the cir-clip is installed so that the tangs are located
under the high side of the cylinder body.
Removing the Chuck Cylinders
HQ Chuck assembly — exploded view

Chuck Reassembly
1 Refit the three small O-Rings into the chuck rear sub-plate and hold in
place with a little grease or petroleum jelly. Fit the three chuck cylinders
individually into position on the sub-plate and torque the socket head
capscrews to 90 Nm (66 ft lb).
2 Refit the three small O-Rings to the back face of the chuck rear sub-plate
and hold it in place with a little grease or petroleum jelly. Being careful not
Potential crush hazard to dislodge the O-rings, position the Chuck into the plate attached to the
between chuck and carriage
main shaft.
when refitting.
Fit the six socket head capscrews and torque to 160 Nm (118 ft lb).
Use correct Personal Protective
and lifting equipment. 3 Slide the chuck hood into place. A smear of grease inside the chuck hood
will help it to pass over the O-rings.
Important
4 Grease the sides of the three chuck jaws and slide into position in the
Ensure that the tee-slots in the
chuck.
back of the jaws are properly
aligned with the tee bolts in the 5 Refit the front retaining plate and torque the twelve socket head capscrews
chuck cylinders. to 90 Nm (66 ft lb).
Torquing Sequence
Breakout Device Servicing

Most parts of the breakout device can be removed and serviced without
the need to remove the rear cover from the rotation unit gearbox. The only
Use the correct Personal service work that requires removal of the rear cover is when the rack gear
Protective Equipment and needs inspection and replacement.
Breakout Device Main Cylinder removal and repair

1 Loosen and remove the 2 hydraulic hoses where they connect to the tee
piece located on the top of the cylinder. Plug the open hose ends.
2 Use a large adjustable wrench or similar to grip on the hexagon area of
the cylinder and slowly unscrew the cylinder from the rotation unit.
3 As the cylinder fully unscrews it will be necessary to continue spiralling the
cylinder upwards with the wrench due to the oil seal fit in the gearbox.
4 Remove the cylinder which also contains the piston encapsulated
inside.
5 Hold the cylinder horizontal in a vice and then remove the threaded plug
from the end.
6 The piston is now free to be pressed from the cylinder.
7 Remove the oil seal and rod wiper from the inside bore of the cylinder.
Remove the two O-rings from the outside of the cylinder.
Inspection and reassembly

Use the correct Personal 1 Carefully inspect both the cylinder bore and the piston for signs of wear
Protective Equipment and or damage. Renew these parts if necessary.
2 Dip a new oil seal in clean hydraulic oil and then fit it to the bore furthest
inside of the cylinder. Install the seal with its lip facing towards the threaded
end of the cylinder. See illustration.
3 Install the rod wiper next with its lip facing the opposite way. See
illustration.
4 Fit a new O-ring to the groove in the outside of the cylinder.
5 Fit a new O-ring to the shoulder of the cylinder where the thread is.
6 Smear clean hydraulic oil throughout the bore of the cylinder and then
press the piston into it, entering from the threaded end with the ungrooved
end of the piston.
7 Inspect the O-ring on the top end of the cylinder and if it shows signs of
deterioration, it should also be replaced.
8 Lubricate the thread on the plug, then screw it firmly into place.
9 Lubricate the thread on the cylinder and then reassemble it back into the
gearbox.
10 Refit the tee piece and the hydraulic hoses to their correct locations.
Breakout Device Return Cylinder removal and repair

Use the correct Personal 1 Disconnect the hydraulic hose where it connects to the fitting on the bottom
Protective Equipment and of the cylinder and plug the open end of the hose.
3 Remove the cylinder which should also contain the piston encapsulated
inside.
4 Hold the cylinder horizontal in a vice and then remove the threaded plug
from the end.
5 The piston is now free to be pressed from the cylinder.
Remove the O-ring from the outside of the cylinder near the thread.
Inspection and re-assembly

1 Carefully inspect both the cylinder bore and the piston for signs of wear
or damage. Renew these parts if necessary.
inside of the cylinder. Install the seal with its lip facing towards the threaded
end of the cylinder. See illustration.
illustration.
5 Smear clean hydraulic oil throughout the bore of the cylinder. Press the
piston into it, entering with the chamfered end of the piston from the
threaded end of the cylinder.
7 Lubricate the thread on the plug, then screw it firmly into place.
gearbox.
9 Refit the hydraulic fitting and then the hydraulic hose.
Cylinder Rack Engaging removal and repair

Use the correct Personal 1 Disconnect the hydraulic hose where it connects to the fitting on the end
Protective Equipment and of the cylinder and plug the open end of the hose.
3 Remove the cylinder which should also contain the piston encapsulated
inside.
4 Carefully tap the end of the cylinder where the piston is located to dislodge
the piston to enable it to be removed.
Remove the O-ring from the outside of the cylinder near the thread.

1 Carefully inspect both the cylinder bore and the piston for signs of wear
or damage. Renew these parts if necessary.
inside of the cylinder. Install the seal with its lip facing towards the bottom
end of the cylinder bore. See illustration.
illustration.
5 Smear clean hydraulic oil throughout the bore of the cylinder and press
the piston into it.
gearbox.
8 Refit the hydraulic fitting and then the hydraulic hose.
Rack Gear removal and repair

To gain service access to the rack gear it is necessary to first remove the
rear cover from the gearbox.
1 Drain the oil from the gearbox by removing the most convenient drain
plug.
3 Prise the guide bush retaining sleeve from the spindle which should also
release the guide bush.
Use the correct Personal 5 Remove the remaining section of the guide bush holder from the end of
Protective Equipment and the spindle. There are no fasteners holding this in position and it can be
tooling for this procedure. removed by levering from the spindle.
6 Disconnect the following hydraulic hoses from the hydraulic motor manifold
block to the rotation unit at the rotation unit end
 lower breakout device connection
 upper breakout device connection
 chuck drain on top of gearbox
 chuck filter.
7 Loosen and remove the four M12 bolts which fasten the hydraulic motor
to the gearbox. Carefully remove the motor from the gearbox and place
Possible crush injury when to one side.
removing motor due to its
weight. 8 Remove the rear cover from the gear box by firstly removing the M10
capscrews from around the circumference of the cover. Note the differing
lengths of some of these capscrews for correct reassembly.
9 Loosen and remove the two cap nuts on the side of the gearbox housing
adjacent to the rack engaging cylinder.
10 Remove the two socket head shoulder bolts and springs located behind
the two cap nuts.
11 The rack carrier and rack gear should now be free to be removed as a
pair.

Note: Ensure main and return 1 Carefully examine the condition of the rack and if it shows signs of
piston are correctly installed. Rack significant wear it should be replaced.
gear must be installed with tooth
The rack is reversible so if one side shows excessive wear it can be
orientation in line with the driven
turned around and the other side used as the working face.
gear and a large, flat surface
against the return cylinder. 2 Reassemble the rack and rack carrier into the rotation unit.
Ensure the ‘Tee’ fitting connected 3 Refit the return springs and the socket head shoulder bolts, tightening
to the main piston is fitted with a these securely.
0.8 mm orifice.
4 Reassemble the remainder of the components in the same order as they
were removed.
Operation
The Break Out Device is a hydraulically activated, automatic engaging rack
gear. It provides additional torque to the Chuck (rod joint) in reverse rotation,
enabling easier uncoupling of tight joints.
Oil flow to the rack mechanism is controlled by the opening of a sequence
valve. The setting of the valve determines the pressure at which the rack
gear will engage. Pressure from the Chuck circuit is combined during this
operation to assist the rack gear complete its cycle.
C
E
A
G
BOD Nomenclature
A. Rack Engaging Connection.
B. Rack Pressure Connection.
C. Chuck Pressure Connection.
D. Rack Return (pilot) Connection.
E. Rotation Speed Poppet
F. Sequence Valve
G. Inspection Plug

Use correct Personal Protective 1 Disconnect the hose at point ‘B’ and place into a container. An increased
Equipment for this procedure. oil flow from the hose will occur when the sequence valve opens. Cap the
open ‘Tee’ fitting.
2 Ensure that reverse rotation flow has been adjusted as per the BOD
specification table overleaf.
3 Place a drill rod through the chuck and rod clamp ensuring the rod clamp
is gripping the rod.
4 Select PT2 on the gauge selector. Gradually pull the rotation control lever
rearward which will increase the pressure on the circuit pressure gauge.
Hose may ‘kick’ when sequence Oil will flow from the hose when the sequence valve ‘F’ opens. Adjust to
valve opens — hold firmly and the setting as specified in the table.
point into bucket.
5 The correct setting of the valve is a commencement of oil flow from the
Circuit pressures are listed in
hose. Adjusting valve clockwise will increase its cracking pressure.
table on page 5-26.
6 Refit hose to fitting ‘B’ and test the operation of the rack assembly while
viewing through the inspection plug ‘G’.
7 Remove the drill rod and rapidly move the rotation control lever from
neutral into reverse. Ensure that the PT2 circuit pressure does not register
a pressure spike exceeding 180 bar.
8 If the pressure exceeds 180 bar, check components listed in the BOD
malfunction checks (see below).
Breakout Device Malfunction Checks

1 Check for blockage in orifice ‘B’.
2 Check fitting ‘C’ is clear.
3 Check size of the orifice in the poppet at ‘E’ is correct.
4 Reconfirm sequence valve setting ‘F’.
5 Check reverse rotation oil flow.
6 Check return (pilot) pressure ‘D’.
7 Check main pump compensator setting.
Breakout Device Specification Table
Rotation Unit Type
HQ45/55/75
Component Mk2 BQ45
Main Piston Length (mm) 129 113

Return Piston (mm) 117 113
Sequence Valve Setting (bar) 220–230 220–230
* Reverse Rotation Flow (lpm) 20 20
Orifice Tee Piece (mm) 0.8 0.8
Orifice Size Poppet (mm) 2.2 2.2
* Approximately 20 lpm oil flow is required in reverse rotation to hold circuit

pressure below sequence valve ‘F’ setting, when rotating without load.
During factory commissioning the reverse flow is set to achieve a pressure
on PT2 of 13–15 MPa. The reverse flow is adjusted up or down from
20 lpm to achieve this.
Rotation Unit Maintenance

Rotation Unit Disassembly
1 Follow steps 1 through to 12 in the ‘Intermediate Oil Seal Replacement’
section starting on page 5-8.
2 Follow steps 1 through to 7 in the ‘Front Oil Seal Replacement’ section
on page 5-11.
3 Disconnect and remove the hydraulic hose between the chuck filter and
the main housing.
4 Undo and remove the six socket head cap screws which fasten the rear
of the gearbox to the main housing. Reinsert two of the removed screws
into the tapped holes in the housing to jack the two mating halves apart.
5 Carefully remove the rotary shaft from the main housing by pressing from
the chuck end.
6 Remove the cir-clip retaining the rotary seal and remove it from the
housing.
cir-clip — cover when removing. 7 Turn the main housing over and press the front bearing out of its
recess.
8 The rear bearing can be removed from the shaft by supporting the bearing
under a press and pressing on the rear oil seal end of the shaft.
Be extremely careful when doing this to prevent the shaft from
dropping unrestrained and becoming damaged.
Clean and inspect all components and replace any worn or damaged
items.
When handling the rotary seal and shaft, use care so as not to damage
the sealing surfaces. Scratches or dings could cause failure of the
rotation unit.
If the shaft shows signs of wear where the rotary seal locates then
a new shaft and seal set must be fitted.
Shaft and seals are provided by Boart Longyear as a matched set
because of the very close mating tolerances involved.
DO NOT mix these components with shafts or seals from other
assemblies.
Removing Gear Housing and O-Ring
Exploded view of main housing components

Preassembly Checks
Before commencing the reassembly of the rotation unit, the following
procedure must be observed.
1 The main housing has a longitudinal oil drain hole which breaks out from
the bearing recess area and is then connected by a groove to the inside
diameter at the main housing. Ensure that this groove has no sharp edges
which may damage the O-ring during assembly.
2 Ensure the shaft has no defects (scratches or burrs) on the diameter on

which the rotary seal is located. That is, in the vicinity of the two radial oil
holes or on the diameter on which the rear lip seal bears.
3 Ensure that the rotary seal has no defects in the bore or on the end
faces.
4 Before fitting the O-rings and back-up washers to the rotary seal, slide the
seal into the main housing. Fit the cir-clip and ensure that the rotary seal
is free to move laterally in the main housing.
Reassembly
Use the correct Personal 1 Clean all the components carefully and use compressed air to blow out the
Protective Equipment and two oil passages in the shaft and the oil passage in the main housing.
tooling for these operations.
2 Dip the O-rings and back-up washers in hydraulic oil and fit them to the
rotary seal as shown in the diagram.
Important 3 Stand the Rotation Unit main body on its front bearing end.
Be careful that the O-rings do not 4 Smear the inside bore of the main housing with hydraulic fluid then carefully
get pinched on the cir-clip groove. push the rotary seal assembly into place.
5 Fit the cir-clip snuggly into its groove.

6 Wipe hydraulic oil in the bearing recess area in the front of the main housing
cir-clip — cover when refitting. and press the front bearing into position.
7 Smear hydraulic oil on the bearing area on the main shaft and press the
rear bearing into position with the two grooves on the outer race of the
bearing facing towards the threaded end of the Rotary Shaft.
8 Carefully feed the shaft, with the rear bearing fitted, through the rotary
seal assembly and press it into place while supporting the front bearing
Possible falling hazard due to in its correct position.
gearbox weight and shape.
9 Slide the O-ring over the rear bearing until it fits against the shoulder of
the main housing.
Important 10 Fit the rear housing onto the rear bearing and tighten up the six socket
Ensure the oil inlet port on the head bolts evenly around the diameter. Torque to 90 Nm (60 ft lb).
main housing is in the correct
position in relation to the rear
11 Fit the oil seal spacer and oil seal to the front of the main housing so that
gear housing. the seal opening is facing toward the bearing. Grease should be lightly
applied to the seal lip surfaces.
Installation is made easier if Boart Longyear tool p/n 602025 is
used.
12 Insert the cir-clip in its groove correctly.
Compression hazard from 13 Press the intermediate oil seal into the intermediate oil seal adaptor so
cir-clip — cover when refitting. that the oil seal opening faces toward the rear bearing.
14 Insert the O-ring into the oil seal adaptor and attach the adaptor by means
of the socket head bolts to the rear housing.
15 Ensure that the four keys are located correctly in the keyways of the main
shaft.
16 Supporting the bottom of the rotary shaft in a correct manner, press the
driven gear into final position with a maximum press force of 10 ton.
DO NOT press into final
position whilst supporting 17 Tighten the locknut very firmly with the taper facing out. A small amount of
the outside of the main housing grease should be placed between the locknut and driven gear to lubricate
as damage may occur. the surfaces. Make sure the driven gear is in the correct final position. It is
Use the correct tooling
critical that no gaps remain between the bearings, spindle shoulder, gear
for these operations. and retaining nut.
18 Using special socket low head capscrews and ‘Loctite 242’ (or similar),
tighten to 70 Nm.
19 Press the rear oil seal into the end cover. Grease should be lightly applied
to the seal lips.
20 Apply sealant to the mating faces and attach the end cover to the rear
housing. Tighten the socket head bolts evenly.
the seal housing.
25 Apply gasket sealant to the hydraulic motor mounting face and the mating
surface on the gearbox housing then assemble the motor into location.
Possible crush hazard Refit the four M10 hexagon head bolts and tighten securely.
when refitting motor.
26 Reconnect the hydraulic hoses to their correct position on the rotation
unit.
27 Place the chuck rear retaining plate on its front face and fit a new O-ring
and back up ring into its internal groove. Ensure that the back up ring is
installed first and faces the chuck end.
O-Ring
Back-up Ring
Chuck Retaining Plate

28 Fit a new O-ring and back up ring into the groove on the end of the rotary
shaft, ensuring that the back up ring faces the rotary seal side.
Back-up Ring
O-Ring Spindle
29 Lubricate the O-rings and back up rings and carefully fit the chuck retaining
plate to the end of the shaft. Ensure to align the threaded holes in the shaft
with the holes in the retaining plate.
30 Fit the twelve M10 socket head capscrews and torque them uniformly to
90 Nm (60 ft lb).
31 Reassemble the chuck to the rotation unit. Refer to the chuck reassembly
section on page 5-18.
Possible crush hazard
between chuck and carriage 32 Refill the gearbox using 0.6 litre (1/7 U.S. gallon) of EP gear oil grade SHC
when refitting. 320 or equivalent.
Use correct Personal Protective 33 If applicable, reassemble the tacho proximity sensor into location on the
and lifting equipment. rotation unit.

The primary objective of this test is to measure the leakage rate past the rotary
seal and to ensure that the leakage falls within the specified limits.
The testing method detailed here is for an on-site check only, and will give a
reasonably accurate indication of the condition of the Rotation Unit.
This may be required for any of the following reasons:
• The Rotation Unit is considered faulty as it is repeatedly blowing the front
and/or intermediate oil seals.
• The Drill is requiring a higher than normal amperage whilst drilling.
• The Rotation Unit has been overhauled and a new matched rotary shaft
and seal set fitted. (This is not a necessity as shaft and seal sets have their
leakage rates checked at the Boart Longyear factory before despatch).
• Demonstration and training purposes.
Requirements
• The Drill must be set up on-site or in a workshop as for normal
operation.
• The only extra items required are a graduated container, a stop watch or
wrist watch, and a magnetic thermometer.
• The graduated container should be approx. 20 litre capacity and be
graduated in one litre increments.
• The magnetic thermometer can be used in conjunction with and as a
check against the sight glass thermometer in the hydraulic reservoir of the
Power Pack. If a magnetic thermometer is not available, the sight glass
thermometer will suffice.
• The stop watch or wrist watch is required to time the one minute testing
cycle.
Important Note for Rotary Seal

Fill the rotary seal housing with hydraulic oil after completing any work
on the Rotation Unit.
To ensure that the housing is filled with oil:
1 Ensure that the Rotation lever is in neutral. Start the Power Pack.
2 Push the Drilling/Rod Handling lever to Drilling.
3 Allow the oil to circulate for at least 5 minutes.
4 Move the lever from Drilling to Rod Handling several times.
5 Rotate the Chuck by hand with the Chuck closed.
If it is free to rotate then the Unit is correctly primed and can be put into
service.
Before Testing
The leakage rate is determined by measuring the amount of oil deposited
into the graduated container whilst the Chuck is pressurised for one minute.
This should be between 1.5 and 10 Lpm.
Note: Refer to the Oil Ensure that the hydraulic reservoir is filled with an oil grade suitable for the
Selection Chart on page 3-3. operating ambient temperature.
The leakage rate is very temperature dependent.
The drill must be brought up to its normal operating temperature before
commencing this test.
This is normally between 35 and 55 degrees C on the sight glass thermometer,
depending on the ambient temperature.
Testing Method
1 Ensure that the Control Panel valves are in the following positions then
start the Power Pack:
• the Rod Handling/Drilling selector is in the Rod Handling position
• the Fine Feed valve is wound right out
• the Rod Feeding/Rod Pulling selector may be in either position
• the Carriage lever is in neutral, and
• the Rotation lever is in neutral.
2 Select PT5 on the pressure gauge selector and move the Rod Handling/
Drilling selector to the Drilling position, to pressurise and close the
Chuck.
3 Confirm the PT5 reading on the circuit pressure gauge is 60–70 bar.
The chuck must now be free to be turned by hand.
4 Return the Rod Handling/Drilling selector to the Rod Handling position.
5 Disconnect the rotation drain hose at the Power Pack and place the end of
the hose into the graduated container. Cap the open fitting on the Power
Pack.
Rotary seal testing

6 Confirm that the hydraulic oil is still at its normal operating temperature
and simultaneously:
a) Move the Rod Handling/Drilling Selector to the Drilling position.
b) Begin timing with the stop watch (or wrist watch) a period of one
minute.
c) Monitor the oil flow from the drain hose into the graduated
container.
7 After one minute, return the Rod Handling/Drilling selector to the Rod
Handling position. This will stop the oil flow out of the rotation drain
hose.
8 Check the quantity of drain oil in the graduated container. This then
becomes the leakage rate in litres per minute (lpm), e.g. if there is 5 litres
of oil in the graduated container, the leakage rate is 5 lpm.
9 Repeat steps 6,7 and 8 three times to ensure that the correct leakage rate
is determined.
10 If the leakage rate does not fall between 1.5 and 10 lpm consult your
nearest Boart Longyear Service Centre.
11 Connect the rotation drain hose back to the Power Pack.
12 Reset the pressure gauge selector to position number two (PT2), and
switch off the Power Pack.
This completes the Rotation Unit Rotary Seal Test.
Rotation Unit Troubleshooting

Refer to the appropriate sections of the manual for detailed
descriptions of repair requirements.
1 Chuck Slippage while Drilling or Rod Handling

Mechanical Fault
Tungsten Carbide grippers on chuck jaws Replace with chuck jaws with new grippers.
worn.
Hydraulic Fault
Low Pressure at PT5. Adjust pressure at V11 (on LM drills) or V7
Should read 60-70 whilst drilling. (on LMA drills) if necessary. If pressure is O.K.
then the drilling bit may be polished and will not
penetrate. Take corrective action, such as
changing to a freer cutting bit.
2 Rotation Unit will not break Rod Joint

Mechanical Fault
Rod joint torqued up tighter than breakout Break joint with pipe wrench — do not
capacity of the drill. overtorque joints on make up of threads.
Rod joints tightening up down the hole Break joint with pipe wrench — take steps to
due to vibration. condition the hole or alter drilling parameters
to reduce vibration.
Break Out Device not functioning correctly. Perform BOD malfunction checks
(see page 5-35).
Hydraulic Fault
Refer to Pressure Checking Table in Section A low pressure at PT4 and/or PT2 will cause a
11 and check pressures for thread breaking loss of breaking capacity. Check main relief
operation. valve or hydraulic pump.
3 Chuck Jaws not retracting fully

Chuck jaws are jamming in cylinders. Remove the jaws. Remove any build-up ofz
scale. Apply a coating of grease and replace
the jaws.
Worn or broken springs in the cylinder Disassemble the cylinder assembly and if
assembly. one or more springs are broken replace all
the springs.
Check all seals and wipers for damage or
wear and replace if necessary.
Seized piston in the cylinder assembly. Disassemble the cylinder assembly and
repair as necessary.
Back pressure in the chuck hose caused by Replace the chuck filter element.
a clogged chuck filter.
4 Rotation Unit leaking oil from behind the Chuck

Front Oil Seal blown. Remove the chuck and rear retaining plate and
fit a new oil seal.
If the rotation unit blows the front oil seal
repeatedly then the rotary seal may be worn
or damaged.
To test this, perform the rotary seal test to
check the leakage rate as detailed earlier in this
section.
5 Rotation Unit Gear Case Filling-Up with Hydraulic Oil

Intermediate oil seal worn or damaged. Remove the hydraulic motor, rear gear housing
cover, gear and adaptor plate.
Fit a new oil seal.
Seal running surface on driven gear Replace the driven gear.
excessively worn.
O-ring on front face of driven gear missing Fit a new O-ring to driven gear and hold it in
or damaged. position with a smear of grease when
reinstalling the gear on the shaft.
Hydraulic motor leaking oil through front Remove and repair the motor.
shaft seal.
Seal or seals in Breakout Device leaking. Dismantle and replace seals.
6 Rotation Unit leaking Gear Oil from Rear Oil Seal

Rear oil seal worn or damaged. Remove rear oil seal retainer and replace the
oil seal. Check also that the gear box case
breather is not blocked.
7 Rotation Unit Overheating

Oil level in gear housing low. Add oil to level of sight glass or drain and add
0.6 litre (1/7 U.S. gallon) of new oil.
Oil level in gear housing too high. Check oil level and drain to correct level.
8 Inability to alter RPM while Drilling

Incorrect setting of Start of Displacement Reset adjustment screw by teeing a pressure
Adjustment. gauge into the PPX connection on the motor.
Adjustment must be made so that rpm control
occurs at between 4 and 14 bar when resetting
the speed control on the control panel.
9 Rotation Unit lacks Torque whilst Drilling

Hydraulic motor control has not stroked. Adjust the motor stroke control screw carefully
This would be indicated by a PT2 pressure inwards using a 3 mm Allen key.
of 285 bar as the Chuck stalls. The adjustment is very sensitive.
Test the drilling function and note the PT2
There will be no steady decrease in RPM, pressure at which the RPM starts to fall as the
rather the Chuck will go from max. RPM to drill is placed under load. Repeat the adjustment
stall. until the speed starts to fall when PT2 lies
between 240 and 250 bar for LM45/55 and
LM75/LMA90.
Start of motor stroke This adjustment is factory set, and should
control adjustment not require resetting on site.
240-250 bar
Start of displacement adjustment

4-14 bar
Hydraulic motor has excessive internal wear, Confirm by checking motor case leakage when
indicated by difficulty in maintaining full under load. This should be no more than
drilling circuit pressure when the oil is warm. 5 percent of the rotation circuit oil flow.
10 Rotation Unit lacks RPM while Drilling

Broken ground, hole deflection or in-hole Ensure that the rotation lever is fully forward.
vibration could cause loss of RPM. Condition hole to reduce torque and vibration,
This would be indicated by a PT2 pressure or slow drilling speed, if necessary.
of 240–250 bar as the RPM starts to fall.
This is the normal PT2 operating range of
the drill and indicates the drill is developing
full power.
Hydraulic motor control has stroked the Adjust the motor stroke control screw carefully
motor prematurely. This would be indicated outwards using a 3 mm allen key.
by a PT2 pressure of less than 240 bar as The adjustment is very sensitive.
the RPM starts to fall. Test the drilling function and note the PT2
pressure at which the RPM starts to fall as the
drill is placed under load.
Repeat the adjustment until the speed starts to
fall when PT2 lies between 240 and 250 bar.
Main hydraulic pump is worn. Refer to Service Guides for action appropriate
to Main Pump.
Speed adjustment valve on control panel is Increase chuck rpm by winding in the setting of
incorrectly set for operating conditions. the speed control valve.

SECTION 6
400 SERIES (DIRECT COUPLED) FEED FRAME

6-2 Introduction
Feed Frame Specifications

Reassembly

Reassembly

6-11 Removing the Cylinder Trunnions
Reassembly

Piston and Piston Rod Disassembly and Inspection
Piston and Piston Rod Reassembly
Rod End Gland
End Cap Gland
Weight: Feed Frame 240 Kg (528 lb) / 350 Kg (770 lb)
Chapter Reference: 400 Series Feed Frame 1.1m:

LM30 drills p/n 3002360
LM45/55 drills p/n 3003893
400 Series Feed Frame 1.7m:

LM30 drills p/n 3002501
LM45/55 drills p/n 3003892
BOART LONGYEAR 400 Series (Direct Coupled) Feed Frame 6-2
Introduction
FEED FRAME (Direct Coupled)
The Feed Frame main chassis is a fabricated steel unit, incorporating the
‘Vee’ profiles which form the basis of the carriage guide system.
The top section of the chassis contains the feed cylinder and feed cylinder
guide system, and its open construction permits easy field service and
maintenance.
The carriage, which is fitted with replaceable synthetic wear pads, slides on
renewable stainless steel guide rails. The ‘Vee’ profile of the rails allows for
easy, one-step adjustment to compensate for wear. The carriage is connected
directly to the feed cylinder, eliminating the need for feed chains. The feed
cylinder is hydraulically cushioned at both ends to reduce shock loads during
rod handling.
Counter balance (or load holding) valves are fitted as a safety interlock in the
event of a pressure loss in the feed circuit, to prevent the load running away.
The design of the Feed Frame allows for an overall short transporting length
of 2200 mm (2900mm), when the rear section is removed.
With the rear section bolted in its working position the feed frame length
becomes 2625 mm (3930 mm).
Specifications 1.1m 1.7m
Feed Length 1100 mm (43.3 in) 1700 mm (66.9 in)

Maximum Push 40 kN (8,993 lbf) 40 kN (8,993 lbf)
Maximum Pull 40 kN (8,993 lbf) 40 kN (8,993 lbf)
Carriage speed, fast 0.5 m/sec (1.6 ft/sec) 0.5 m/sec (1.6 ft/sec)
Weight: 240 Kg (528 lb) 350 Kg (770 lb)
Assembling the Feed Frame

Remove any restraining device which is between the cylinder cover assembly
and the feed frame chassis. Bolt the cover into its working position and ensure
Use the correct manual that the four M12 bolts are firmly tightened.
handling procedures
at all times.

Ø
Ø
Fit and tighten the four M12 bolts
Direct Coupled Feed Frame — working position

400 Series (Direct Coupled) Feed Frame 6-4
Feed Frame Maintenance

Recommended Service Intervals:
Use the correct Personal Daily:
Protective Equipment and 1 Grease carriage slides at the commencement of each shift — grease
nipples on each side.
Note: It is important that Feed 2 Grease rod clamp outer housing — grease nipples in top and bottom
Frame maintenance is done on faces.
a regular basis to ensure a long
service life of all components.
3 Grease wireline sheaves — grease nipple in each sheave.
4 Check filter tell-tale while drilling — replace element if indicator is in the
raised red position.
5 Grease nipples in adjusting block spigots — grease nipples on both sides.
6 Grease trunnion nipples — located in carriage top.
Weekly:
7 Grease carriage hinge pin — one grease nipple at each end.
Multi-Purpose Grease (MPG)
Suitable grease types and brand 8 Check oil level in rotation unit gearbox and add oil if necessary.
names/manufacturers include: 9 Check adjustment of carriage slides and adjust if necessary. See page
— Unirex EP2 (Imperial Oil)
6-6 for further details.
— Darina XL EP2 (Shell)
— Ulti-Plex EP2 (Chevron) 10 Check the rod holder and rotation unit guide bushings for wear and replace
— Mobilux EP2 (Mobil) if necessary.
— Mobilith AW2 (Mobil)
11 Check for any oil leaks from hoses or fittings and replace any worn parts.
Check rod holder bolts for tightness.
Fortnightly:
12 Remove chuck and rod holder jaws, check for gripper wear.
If O.K., clean off any scale, regrease the sides and replace.
13 Check rotation unit clamp, bushes, pins, etc., for wear and replace any
worn parts.
8 4
7
13
7
10,12
2
10,12
3
6
5 9 1
5
11
Feed Frame service and maintenance points
Adjusting the Carriage

1 Move the drill head carriage fully forward against the rod clamp and leave
the LM30 running.
Protective Equipment and 2 Undo the four locknuts on the carriage slide adjusting bolts and leave
tools for this operation. loose.
Important
The correct procedure must
be followed when adjusting
the Carriage.
Loosen in two places on each side
3 Release the tension on the hex. nut which fixes the feed cylinder piston
rod to the Feed Frame chassis. Do not loosen right off.
Ø
4 Insert a drill rod through the back of the Chuck and open the rod clamp.
Use the correct manual Isolate the rod clamp in the open position. Push the drill rod through the
handling procedures rod clamp and close the Chuck on the rod.
for this operation.
5 Adjust the carriage slides evenly from both sides, ensuring that the rod is
Possible crush hazard
evenly spaced within the rod clamp guide bushings. The Chuck should be
— Do not get hands caught
between the Chuck and the
rotated by hand whilst performing this adjustment.
carriage top plate.
6 The adjustment should be made so that both carriage wear strips are
making light contact with the feed frame slides.
If adjusting with the Feed Frame in the horizontal position, ensure that the
upper wear strip is contacting the guide rail.
Ø
Ø
Do not over tighten, otherwise overheating and premature wear to sliding

components will occur.
7 When adjustment is satisfactory, lock the wear strips in position by

tightening the four locknuts.
8 Retighten the hex. nut on the end of the feed cylinder piston rod.
9 Slowly move the Carriage forwards and rearwards. Ensure that the travel
Use the correct Personal is smooth in either direction and that the drill rod passes evenly through
Protective Equipment, tools, the rod clamp.
and manual handling
procedures for this operation.
10 Open the Chuck and remove the drill rod. Add lithium based grease to the
four grease nipples on the carriage slides.
Replacing the Carriage Wear Strips

1 Move the drill head carriage to a suitable working position on the Feed
Frame and switch off the Skid Steer.
Carriage side plate may fall —
use correct lifting equipment. 2 Remove the carriage side plate by firstly removing the nine M10 hex.
head bolts using the correct spanner. Be careful to securely hold the side
Important
plate as the bolts are removed.
Complete work to one carriage
side before beginning the other. 3 Clean the removed carriage side plate assembly with degreasing fluid (or
similar) and check for any other worn or damaged components.
Personal Protective Equipment 4 Remove the two plastic wear strips from the adjusting block by levering
when handling and using out with a screwdriver.
cleaning fluids.

tools for this procedure.
Carriage Assembly
Reassembly
Use the correct Personal 1 Clean the inner area where wear strips locate in the adjusting block, prior
Protective Equipment and to fitting the new wear strips.
2 Install the new wear strips and insert new trim clips (four per side) to hold
Always wear the correct them in position.
when handling and using 3 Turn the adjusting screws counterclockwise to back-off the position of the
cleaning fluids. adjusting blocks.
Carriage side plate assembly This will be necessary otherwise the additional thickness of the new wear
may fall — use the correct strips will obstruct proper reassembly of the side plates.
lifting equipment.
4 Reassemble the side plate assembly to the carriage and tighten the
nine M10 bolts to 44 Nm (32.5 lb/ft) torque.
5 Follow the same disassembly and reassembly steps for the other side of
the carriage.
When both sides have been completed, the carriage must be correctly
adjusted. See the previous section, ‘Adjusting the Carriage’, for further
details.
Tighten nine M10 bolts to 44 Nm (30 lbft) torque


1 Perform steps 1 to 4 in the previous section, ‘Replacing the Carriage Wear
Strips’.
Protective Equipment and 2 Remove the two circlips located on the ends of the adjusting block spigot.
tools for this operation. 3 The adjusting block should now be free to be removed from the side plate.
Adjusting block may fall —
4 Loosen the two hex. locknuts and unscrew the two adjusting screws from
remove when at ground level
the side plate.
or on bench.
Compression hazard Reassembly

— circlip may come off pliers.
Cover when removing. Reassembly is the reverse procedure.
Ensure a good quality lubricant is applied to the adjusting screws and the
bosses of the adjusting block.
Wear strip
Adjusting
screw
Trim clip
Adjusting
Locknut block
Cir-clip
Removing the Feed Cylinder

1 Switch on the LM30 Skid Steer and move the drill head carriage forward
until it is at the end of the cylinder stroke.
Protective Equipment and 2 Remove the rear cylinder cover from the Feed Frame by removing the
tools for this operation. M12 bolts.
Ensure the Feed Frame is 3 Loosen and remove the hex. nut that fastens the feed cylinder piston rod
positioned horizontally to to the feed frame chassis. Remove the flatwasher and store the nut and
allow for the safe removal washer for reassembly.
of the feed cylinder.
4 Disconnect the hydraulic hoses going to the feed cylinder connections on
Beware of Hydraulic Oil under the counterbalance valve and plug the hose ends.
pressure — vent hose by
cycling the Feed lever on 5 Undo the Rotation Unit latch bolts and swing them free. Swing the Rotation
the Control Panel. Unit over to one side.
Use the correct lifting 6 Remove the twelve M12 bolts holding the cylinder trunnions to the carriage
equipment and manual handling top plate and store for reassembly.
procedures for this operation.
7 The feed cylinder should now be free to be withdrawn through the back of
Rotation Unit is difficult to the feed frame.
initially pivot — use assistance.
Feed cylinder removal

Removing the Cylinder Trunnions

1 Perform the steps described in the previous section to remove the Feed
Cylinder.
Change out trunnions
before failure — keep clear 2 Carefully remove the cylinder mounting brackets from the trunnions by
of moving parts. sliding off the spigot.
Use the correct Personal 3 Using a 6 mm Allen key, remove the eight M8 socket head capscrews
Protective Equipment and holding the trunnions to the cylinder assembly.
4 Remove the trunnions from the cylinder and clean all components
Use the correct Personal thoroughly.
fluids.
Socket head
capscrews Cylinder
assembly
Bush
Cylinder
trunnion
Cylinder mounting
bracket
Reassembly
1 If necessary, replace the cylinder mounting bracket bushes by pressing
out the old bush and replacing with a new one.
when handling and using 2 Clean all components and apply a quality lubricant to all surfaces.
cleaning fluids.
3 Using new M8 socket head capscrews, fit the trunnion to the cylinder
Use the correct tools assembly and torque to 45 Nm (33 ftlb).
for this operation.
4 Apply a lubricant to the trunnion spigot and fit the cylinder mounting
brackets onto the spigots.
5 The cylinder assembly is now ready to be fitted into the feed frame chassis.
Replacing the Feed Cylinder

1 Insert the cylinder in through the opening in the back of the feed frame,
ensuring that the rod end of the cylinder goes in first.
Protective Equipment and 2 Lift the feed cylinder from underneath and align the twelve holes in the
tools for this operation. cylinder trunnion brackets with the carriage top plate holes.
Use the correct lifting Fit the twelve M12 bolts and torque to 77 Nm (57 lb/ft). Use Loctite stud
equipment and manual handling lock on threads.
procedures for this operation. Pivot the Rotation Unit over and tighten the latch bolts.
3 Re-connect the hydraulic hoses to the counterbalance valve connection
on the rear of the Carriage and tighten firmly.
4 Ensure the hex. half nut and lockwasher are fitted to the feed cylinder rod
and are against the cylinder rod shoulder.
5 Start the Skid Steer and move the Carriage lever rearwards to extend the
piston rod through the opening in the front of the feed frame chassis.
Possible pinch point hazard
between cylinder rod and 6 Fit the front washer and Nyloc nut to the piston rod and tighten them
opening in front of chassis finger tight.
— keep hands well clear. 7 Visually check to see if it is necessary to readjust the carriage wear strips
by looking for excessive clearance between the strips and the guide rails.
If the clearance is greater than approximately 1 mm, then the adjustment
procedure should be performed. See page 6–5 for details.
8 Re-tighten the Nyloc nut on the end of the feed cylinder piston rod.
9 Slowly move the Carriage forwards and rearwards. Ensure that the travel
is smooth in both directions and that any trapped air is removed from the
Hoses moving forwards and cylinder.
rearwards — keep immediate
area clear. This completes replacement of the feed cylinder.
Feed Cylinder Disassembly

1 Carefully tilt the removed cylinder up on its ends and drain any remaining
oil through the port openings.
Collect spent oil in a suitable
container and dispose of in an 2 Using a suitably sized ‘C’ spanner, unscrew the gland from the rod end of
environmentally responsible the cylinder and remove it. The gland may be tight to unscrew due to the
manner. rod seal and wiper gripping the rod.
Store the gland in a clean place for inspection and reassembly.
3 The piston rod assembly can now be withdrawn from the cylinder.
Withdrawal can be assisted by placing a spanner on the machined flats at
Use the correct Personal the threaded end of the piston rod and rotating it counterclockwise while
Protective Equipment and pulling.
Store the rod in a clean place for inspection and reassembly. Be careful
Cylinder may topple over not to scratch or damage it.
due to its weight — get
assistance if required. 4 Using the ‘C’ spanner, unscrew the rear end cap from the cylinder. Store
it in a clean place for inspection and reassembly.

5 Hold the piston rod assembly securely in a vice.
Use a set of soft jaws to prevent any damage to the rod.
6 It will be necessary to hold the piston rod on the machined flats with a
spanner to prevent the rod from turning in the soft jaws.
7 Remove the piston seal from the piston which will then allow access to
the locking grubscrews.
8 Remove the two M5 locking grubscrews from the piston and keep for
future use.
9 Remove the piston from the rod by fitting two M8 bolts into the tapped
holes on the end of of the piston and unscrewing.
Slide the remaining cushion collar off the rod.
10 Check the piston rod for damage and straightness. Any small scratches
or burrs can be cleaned up by rubbing with ‘wet and dry’ paper.
However, if any major damage is present the rod must be replaced.
Otherwise damage will result to the wipers and packings.
Piston rod
End cap gland Rod end gland
Feed cylinder disassembly


Use the correct Personal 11 Place the piston rod in the vice and secure firmly using soft jaws to prevent
Protective Equipment when damage to the rod.
using the drill and handling oils.
12 Apply a generous amount of hydraulic oil to the area of the rod where the
Use the correct tools piston and cushioning collar slide.
for this operation.
13 Slide the cushioning collar into position, making sure that the collar seats
firmly against the shoulder of the rod. Position the collar so that the tapered
end of the collar is against the shoulder of the rod.
14 Slide a new ‘O’ ring along the rod until it fits into the recess in the collar
cushion.
15 Fit the piston onto the rod and lock on until it is firmly against the cushion
collar.
16 Using a 4 mm drill, “dimple” the piston rod (1 mm deep) through the M5
tapped hole.
Remove the piston and clean.
17 Reassemble the piston and rod assembly, and use ‘Loctite’ (or similar) to
secure the two M5 grubscrews in place.
Ensure the grubscrews are located into the dimpled recess to hold and
prevent the rod assembly from unscrewing.
18 Fit new seals and back-up ring to the piston assembly, and lubricate with
hydraulic oil.
19 The piston rod assembly is now ready for replacement in the Cylinder.
Piston
Cushion
collar
Piston rod
Piston
seal
Piston rod assembly

Rod End Gland

Use the correct tools when 20 Remove the two ‘O’ rings from the outside diameter of the gland.
removing and refitting seals.
21 Remove both the rod seals and rod wiper from the bore of the gland and
Use the correct Personal check the gland for any damage.
for this operation. 22 Fit new rod seals into the bore of the gland, ensuring that the lip on the
seal is facing inwards towards the cylinder.
23 Fit a new rod wiper to the bore of the gland, ensuring that the lip is facing
out, i.e. away from the rod seal.
24 Fit two new ‘O’ rings to the outside grooves in the gland. Both ‘O’ rings
are identical.
Rod wiper
Rod seals
‘O’ ring
and
‘O’ ring
BU ring
and
BU ring
‘O’ ring
‘O’ ring
and
and
BU ring
BU ring
Rod end gland End cap gland
End Cap Gland

25 Remove the two ‘O’ rings from the outside of the gland and inspect the
gland for any damage.
26 Fit two new ‘O’ rings into the outside grooves.
The ‘O’ rings are identical to the ‘O’ rings used in the rod end gland.
Cylinder Reassembly
1 Clean the bore of the cylinder thoroughly with cleaning fluid, ensuring no
old oil or contamination is left behind.
Protective Equipment 2 Inspect the bore of the cylinder for any scoring.
when handling and using If O.K., apply a coating of clean hydraulic oil.
cleaning fluids.
3 Lubricate the ‘O’ rings on the end cap gland then push and screw the
gland into position in the cylinder. Lock it firmly against the cylinder using
the ‘C’ spanner.
4 Apply clean hydraulic oil to the piston seals on the piston rod. Slide the
piston rod into the cylinder, being careful to keep the rod square to prevent
damage to the seals on entry.
5 Lubricate the ‘O’ rings on the outside of the rod end gland, the rod seal
and rod wiper inside the gland with clean hydraulic oil.
6 Apply a suitable thread lubricant to the threads and carefully slide the
gland over the piston rod.
7 Push the gland into the cylinder whilst simultaneously screwing it to engage
the threads.
Use the correct tools
Tighten the gland firmly against the shoulder of the cylinder using the ‘C’
for this operation.
spanner.
The cylinder is now ready for replacement into the Feed Frame.
SECTION 6
700 SERIES (direct coupled) feed frame

6-2 Introduction
6-10 Load Transfer Direct Linkage Disassembly
Weight: Feed Frame (1.8m) 900 Kg (1.0m) 449 Kg

(incl. Rotation Unit and Rod Holder)
Chapter Reference: 700 Series Feed Frame 1.8m: P/N 3000144, 3003604
700 Series Feed Frame 1.5m: P/N 3003752
700 Series Feed Frame 1.0m: P/N 3000427
700 Series (Direct Coupled) Feed Frame 6-
Introduction
FEED FRAME (Direct Coupled)
The Feed Frame main chassis is a fabricated steel unit, incorporating the vee
profiles which form the basis of the carriage guide system.
The top section contains the feed cylinder and feed cylinder guide system
and its open construction permits easy field service and maintenance.
renewable stainless steel guide rails. The Vee-profile of the rails allows for
easy, one-step adjustment to compensate for wear. The carriage is connected
directly to the feed cylinder, eliminating the need for feed chains. The Feed
Cylinder is hydraulically cushioned at both ends to reduce shock loads during
rod handling. The feed cylinder is also fitted with counterbalance valves to
prevent dropping the load if a hose is blown.
The design of the Feed Frame allows for an overall short transporting length
when the rear section is folded inwards. (It is hinged outwards to its working
position before operations commence.)
Specifications 1.8 m 1.0 m
Feed Frame Length

(Transportation) 2990 mm (118 in) 2265 mm (89 in)
(Working) 4090 mm (161 in) 2679 mm (105 in)
Feed Length 1800 mm (71 in) 1000 mm (39.4 in)
Maximum Push 49.3 kN (11090 lbf) 55 kN (12100 lbf)
Maximum Pull 74.3 kN (16700 lbf) 85.7 kN (18855 lbf)
Carriage speed, fast 0.9 m/sec (3 ft/sec) 1.2 m/sec (3.9 ft/sec)
Weight: 900 kg (1584 lb) 449 kg (988 lb)
(Incl. Rod Holder & Rotation Unit less Jaws)
1.8 m Direct Coupled Feed Frame
1.0 m Direct Coupled Feed Frame

Assembling the Feed Frame

Remove any restraining device which is between the cylinder cover assembly
and the feed frame chassis. Using the lifting handles fitted to the guard, hinge
the cover into its working position and ensure that the eight M12 bolts are
firmly tightened.
Assembling the cylinder cover
Fit and tighten the eight M12 bolts


Important Recommended Service Intervals
Feed Frame maintenance must
be done on a regular basis to Daily:
ensure a long service life of all
components. 1 Grease carriage slides at the commencement of each shift — grease
nipples on each side.
2 Grease rod clamp outer housing — grease nipples in top and bottom
faces.
3 Grease wireline sheaves — grease nipple in each sheave.
Multi-Purpose Grease (MPG) 4 Check filter tell-tale while drilling — replace element if indicator is in raised
Suitable grease types and brand position.
names/manufacturers include:
Weekly:
— Ulti-Plex EP2 (Chevron) 5 Grease carriage hinge pin — one grease nipple at each end.
— Mobilux EP2 (Mobil)
6 Check oil level in Rotation Unit gearbox and add oil if necessary.
— Mobilith AW2 (Mobil)
7 Check adjustment of carriage slides and adjust if necessary. See page
6-6.
8 Check guide bushings in rod holder and rotation unit for wear and if
necessary, replace.
9 Check for any oil leaks from hoses or fittings and replace any worn parts.
Check rod holder bolts for tightness.
Fortnightly:
10 Remove chuck and rod holder jaws, check for gripper wear and if O.K.
clean off any scale, regrease the sides and replace.
11 Check rotation unit clamp, bushes, pins etc. for wear and replace any worn
parts.
6 4
3 11 2
3
5 8, 10
5
8,10
7 1
3 9

Important 1 Move the drill head carriage fully forward against the rod clamp and leave
The correct procedure must the Power Pack running.
the carriage. 2 Undo the four locknuts on the carriage slide adjusting bolts and leave
loose.

Loosen in two places, on each side
3 Release the tension on the hex nut which is affixing the feed cylinder piston
rod to the feed frame chassis. Do not loosen right off.

4 Insert a drill rod through the back of the chuck and open the rod clamp.
Isolate the rod clamp in the open position. Push the drill rod through the
this operation. rod clamp and close the chuck on the rod.
5 Adjust the carriage slides evenly from both sides, ensuring that the rod
is evenly spaced within the rod clamp guide bushings. The chuck should
Possible crush hazard be rotated by hand whilst performing this adjustment.
— DO NOT get hand caught
top plate.


6 Adjustment should be made so that both carriage wear strips are making
light contact with the feed frame slides. If adjusting with the feed frame in
the horizontal position, ensure that the upper wear strip is contacting the
guide rail.
Do not overtighten, otherwise overheating and premature wear to sliding

8 Retighten the hex nut on the end of the feed cylinder piston rod.
9 Slowly move the carriage forwards and rearwards and ensure that the
travel is smooth in either direction and that the drill rod passes evenly
through the rod clamp.
handling procedures for 10 Open the chuck and remove the drill rod. Add lithium base grease to the
this operation. four grease nipples on the carriage slides.

Important 1 Move the drill head carriage to a suitable working position on the feed
Complete work to one carriage frame and switch off the power pack.
side before beginning the other.
2 Disconnect hydraulic hose connecting the front feed cylinder port to the
manifold block on the carriage at the manifold block. Plug open hose
end.
High pressure oil may be
present in hydraulic hoses. 3 Remove the rear hydraulic tube connecting the other manifold block to the
Always vent feed lever on rear feed cylinder connection.
Control Panel before
4 Remove the carriage side plate by firstly removing the ten M12 capscrews
removing hoses.
using a 10mm allen key. Be careful to securely hold the side plate as the
Always wear correct Personal capscrews are removed.
5 Clean the removed carriage side plate assembly with degreasing fluid or
fluids. similar and check for any other worn or damaged components.
Ensure correct Personal 6 Remove the two plastic wear strips from the adjusting block by levering
Protective Equipment and tools out with a screwdriver.
are used for this procedure.
Rear
Manifold
Front
Manifold
Carriage Assembly
Reassembly
1 Clean the inner area where wear strips locate in the adjusting block, prior
Ensure correct Personal
to fitting the new wear strips.
Protective Equipment and tools 2 Install the new wear strips and insert new trim clips (four per side) to hold
are used for this procedure. them in position.
3 Turn the adjusting screws counterclockwise to back-off the position of the
adjusting blocks.
This will be necessary otherwise the additional thickness of the new wear
strips will obstruct proper reassembly of the side plates.
4 Reassemble the side plate assembly to the carriage and tighten the nine
(or ten) M12 socket head capscrews to 160 Nm (118 lb/ft) torque.
5 Fit the rear manifold block onto the rear of the carriage and replace the
tube clamp. Tighten the capscrews to 160 Nm (118 lb/ft).
6 Fit the front manifold block onto the carriage.
the carriage.
adjusted. See the service schedule on page 6-4 for details.

1 First remove the complete carriage side plate as already detailed.
Use the correct Personal 2 Remove the two M12 bolts and washers located at the ends of the two
Protective Equipment and adjusting screws.
tools for this application. Store these parts in a secure place for reassembly.
Adjusting block may fall 3 The adjusting block should now be free to be removed from the side
— remove when at ground level. plate.
4 Loosen the two hexagon locknuts and unscrew the two adjusting screws
from the side plate.
5 Remove the two M8 bolts to allow the threaded bushes to be pressed from
the side plate.
Reassembly
Reassembly is the reverse procedure ensuring a good quality lubricant is
applied to the adjusting screws and the bosses of the adjusting block.
Wear strip
Adjusting
Bolt block
Adjusting
screw
Locknut Threaded
bush
Trim dip
Carriage Slide assembly

1 Switch on the Power Pack and move the drill head carriage forward until
it is at the end of the cylinder stroke.
Ensure the Feed Frame is
positioned horizontally to 2 Remove the rear cylinder cover from the Feed Frame by removing the
allow for the safe removal M12 bolts and the hinge pin.
of the feed cylinder.
3 Loosen and remove the hex nut which is fastening the feed cylinder piston
Use the correct Personal rod to the feed frame chassis. Remove the flatwasher and store the nut
Protective Equipment and and washer for reassembly.
4 Disconnect the hydraulic hoses going to the feed cylinder connections on
the carriage and plug the hoses.
5 Disconnect the hydraulic hose between the front cylinder port and the
manifold block and plug both ends of the hose.
Hydraulic oil under pressure
— vent hose by cycling the 6 Disconnect the hydraulic hose from the rear cylinder port where it joins
feed lever on the Control Panel. the connection on the carriage and plug the open hose end.
7 Remove the four M12 socket head capscrews fastening the front cylinder
support bracket to the cylinder and store the capscrews safely for
reassembly.
8 Support the underneath of the feed cylinder and remove the four M12
socket head capscrews fastening the rear cylinder support bracket to the
cylinder. Store the capscrews in a safe place for reassembly.
9 The feed cylinder should now be free to be withdrawn through the back
Use the correct lifting of the feed frame.
equipment and manual
handling procedures for this
operation.
Feed Cylinder removal

Load Transfer Direct Linkage Disassembly

This part of the Feed Frame provides the method of transmitting the feed
force from the hydraulic cylinder to the drill head. The out links must always
Change out links before failure. be free to pivot and also excess clearance must not be allowed to develop
Keep clear of moving parts. between the pins and bushes. When wear does eventually occur it will be
necessary to replace the worn components.
Disassembly
Important 1 Place the Feed Frame in a horizontal position.
Refer to Rotation Unit section for
complete details of this operation. 2 Loosen the four lock nuts on the side adjusting screws and turn the screws
counterclockwise to fully back them off.
3 Loosen and remove the capscrews on the rear cylinder support bracket
bolts and the rear wear strip plates. Remove the wear strips and their
retaining plates.
4 Place four wedges between the underside of the carriage top plate and
the chassis rails to jack up the carriage.
5 Loosen the two nuts holding the head to the carriage and swing the head
away to one side.
Use correct Personal Protective
Equipment for this procedure. 6 Loosen and remove the four M10 capscrews holding the front cylinder
brackets onto the carriage top plate.
Rotation Unit is difficult to
initially pivot — use assistance. 7 Remove the rear cylinder support bracket with the links and front cylinder
bracket still attached.
8 The two links can be removed by first removing the M6 hex head bolts
and retaining plates.
Reassembly
1 Use a new bush to check the fit of the bush to the pins on the rear cylinder
support bracket and also on the carriage cylinder bracket. Replace either of
these two items if wear is excessive, as a guide up to 1 mm total clearance
is tolerable on either end.
2 Fit four new bushes to the pivot links and assemble the links to the brackets
using a good smear of grease between the mating surfaces. Install the
retaining plates and tighten the M6 hex. head bolts to 9 Nm (7 lb/ft).
3 Refit the linkage assembly into the Feed Frame. Align the four holes in
the carriage top plate with the holes in the carriage cylinder bracket. Refit
the four M10 socket cap screws and torque to 90 Nm (66 ft/lb).
4 Refit the six M12 socket cap screws to the rear cylinder support bracket.
Torque these to 160 Nm (118 lb/ft).
5 Examine the wear blocks on the two wear plates before reassembling
them to the feed cylinder. If wear is excessive, replace the wear blocks.
Torque the three M10 socket cap screws either side to 90 Nm (66 ft/lb).
6 Return the Rotation Unit to its operating position and tighten the two
nuts.
7 Adjust the carriage slide plate adjusting screws to give the correct line-up
of the drill rod through the Rod Holder. When satisfactory, tighten the four
lock nuts.
Torque to
160 Nm
(118 ft/lb)
Torque to Wear strips
90 Nm
(66 ft/lb)
Wear strip plates
Rear Cylinder
support bracket Pivot link bushes
Pivot links
Torque to
9 Nm
(7 lb/ft)
Retaining plate
Front cylinder bracket
Load Transfer Direct Linkage Assembly

Replacing the Cylinder Support Wear Strips

1 Perform steps 1–9 from the ‘Removing the Feed Cylinder’ section described
on page 6-9.
Protective Equipment 2 Slide the drill head carriage along the feed frame until the wear strips slide
for this operation. out from the rear of the chassis.
If it is also intended to replace the wear strips on the front cylinder support,
remove the carriage completely using a suitable mechanical lifting device
such as a ton chain block attached to the lifting lugs provided on the sides
of the carriage assembly.
Lifting lugs, on each side
3 The wear strips are a push fit on and off the wings of the support
bracket.
Pinch point hazard between
wear strips and chassis 4 To remove the front support bracket slide it along the guide rail and from
— slide out carefully. the end of the chassis.
Reassembly
Reassembly of the cylinder supports is the reverse procedure, applying a clean,
thin coating of grease to the stainless steel inserts when reassembling.
Replacing the Feed Cylinder

1 Insert the cylinder in through the opening in the back of the feed frame,
ensuring that the rod end of the cylinder goes in first.
equipment, Personal 2 Lift the feed cylinder from underneath and align the four holes in the
Protective Equipment, and tools rear cylinder mounting block with the holes in the rear cylinder support
for this application. bracket.
Fit the four M12 socket head capscrews and do them up finger tight.

160 Nm
3 Align the four holes in the front cylinder mounting block with the front
support bracket, and fit the four M12 socket head capscrews. Tighten
them finger tight.

160 Nm
4 Re-connect the hydraulic hose to the pipe connection on the rear of the
carriage and tighten firmly.
5 Refit the other hydraulic hose between the front cylinder port and carriage
manifold block and tighten firmly.
Ensure that all fittings are clean prior to connecting them.
6 Ensure that hex half nut and lockwasher are fitted to the feed cylinder rod
and are against the cylinder rod shoulder.
7 Start the power pack and move the carriage lever rearwards to extend the
piston rod through the opening in the front of the feed frame chassis.
between cylinder rod and 8 Fit the front washer and Nyloc nut to the piston rod and tighten them finger
opening in front of chassis tight.
— keep hands well clear.
9 The eight M12 socket head capscews which attach the front and rear
Use the correct Personal cylinder support brackets to the feed cylinder can now be tightened to
Protective Equipment and 160Nm (118lb/ft) torque.
10 Visually check to see if it is necessary to readjust the carriage wear strips by
looking for excessive clearance between the strips and the guide rails.
If the clearance is greater than approximately 1mm, then the adjustment
procedure should be performed.
See page 6-5 for details.
11 Re-tighten the Nyloc nut on the end of the feed cylinder piston rod.
travel is smooth in both directions and that any trapped air is removed
Be aware of moving hoses
from the cylinder.
when cycling.
This completes the replacement of the feed cylinder.
Feed cylinder piping assembly


1 Carefully tilt the removed cylinder up on its ends and drain any remaining
oil through the port openings.
Cylinder may topple due to its
weight — get assistance. 2 Using a suitable size ‘C’ spanner, unscrew the gland from the rod end of
the cylinder and remove it. The gland may be tight to unscrew due to the
Collect spent oil in suitable
rod seal and wiper, gripping the rod.
container and dispose of in an
environmentally responsible Store the gland in a clean place for inspection and reassembly.
manner.
3 The piston rod assembly can now be withdrawn from the cylinder.
Use the correct Personal Withdrawal can be assisted by placing a spanner on the machined flats at
Protective Equipment and the threaded end of the piston rod and rotating it counterclockwise while
tools for this application. pulling. Store the rod in a clean place for inspection and reassembly.
Be careful not to scratch or damage it.
4 Using the ‘C’ spanner, unscrew the rear end cap from the cylinder. Store
it in a clean place for inspection and reassembly.

5 Hold the piston rod assembly securely in a vice.
Use a set of soft jaws to prevent any damage to the rod.
6 Remove the Nyloc nut from the rear end of the piston rod. It will be
necessary to hold the piston rod on the machined flats with a spanner to
prevent the rod from turning in the soft jaws.
7 Slide the first cushion collar off the rod, followed by the first and second
halves of the piston assembly.
Slide the remaining cushion collar off the rod.
8 Check the piston rod for damage and straightness. Any small scratches
or burrs can be cleaned up by rubbing with wet and dry paper, but if any
major damage is present the rod must be replaced. Otherwise damage
will result to the wipers and packings.
Piston rod
Rear end cap Gland
Feed cylinder disassembly


9 Place the piston rod in the vice and secure firmly using soft jaws to prevent
damage to the rod.
10 Apply a generous amount of hydraulic oil to the area of the rod where the
cushioning collar and piston halves slide.
Protective Equipment when 11 Slide the front cushioning collar into position making sure that the collar
handling oils. seats firmly against the shoulder of the rod. Position the collar so that the
deep end of the tapered scallop section is against the shoulder of the
piston rod.
12 Slide the front half of the piston into position making sure that it seats firmly
against the front cushioning collar.
13 Slide a new piston seal along the rod using hydraulic oil for lubrication and
position it in the chamfer in the front piston half.
It is recommended that a new piston seal set be used when
reassembling.
14 Fit the back-up ring of the piston seal set to the front piston half and
lubricate with hydraulic oil.
15 Fit the central seal into position on the front piston half and lubricate with
hydraulic oil.
16 Fit the other back-up ring to the rear piston half and lubricate with hydraulic
oil. Slide the assembly into position against the front piston half.
17 Slide the rear cushioning collar into position against the rear piston half.
Position the collar so that the deep end of the tapered scallops are against
the Nyloc nut.
18 Fit a new Nyloc nut to the piston rod and lock it up firmly against the rear
cushion.
The piston rod assembly is now ready for replacement in the Cylinder.
O-ring Piston
Cushion Back-up Piston Back-up Cushion
Piston rod collar Piston ring seal ring collar Locknut
Piston rod assembly

Rod End Gland

20 Remove the two O-rings from the outside diameter of the gland.
21 Remove both the rod seal and rod wiper from the bore of the gland and
check the gland for any damage.
22 Fit a new rod seal into the bore of the gland, ensuring that the lip on the
seal is facing inwards towards the cylinder.
Use the correct tools when
removing and fitting seals. 23 Fit a new rod wiper to the bore of the gland, ensuring that the lip is facing
out, i.e. away from the rod seal.
24 Fit two new O-rings to the outside grooves in the gland. Both O-rings are
identical.
Rod wiper
Rod seals
O-ring
O-ring
Rod end gland
End Cap Gland

25 Remove the two O-rings from the outside of the gland and inspect the
gland for any damage.
26 Fit two new O-rings into the outside grooves.
The O-rings are identical to the O-rings used in the rod end gland.
O-ring
O-ring
End cap gland

Cylinder Reassembly
1 Clean the bore of the cylinder thoroughly with cleaning fluid, ensuring no
old oil or contamination is left behind.
Protective Equipment when 2 Inspect the bore of the cylinder for any scoring and if O.K., apply a coating
handling and using cleaning of clean hydraulic oil.
fluids.
3 Lubricate the O-rings on the end cap gland and push and screw the gland
into position in the cylinder. Lock it firmly against the cylinder using the ‘C’
spanner.
4 Apply clean hydraulic oil to the piston seals on the piston rod. Slide the
piston rod into the cylinder, being careful to keep the rod square to prevent
damage to the seals on entry.
5 Lubricate the O-rings on the outside of the rod end gland and the rod seal
and rod wiper inside the gland with clean hydraulic oil.
6 Apply a suitable thread lubricant to the threads and carefully slide the
gland over the piston rod.
7 Push the gland into the cylinder whilst simultaneously screwing it to engage
the threads.
Tighten the gland firmly against the shoulder of the cylinder using the ‘C’
spanner.
The cylinder is now ready for replacement in the Feed Frame.
Bit Weight Chart

Change in Resultant Bit Force
Holdback Pressure
(P2) in MPa kN lbf
1 2.86 642
2 5.72 1285
3 8.57 1927
4 11.43 2570
5 14.29 3212
6 17.15 3855
7 20.01 4497
8 22.86 5140
9 25.72 5782
10 28.58 6425
11 31.44 7067
12 34.30 7710
13 37.15 8352
14 40.01 8995
15 42.87 9637
(1 MPa = 10 bar)

700 SERIES (CHAIN COUPLED) FEED FRAME

6-2 Introduction
6-7 Carriage Side Plate Reassembly
6-8 Adjusting the Feed Chains
6-10 Chain Sheave Removal and Disassembly
Weight: Chain Coupled Feed Frame 750 Kg (1650 lb)

(incl Rotation Unit and Rod Holder)
Chapter Reference: 700 Series Feed Frame 1.8m: P/N 600908

BOART LONGYEAR 700 Series (Chain Coupled) Feed Frame 6-2
Introduction
FEED FRAME (Chain Coupled)
The Feed Frame main chassis is a fabricated steel unit, incorporating the
vee profiles which form the basis of the carriage guide system.
The chassis contains a double ended feed cylinder, which has hardened,
smooth sheave wheels fastened at each piston rod end. The sheaves transmit
the feed to the drill head carriage by way of high capacity leaf chains
connected to the front and rear of the carriage.
renewable stainless steel guide rails. The vee profile of the rails allows for
easy, one-step adjustment to compensate for wear.

Feed Length 1800 mm (71 in)
Maximum Push 66.5 kN (14,960 lbf)
Maximum Pull 66.5 kN (14,960 lbf)
Carriage speed, fast 0.75 m/sec (30 in/sec)
Weight 750 Kg (1650 lb)
(incl. Rotation Unit and Rod Holder)
1.8m Chain Coupled Feed Frame


Recommended Service Intervals
Use the correct Personal 1 Apply E.P. grade grease to all 9 grease nipple points at intervals noted:
• carriage slides, daily 2 places.
for this operation.
• feed cylinder sheave assemblies, daily 2 places.
Important • rod clamp, daily 2 places.
It is important for a long service
life of components and optimum • carriage hinge pin, weekly 2 places.
drilling performance, that Feed • chuck labyrinth seal, weekly 1 place.
Frame maintenance be done on a
regular basis to ensure a long 40 hour Checks
service life of all components.
2 Check carriage guide system wear and if necessary perform adjustment
as detailed on page 6-4.
3 Check feed chain tension and if necessary perform adjustment as detailed
on page 6-8.
Suitable grease types and brand 4 Check guide bushings in rotation unit and rod clamp for wear and replace
names/manufacturers include: if necessary.
5 Check oil level in rotation unit gear case and top up if required. See page
— Ulti-Plex EP2 (Chevron) 5-3 for oil specifications and quantity.
— Mobilux EP2 (Mobil) 6 Check all bolts and screws for tightness or being missing. Rectify as
— Mobilith AW2 (Mobil) required.
100 hour Checks

7 Remove chuck and clamp jaws, clean and inspect and if O.K. replace
after applying grease to sides of jaws.
8 Check rotation unit mounting pins, bushes and hinge bolts are all tight
and the rotation unit is secure.
9 Inspect guide rail inserts for excessive wear and replace when necessary.
10 Inspect rod clamp for loose or missing bolts, retaining pins, bushes, etc.
and rectify as required.
6 5 7 4 3 10
Grease nipple
location
9 8 2
Feed Frame service and maintenance points


The following procedure is recommended when attempting carriage alignment
and adjustment.
1 Position the drill head carriage towards the rear of the feed frame and
insert a straight drill rod through the chuck, stopping the rod before it
for this operation.
contacts the rod clamp.
Important 2 Close the chuck by moving the rod handling/drilling selector lever to the
The correct procedure must drill position.
the carriage. 3 Undo the four hexagon lock nuts on the carriage slide adjusting bolts and
leave them loose.
Loosen in two places each side
4 Carefully adjust the carriage wear blocks evenly from both sides, aiming
to position the drill rod evenly within the guide bush in the rod clamp.
The chuck should be rotated by hand whilst performing this adjustment.
operation. 5 Adjustment should be made so that both carriage wear strips are making
Possible crush hazard — Do not
light contact with the vee profile in the feed frame. If adjusting with the
get hands caught between the feed frame in the horizontal position, ensure that the upper wear strip on
Chuck and the carriage top the carriage is in contact with the feed frame guide.
plate. Do not overtighten!
Adjust
6 When adjustment is satisfactory, lock the wear blocks in position by

tightening the four carriage locknuts.
7 Slowly feed the carriage forwards and rearwards using the fine feed control.
Ensure that the travel is smooth and that the drill rod passes evenly through
the rod clamp.
8 Open the chuck and remove the drill rod.
Add lithium base E.P. grease to the grease nipple on each side of the
carriage.

1 Move the drill head carriage to a suitable working position on the feed
frame and switch off the Power Pack.
Carriage side plate may fall —
Complete work to one carriage side before beginning the other.
Always use the correct

2 Remove the ten M12 socket head capscrews along the side of the carriage
Personal Protective Equipment using a 10mm allen key.
and tools for this procedure, 3 Clean the removed carriage side plate assembly with a degreasing fluid
especially when handling and and check further for any other worn or damaged components.
using cleaning fluids.
4 Remove the two plastic wear strips from the adjusting block by levering
out with a screwdriver.
Rear
Manifold
Front
Manifold
Carriage assembly

1 Perform steps 1-4 in the preceding section.
Use the correct Personal 2 Remove the two M12 socket head capscrews located at the ends of the
Protective Equipment and tools two adjusting screws using a 10mm allen key.
for this operation. Store these parts in a secure place for reassembly.
Adjusting block may fall — 3 The adjusting block should now be free to be removed from the side
remove when at ground level plate.
or on bench.
4 Loosen the two hexagon locknuts and unscrew the two adjusting screws
Reassembly
Reassembly is the reverse procedure ensuring a good quality lubricant is
applied to the adjusting screws and the bosses of the adjusting block.
Carriage Side Plate Reassembly

1 Clean the inner area where the wear strips locate in the adjusting block,
prior to fitting the new wear strips.
Protective Equipment and tools 2 Install the new wear strips and insert four new trim clips to hold them in
for this operation. position.
3 Loosen the two locknuts on the adjusting screws and turn the screws
counterclockwise to back-off the position of the adjusting blocks.
This may be necessary, otherwise the additional thickness of the new
wear strips may obstruct proper reassembly of the side plates.
4 Reassemble the side plate assembly to the carriage and tighten the ten
M12 socket head capscrews to 160Nm (118 lb/ft) torque.
Tighten to 160 Nm (118 lb/ft)
the carriage.
adjusted. For further details see the previous section, ‘Adjusting the
Carriage Slides’, on page 6-4.
Adjusting the Feed Chains

Check chain tension at least once a week. With a correct chain tension, the
chain should be taut whenever the carriage is at the end of its stroke.
The procedure for adjusting both the front and rear chains is the same.
for this operation.
1 To adjust the front chain it may be easier if the Rotation Unit is first hinged
open to provide easier access.
2 The Rotation Unit can be left in place when adjusting the rear chain.
Adjust
Loosen
Adjust
Loosen
Front chain adjustment Rear chain adjustment
3 Loosen the M24 locknut on the chain clevis.

4 Adjust chain to the required tension by tightening the adjusting nut.
Retighten the locknut when this is achieved.
5 Apply lubricating oil or similar to the chains before recommencing
operation.

1 Move the carriage to a suitable working position on the Feed Frame and
switch off the Power Pack.
Protective Equipment and tools 2 Disconnect the two hydraulic hoses where they connect to the fittings and
for this operation. on the rear of the Feed Frame and plug and cap the open ports.
Ensure the Feed Frame is 3 Loosen the locknuts on the front and rear feed chains and release the
positioned horizontally to allow chain tension.
for the safe removal of the feed
4 Remove the chain clevis pins and separate the chains from the clevises.
cylinder.
Secure the Rotation Unit by a sling and mechanical lifting device before
proceeding with step 5.
handling and lifting procedures
for this operation. 5 Loosen and remove the seven M12 socket head capscrews on each
The Rotation Unit may be carriage side plate and remove the plates as an assembly.
difficult to initially move 6 Lift the Rotation Unit from the Feed Frame complete with the carriage top
— seek assistance. plate.
7 From underneath the Feed Frame, disconnect the short hydraulic tubes
which are connected to the feed cylinder ports and remove the two tubes.
Store these for reassembly.
8 Loosen and remove the four M20 nuts and socket head capscrews which
fasten the front and rear cylinder retaining plates in position.
9 To allow removal of the feed cylinder, the retaining plates must first be
turned lengthwise inside the chassis (see illustration below).
10 The feed cylinder can now be removed from the chassis by lifting it through
the opening in the top of the frame.
11 Be careful not to damage the piston rods as the cylinder is removed and
transported to a suitable working area.
Feed Cylinder Replacement

Replacing the feed cylinder is the reverse procedure ensuring that the carriage
alignment is correctly adjusted prior to restarting drilling.
Feed Cylinder removal

Chain Sheave Removal and Disassembly

Removal
Use the correct Personal 1 To remove the sheave assembly from the cylinder rod, loosen the M20
Protective Equipment and tools capscrew which crimps the yoke onto the rod.
for this operation.
2 The sheave assembly can be removed by unscrewing it from the rod.
3 Remove the keeper plate which retains the sheave pin in place by removing
the two M10 hex head bolts.
4 Using a suitable mandril or soft punch, remove the sheave pin from the
yoke.
5 Remove the sheave wheel from the yoke along with the bearing seals
and spacers.
between sheaves and feed 6 To remove the bearings from the sheaves, firstly remove the circlips and
frame — remove slowly. then remove the bearings by pressing on their outside diameter.
Circlip under pressure
There is a spacer between the two bearings which will drop out as the
— cover whilst removing. bearings are removed.

removing and refitting bearings.
Reassembly
Use the correct Personal 1 Clean the bare sheave wheels thoroughly and carefully inspect them for
Protective Equipment when excessive wear or damage. If necessary they should be replaced.
2 Fit a new circlip into one of the circlip grooves.
fluids.
3 Place the sheave on its side and carefully press a new bearing evenly
into position so that it sits snugly against the installed circlip.
4 Install the bearing spacer into position against the located bearing.
5 Fit the second bearing into the sheave bore and carefully press it into
location against the spacer.
6 Fit the top circlip so that it fits snugly into its groove.
7 Fit new Vee Seals onto the spacer shoulders.
8 Carefully manoeuvre the sheave wheel and spacers into position in the
yoke.
9 Align the bore diameters together and carefully insert the sheave pin into
location, gently tapping it through the sheave wheel.
10 When the pin is completely through, fit the keeper plate into the slot,
locking it in place with the two M10 bolts.
11 Apply good quality, lithium based grease to the grease nipple in the ned
of the pin.
When refitting the sheave assemblies to the piston rods, they must
be tightened so that they are aligned parallel and that the overall
length from the centres of the two clevis pins is approx. 2370 mm.
Also a gap of approx. 2.5 mm should exist from the back face of
each yoke, to the cylinder rod shoulder.
Keeper plate
Pin
Spacer
Circlip
Bearing
Vee seal
Spacer
Sheave assembly

1 The cylinder end caps are a push fit into the ends of the cylinder body and
can be separated from the body by either:
a) rotating the end cap whilst pulling on it
for this operation. or
Use the correct Personal b) clamping the cylinder body, then rotating and simultaneously pulling
Protective Equipment when or pushing on the cylinder rod. This will push or pull one of the end
using cleaning fluids and caps from the body.
handling oils.
2 When all components are separated, clean thoroughly and carefully
inspect for wear or damage.
3 It is not necessary to separate the piston rods from the piston assy for the
purpose of fitting new piston seals.
Feed Cylinder Reassembly

4 Lubricate the grooves in the two end caps and carefully fit into position
the new rod wipers and rod seals.
Note correct orientation of these parts as shown on the Feed Cylinder
assembly illustration below.
5 Lubricate the grooves on the outside of the two end caps with clean
hydraulic oil and fit the new backup washers and o-rings.
Note the correct location of the backup rings as shown on the illustration
below.
6 Smear oil over the outside of the rod piston and slide two new piston
seals into the grooves.
Note the correct orientation of the seals as shown on the illustration below.
7 Ensure that the bore of the cylinder body is clean and free from scratches
and apply a smear of clean hydraulic oil.
8 Carefully insert the piston rod assembly into the cylinder body making
sure it is square on entry.
Stop when it is approximately in half way, i.e. there is equal rod length
protruding from either end of the cylinder body.
9 Slide the two end caps over the piston rods and push them into position in
the ends of the body.
10 The feed cylinder is now ready for replacement in the Feed Frame.
Rod wiper
Cylinder body Rod seal
End cap
Cylinder rod
Piston seal
Piston
Feed Cylinder arrangement

Bit Weight Chart

Chang e i n R esultant B i t Force
H old b ack Pressure
(P2) i n MPa kN lb f
1 2.55 573
2 5.10 1146
3 7.64 1719
4 10.19 2291
5 12.74 2864
6 15.29 3437
7 17.84 4010
8 20.38 4583
9 22.93 5156
10 25.48 5730
11 28.03 6302
12 30.58 6874
13 33.12 7447
14 35.67 8020
15 38.22 8593
(1 MPa = 10 bar)
SECTION 6
1300 Series Feed Frame

6-2 Introduction
6-3 The Cylinder Cover
Extending the Cylinder Cover
Retracting the Cylinder Cover for transportation
6-5 The Telescopic Rod Slide

Extending the Telescopic Rod Slide

Recommended Service Intervals

6-11 Changing the Feed Frame Push and Pull Forces
Reconfiguring the Feed Frame for Greater Push Force
Reverting back to Maximum Pull Configuration
6-19 The Feed Cylinder


6-24 Feed Cylinder Reassembly

6-25 Bit Weight Charts
Weight: 1300 Series Feed Frame 980 Kg (2156 lb)
Chapter Reference: 1300 Series Feed Frame: p/n 602096

1300 Series Feed Frame 6-
Introduction
FEED FRAME
The feed frame main chassis is a fabricated steel unit incorporating the vee
profiles which form the carriage guide system. Stainless steel slides are fitted
to the chassis to provide a long life, replaceable system.
The rear cover section of the feed frame contains the rod support roller and
the wireline sheaves. This section can be partly disassembled to allow the
overall length of the feed frame to be reduced for transport purposes. A
telescopic rod slide is also included which can be extended when working
space permits, providing improved inner tube handling facilities.
The design of the feed frame allows for the push and pull forces to be reversed,
providing increased up hole drilling capacity. The feed cylinder is hydraulically
cushioned at both ends to reduce shock loads during rod handling.
The drill head carriage assembly is fitted with renewable synthetic wear pads
which are adjustable with the slides on the feed frame. The vee profile provides
for easy, one step adjustment without the need for shims.

Feed Length 1830 mm (72 in)
Maximum Push 61 kN (13420 lbf)
Maximum Pull 123.4 kN (27148 lbf)
Carriage speed, fast 0.77 m/sec (30 in/sec)
Weight (approx.) 980 kg (2156 lb)
excl. Rod Holder & Rotation Unit
The Cylinder Cover

The feed frame is shipped with the rear cylinder cover containing the wireline
sheaves moved into the forward travelling position. The cover must be
extended before drilling can commence.
Extending the Cylinder Cover

1 Start the drill and carefully move the carriage on the frame to align the
holes in the two carriage lugs with the matching holes in the cylinder cover
Use the correct Personal lugs. Fit the two pins when this is achieved.
tools for this operation. 2 Slowly drive the carriage and cover rearwards until the stop located under
the cylinder cover slides out of the feed frame chassis.
Ensure the area is clear of
personnel before moving the 3 It is necessary to align the stop firmly against the feed frame chassis. Do
carriage and extending the this by first selecting drilling mode and, under a light feed pressure, move
cover. the carriage forwards until the stop makes contact.
4 Secure the lower channel section in place with the two M10 hexagon head
bolts.
5 Secure the M24 sheave extension bolt.
6 Adjust the two lock nuts to tighten the vee blocks into the chassis vee
slides.
7 Install the two retaining plates and position with M10 hex. head bolts.
8 Remove the two cover movement pins and stow these in the nylon retaining
clips provided on top of the cover.
9 The wireline sheave bracket can now be attached to the lower channel
section using the four bolts provided.
Wireline sheave bracket
Vee blocks
is awkward to handle
— get assistance to fit.
Lock nuts
M24 sheave extension bolt
Retaining plates
M10 hex. head bolts
Removable wireline sheave
Extending and retracting the Cylinder Cover

Retracting the Cylinder Cover for transportation

Use the correct Personal 1 Unbolt the wireline sheave assembly and store it and the bolts in a secure
Protective Equipment and tools location for reassembly.
for this operation.
2 Remove the two securing bolts located under the lower channel section.
Wireline sheave bracket is
3 Back off the two locknuts on the two side locking bolts and then unscrew
awkward to handle — seek
assistance when removing.
the two bolts, but leaving them retained in the cover assembly.
4 Undo the M10 hex. head bolts holding the two retaining plates in position
and remove the plates.
5 Move the carriage slowly rearwards until the holes in the two lugs align
with their corresponding holes in the cylinder cover. Fit the two pins when
this is achieved.
6 Using feed control, move the carriage a small distance further rearwards
to relieve the load on the lower channel stop.
personnel before moving the 7 Lift the lower channel slightly to permit the stop to go back inside the feed
carriage and retracting the frame chassis. Now move the carriage carefully forwards until the cover
cover. has been fully retracted.
Important
Carriage movement is 1830 mm.
Cover movement is only 800
mm. DO NOT attempt to move
forwards by more than this
amount.
The Telescopic Rod Slide

Extending the Telescopic Rod Slide
The rod slide must be extended 1 First loosen the four locking bolts in each of the tube locking rings.
prior to setting the feed frame
onto its angle.
2 Manually pull out the extension to the desired position which is normally
fully extended if working space permits.
protective Equipment and tools 3 Securely tighten the four locking rings.
Use the correct manual Four locking rings

operation.
Four locking bolts
Telescopic Rod Slide
Use the correct supports when

clamping the extension. 4 Support the end of the extension to prevent its deflection during the
operation of the wireline hoist.
1300 Series Feed Frame 6-6

Important Recommended Service Intervals
Feed Frame maintenance must
be done on a regular basis to
Daily:
ensure a long service life of all 1 Grease carriage slides at the commencement of each shift — grease
components. nipples on each side.
2 Grease wireline sheave — grease nipple in each sheave.
3 Check clogging indicator on the chuck filter whilst drilling — replace element
Use the correct Personal if the indicator is in the “red” zone.
4 Using a clean rag or brush, apply grease to the slide rails.
tools when handling and
using cleaning fluids.
Weekly:
5 Grease carriage hinge pin — one grease nipple each end.
6 Check oil level in Rotation Unit gearbox and add oil if necessary.
7 Check the gap between the carriage wear strips and feed frame rails, and
Suitable grease types and brand
names/manufacturers include:
adjust if necessary. See page 6-7.
— Unirex EP2 (Imperial Oil) 8 Check guide bushings in rod holder and rotation unit for wear — replace
— Darina XL EP2 (Shell) if necessary.
— Ulti-Plex EP2 (Chevron)
— Mobilux EP2 (Mobil) 9 Check for any oil leaks from hoses or fittings and replace any worn parts.
— Mobilith AW2 (Mobil) Check rod holder bolts for tightness.
Fortnightly:
10 Remove the chuck and rod holder jaws, and clean out the empty recesses.
Check for gripper wear and if O.K. clean off any scale, regrease the sides,
and replace.
handling procedures when 11 Check rotation unit clamp, bushes, pins etc. for wear and replace any worn
lifting and cleaning jaws. parts.
6 3
11 8,10
8,10
2 5
7 7 9
2 2 1 1

Important 1 Move the drill head carriage fully forward against the rod clamp and leave
The correct procedure must the Power Pack running.
the carriage. 2 Undo the four locknuts on the carriage slide adjusting bolts and leave
loose.

Personal Protective Equipment Removable links
Loosen in two places on each side
3 Insert a drill rod through the back of the chuck and open the rod clamp.
Isolate the rod clamp in the open position. Push the drill rod through the
Use the correct manual rod clamp and close the chuck on the rod.
this operation.
4 Adjust the carriage slides evenly from both sides, ensuring that the rod
is evenly spaced within the rod clamp guide bushings. The chuck should
Possible crush hazard be rotated by hand whilst performing this adjustment.
— DO NOT get hand caught
top plate.


5 Adjustment should be made so that both carriage wear strips are making
light contact with the feed frame slides. If adjusting with the feed frame in
the horizontal position, ensure that the upper wear strip is contacting the
guide rail.
Do not overtighten, otherwise overheating and premature wear to sliding

7 Retighten the hex nut on the end of the feed cylinder piston rod.
travel is smooth in either direction and that the drill rod passes evenly
Use the correct manual through the rod clamp.
this operation. 9 Open the chuck and remove the drill rod. Add lithium base grease to the
four grease nipples on the carriage slides.

Important 1 Move the carriage to a suitable working position on the feed frame and
Complete work to one carriage switch off the drill.
side plate before commencing
work on the opposite side. 2 Loosen and remove the eight M16 capscrews located on the carriage side
plate which bolt though to the top plate.
3 Carefully remove the side plate as an assembly and transfer it to convenient
working location.
Protective Equipment and 4 Clean the removed carriage side plate assembly with a degreasing
tools for this operation. compound and check for any other worn or damaged components.
Side plate assembly is heavy 5 Remove the wear strips from the two adjusting blocks by levering them
— use the correct lifting out with a screwdriver.
equipment, or seek assistance
6 Clean the vacated cavity in the block then press in a new wear strip, holding
if needed.
it in place with a new set of trim clips.
See page 6-7 for the correct 7 Reassembly of the carriage is in the reverse procedure paying careful
carriage adjustment procedure. attention to the realignment of the drill head with the rod holder.

when handling and using
cleaning fluids.
Carriage disassembly

1 Remove the complete carriage side plate assembly as already detailed
on page 6-9.
Protective Equipment and 2 Remove the two M12 socket head capscrews and washers located at the
tools for this application. ends of the two adjusting screws.
Side plate assembly is heavy Store these parts in a secure place for reassembly.
— use the correct lifting 3 The two adjusting blocks should now be free to be removed from the side
equipment or seek assistance
plate.
if required.
4 Loosen the two hexagonal locknuts and unscrew the two adjusting screws
5 Remove the two M8 bolts to allow the threaded bushes to be pressed from
the side plate.
Reassembly
Reassembly is the reverse procedure. Ensure a good quality lubricant is
applied to the adjusting screws and bosses of the adjusting blocks. Clean
when handling and using all components.
cleaning fluids.
Threaded bush
Wear strip
Trim clip
Adjusting block
Side plate
Locknut
Adjusting screw
Changing the Feed Frame Push and Pull Forces

The design of the 1300 Series feed frame permits the push and pull ratings
of the feed frame to be reversed. This provides additional feed force for the
drilling of long holes that are inclined upwards. In the majority of applications
the feed frame will have sufficient capacity when set in the high pull/low push
mode. This is the configuration in which it will be delivered from the factory.
Reconfiguring the Feed Frame for Greater Push Force

In this configuration, the cylinder barrel is locked stationary and the cylinder
rod moves with the carriage. Therefore on an LMA drill the linear transducer
Use the correct Personal cable must be unplugged from the junction box and connected directly (i.e.
Protective Equipment and via an adaptor) to the PLC enclosure. The linear transducer is not used on
tools for this application. an LM drill.
Rotation Unit is difficult
to initially pivot — seek 1 Using the feed control, move the carriage to its fully forward position.
assistance. 2 Remove the six M16 capscrews in the carriage top plate and then loosen
Ensure the area is clear of the rotation unit rear wedge arrangement. Swing over the rotation unit
personnel before moving together with its base plate. This will give access to the two links that must
the carriage. be removed and relocated.
Removable links
Cylinder set-up for Maximum Pull mode

3 Loosen and remove the eight M12 retaining capscrews that are fastening
the links to the lugs on the cylinder and on the carriage. Remove the
Use the correct Personal links.
Remove links
4 Next remove the link caps from the front mounts at the end of the piston
rod. Clean and lubricate these and then refit them to the rear mounts which
Always wear the correct are on the cylinder.
when handling and using
cleaning fluids. Rear mounts
Be aware of possible pinch

point between chassis and link
caps when removing.
Note: It will be necessary to move 5 Clean and lubricate the two moveable links and align these over the front
the carriage to achieve this using mounts on the end of the cylinder and also on the intermediate mounts
the Fine Feed control. located under the carriage.
Front mounts
Moveable link
Use the correct Personal Intermediate mounts
when handling cleaning fluids
6 Refit the eight M12 capscrews and torque these uniformly to 135 Nm
(100 lb/ft). Loctite 222 can be used on these capscrews.
Rotation Unit is difficult to
initially pivot — use assistance. 7 Lower the rotation unit back into its operating position and refit the six
M16 capscrews and torque these to 330 Nm (245 lb/ft).
points when hinging out the 8 Re-tighten the wedge arrangement at rear of rotation unit. This absorbs
Rod Holder. the axial forces applied through the feed frame when rod handling.
9 Release the M24 holding bolts securing the rod holder in the drilling
position and then hinge it out of location.
10 Remove the four M16 capscrews used for securing the end of the cylinder
rod bracket to the feed frame chassis. The capscrews are not required
Use the correct Personal for the new configuration so store them in a safe location for future
reassembly.
Store for reassembly
11 Lower the rod holder back into location and tighten the retaining bolt
firmly.
points between rod holder and 12 Using the feed control, carefully extend the cylinder barrel until it is about
chassis when lowering. half way out beyond the end of the feed frame chassis. Lever the cylinder
assembly rearwards until the attaching bracket can be fitted.
handling procedures when 13 Fit the bracket for attaching the cylinder barrel to the chassis into location.
levering the cylinder. This bracket is kept stored at the end of the chassis when not in use. Fit
Use the correct Personal the four M16 capscrews and do them up tight. Lubricate the threads.
handling greases, oils, etc. Rear mounts
Note: It is necessary to interchange 14 Using the feed control, move the carriage slowly forwards until the bracket
the feed cylinder hoses on the attached to the cylinder contacts the chassis. Fit the three M16 capscrews
cylinder port connections. Place into place to fasten the cylinder barrel to the chassis.
hose marked A on the B port
connection and the hose marked B
Tighten all seven M16 capscrews to 330 Nm (245 lb/ft).
on the A port connection. The feed frame is now ready for operation.


personnel before moving the
carriage.
Feed Frame configured for Maximum Push Force

Reverting back to Maximum Pull Configuration

Use the correct Personal In this configuration the cylinder rod is stationary and cylinder barrel moves
Protective Equipment and together with the carriage. Therefore on an LMA drill the linear transducer
tools for this application. cable can be plugged back into the junction box. The linear transducer is not
used on an LM drill.
1 Use the feed control to drive the carriage to its maximum forward
position.
2 Loosen and remove the seven M16 capscrews to detach the mounting
personnel before moving the
bracket from between the cylinder barrel and feed frame chassis.
carriage.
Exploded view of set-up for Maximum Push mode
3 Reposition the bracket into its storage location on the end of the feed
frame chassis. Refit the remaining capscrews to the cylinder.
4 Release the M24 holding bolts and swing over the rod holder.
Be aware of possible pinch 5 Install the four M16 cap screws to attach the rod end mounting bracket to
points when pivoting the rod the chassis. Tighten to 330 Nm (245 lb/ft).
holder.
Use the correct manual Stored for reassembly

handling procedures when
pivoting the rod holder.
6 Lower the rod holder back into location and re-tighten the M24 bolts.
Use the correct Personal 7 Loosen and remove the six M12 capscrews on the carriage top plate and
Protective Equipment and loosen the locking wedge at the back of the rotation unit. Hinge the rotation
tools for this application. unit over.
Be aware of possible pinch 8 Loosen and remove the eight M12 capscrews fastening the moveable links
points between the rod holder to the front mount on the cylinder rod bracket and the carriage mounts.
and chassis when lowering. Remove the links.
9 Remove the link caps which were being stored on the rear mounts on the
cylinder barrel and fit these to the front mounts at the cylinder rod end.
Use the correct manual Apply a smear of grease to the inside of the caps before refitting them.
handling procedure.
10 Clean and lubricate the bearing surfaces of the moveable links and fit these
Note: It may be necessary to to join the mounts on the carriage with the rear mounts on the cylinder
have the drill running to position barrel.
the cylinder.
11 Fit the eight M12 capscrews to the moveable links and uniformly pre-torque
to 135 Nm (100 lb/ft).
Torque to 135 Nm (100 lb/ft)
Cylinder set-up for Maximum Pull mode

12 Lower the rotation unit back onto the carriage and fit the six M16 capscrews
finger tight. Reset the locking wedge at the back of the rotation unit and
Use the correct Personal torque the M16 capscrews to 330 Nm (245 lb/ft).
tools for this application. 13 Interchange the feed cylinder hoses so that the hose marked A is connected
to the A port on the feed frame and the hose marked B is connected to
Rotation Unit is difficult
to initially pivot — seek
the B port.
assistance. The feed frame is now set ready for use.
Oil under pressure may be

present in hoses. Always vent
the Feed lever on the Control
Panel before removing hoses.
Collect waste oil in a suitable

container and dispose of in an
manner.
Feed Frame configured for Maximum Pull Force

The Feed Cylinder

Important: Removing the Feed Cylinder
The work should be performed
with the feed frame lowered into a 1 When in Maximum Pull Configuration
horizontal position.
Follow this procedure to remove the feed cylinder for servicing when the feed
frame is set up in its standard (high pull) configuration.
On an LMA drill it is first necessary to unplug the cable for the linear transducer
at the rotation unit junction box.
Use the correct Personal If the feed frame is fitted with the optional belt guard for the cylinder rod it
Protective Equipment and is also necessary to release the tension on the belt and then detaching the
tools for this application. belt from the cylinder.
1 It is first necessary to remove the rear cylinder cover assembly. Do this
equipment to remove the cover.
by retracting the rod slide and by removing the two bolts located on the
lower cylinder guard, the two side securing bolts, and the two retaining
plates.
2 Remove the six M16 capscrews in the carriage top plate and then loosen
Rotation Unit is difficult to the rotation unit rear wedge arrangement. Swing over the rotation unit
initially pivot — use assistance. together with its base plate. This will give access to the two links that must
be removed.
3 Loosen and remove the eight M12 retaining capscrews that are fastening
the links to the lugs on the cylinder and on the carriage. Remove the links
and store all removed parts in a safe place for reassembly.
4 Remove the four M16 capscrews used for securing the end of the cylinder
Use the correct manual rod bracket to the feed frame chassis.
handling procedures and lifting
5 Loosen and remove the single M24 capscrew which is fastening the
equipment when removing the
cylinder.
cylinder rod bracket to the end of the cylinder piston rod.
6 Withdraw the cylinder through the back of the feed frame.
7 Refitting the cylinder is the reverse procedure. Ensure a good quality
lubricant is applied to bolts, and replace any damaged components.
Cylinder removal from Maximum Pull mode

2 When in Maximum Push Configuration

Use the correct Personal 1 It is first necessary to remove the rear cylinder cover assembly. Do this
Protective Equipment and tools by retracting the rod slide and by removing the two bolts located on the
for this application. lower cylinder guard and the two side securing bolts.
Use the correct lifting 2 Loosen and remove the three M16 capscrews to detach the mounting
equipment to remove the cover bracket from between the cylinder barrel and feed frame chassis.
and when removing the cylinder
assembly. 3 Loosen and remove the single M24 capscrew which is fastening the
cylinder rod bracket to the end of the cylinder piston rod.
4 Withdraw the cylinder through the back of the feed frame.
5 Refitting the feed cylinder is the reverse procedure. Ensure a good quality
lubricant is applied to bolts, and replace any damaged components.

handling procedures when
removing the cylinder.
Cylinder removal from Maximum Push mode (with end cover removed)
Replacing the Cylinder Support Wear Strips

1 Move the carriage assembly to the front of the Feed Frame to allow easier
access.
Protective Equipment and tools 2 Undo the three M12 socket head capscrews and slide the wings out of
for this application. the ‘C’ channel slides.
Beware of potential pinch point Do one assembly at a time.
hazard between wear strips and 3 The wear strips are a push on and off fit onto the wings.
chassis — slide out carefully.
4 Reassembly of the cylinder supports is the reverse procedure. When
reassembling, apply a clean, thin coating of grease to the stainless steel
inserts.
M12 socket head capscrews
Support wings
Wear strips

1 Carefully tilt the removed cylinder up on its ends to drain any residual oil
from the port openings.
Cylinder may topple due to its
weight — get assistance. 2 Using a suitable size ‘C’ spanner, carefully unscrew the gland from the rod
Collect spent oil in a suitable
end of the cylinder. Store the gland in a safe place for further dismantling
container and dispose of in an at a later stage.
manner. 3 The piston rod assembly can now be withdrawn from the cylinder. Store
the rod for further dismantling. Withdrawal can be assisted by placing a
wrench on the flats on the rod and rotating the assembly while pulling.
for this application. 4 Unscrew the rear gland from the opposite end of the cylinder.
Store the gland in a safe place for further dismantling at a later stage.
Note: The rod should be
extended a small amount when
doing this so that the seals and
wipers slide over the piston rod as
1 Hold the piston rod assembly securely in a vice, and use soft jaws in the
the gland is being unscrewed.
vice to prevent damage to the piston rod.
2 Undo and remove the rod end piece from the end of the piston rod.
3 Loosen and remove the four M4 socket head capscrews from the opposite
end of the piston rod and remove the magnet and spacer washer. Store
these components in a safe place for reassembly.
Important
4 If necessary, the piston can be unscrewed from the piston rod. The piston
Be careful not to damage any of
the sealing surfaces whilst this is
has two tapped holes on its end face which are intended for attaching a
being done. makeshift assembly/disassembly tool. It is not necessary to remove the
piston to replace the piston packing.
5 Slide the cushion sleeve from the piston rod.
6 Check the piston rod for damage and straightness.
7 Any small damage can be cleaned up by rubbing with wet and dry paper,
however if major damage is noticeable, the rod should be replaced.
Otherwise damage will result to the rod wipers and seals.
Front gland
Rear gland
Cylinder Gland removal

Feed Cylinder arrangement
Removal of transducer (LMA90 only)

Feed Cylinder Reassembly

Use the correct Personal 1 Place the piston rod in the vice and secure firmly using soft jaws to prevent
Protective Equipment and tools damage to the rod.
for this application, and when
handling oils.
2 Apply a smear of clean hydraulic oil to the surface where the cushion
sleeve and piston locate.
Beware of burns resulting from
exposure to hot water — use 3 Slide the cushion sleeve into position until it comes into contact with the
correct Personal Protective shoulder on the rod.
Equipment.
4 The new O-ring that locates into the groove in the bore of the piston should
Use the correct manual be dipped in clean hydraulic oil and then fitted into place.
handling procedures for the
5 Locate the O-ring seal that goes into the groove on the outside of the
cylinder rod and barrel.
piston, dip it in hydraulic oil and then fit it into position.
removing and refitting seals, 6 Screw the piston assembly into location on the end of the piston rod
etc. tightening it firmly against the cushion sleeve.
7 The new piston packing must be heated up and softened before it can be
Note: The piston packing must
stretched over the piston. This can be done by immersing it in either hot
be assisted back into its normal
oil or water which has been heated to 80 to 90 degrees C. When it is soft
shape after it has been stretched.
This can be done with a 10 deg.
(usually after a few minutes) carefully remove it and fit it into place.
tapered sleeve which has been 8 Fit new O-rings and backup rings into place on the rear gland, using
machined approx. 2 mm bigger hydraulic oil as lubricant.
than the piston at its opening and
reducing to approx. 0.02 mm at 9 Apply some thread grease to the gland to prevent thread galling and screw
the opposite end. The smaller it into place in the cylinder.
end of the sleeve should have a If the cylinder has a transducer fitted do not install it at this stage
parallel section the length of the (see para 13 below).
piston packing plus another 2 mm
either end. 10 Smear clean hydraulic oil in the opening of the cylinder barrel then
carefully insert the piston rod assembly. Tap it into the cylinder until it is
Alternatively, a piston ring approximately half way inside.
compressing tool can be used if
adequate care is taken. Either 11 The front cylinder gland has two internal rod seals and one rod wiper
tool must be left in position for and two o-ring and backup ring sets on the outside. Lubricate all of these
a further 10 minutes to allow components with clean oil when assembling and refer to the illustration for
sufficient time for the packing to their correct placement. Apply thread grease to the thread on the gland.
cool and return to shape.
12 Carefully slide the gland over the piston rod and engage the threads by
Important hand. It will be necessary to support the weight of the piston rod and to
Pay careful attention on the centralise it at the same time. Use the C spanner to screw the gland into
correct orientation of these, place and tighten it firmly.
installing them as shown
in the illustration. 13 If the cylinder has a transducer, retract the piston rod completely and then
fit the transducer into place.
This completes reassembly of the feed cylinder.
Bit Weight Charts

When connected to LM75 Power Pack
Listed below are the Bit Weight Charts that apply when the 1300 Series Direct
Coupled Feed Frame is connected to the LM75 Power Pack.
Change in Resultant Bit Force Change in Resultant Bit Force

Holdback Pressure Holdback Pressure
(P2) in MPa kN lbf (P2) in MPa kN lbf
1 4.56 1024 1 2.28 515
2 9.12 2052 2 4.56 1025
3 13.68 3076 3 6.84 1539
4 18.24 4100 4 9.12 2050
5 22.80 5124 5 11.40 2565
6 27.36 6148 6 13.68 3080
7 31.92 7172 7 15.96 3590
8 36.48 8196 8 18.24 4100
9 40.14 9220 9 20.52 4615
10 45.60 10244 10 22.80 5130
11 50.16 11268 11 25.08 5645
12 54.72 12292 12 27.36 6155
13 59.28 13316 13 29.64 6670
14 63.84 14340 14 31.92 7180
15 68.40 15364 15 34.20 7695
16 36.48 8210
17 38.76 8721
This table is for the 1300 Series Feed Frame
configured for a pushing force of 61 kN 18 41.04 9234
(13664 lbf) and a pulling force of 123.4 kN 19 43.32 9750
(27641 lbf) 20 45.60 10260
This table is for the 1300 Series Feed Frame

For both charts, 1 MPa = 10 bar. configured for a pushing force of 123.4 kN
(27641 lbf) and a pulling force of 61 kN
(13664 lbf)
This page is intentionally blank.

SECTION 7
THE POWER PACK

7-2 Introduction
7-3 The Main Pump
Main Pump Condition Test
Main Pump Removal
Main Pump Reassembly
Main Pump Pressure Setting
7-9 Heat Exchanger

7-10 Swagelok Connections
7-12 Power Pack Troubleshooting
Weight: Diesel Power Pack 1800 Kg

The Power Pack 7-
Introduction
The Power Pack contains the components to provide the hydraulic power
requirements.
Two power pack options are available:
• electronically driven hydraulic pump, or
• diesel driven hydraulic pump.
Other facilities contained in the compact unit include a sealed hydraulic
reservoir, hydraulic logic and integrated diagnosis.
All Power Packs are factory cycle tested and adjusted for optimum hydraulic
performance.
Hose connections are made to clearly labelled bulkhead fittings at one end
of the unit.
Weight: Diesel Power Pack 1800 Kg
Diesel driven Power Pack
Electrically driven Power Pack

The Power Pack 7-
The Main Pump

Main Pump Condition Test
Ensure the drill is turned It may be necessary to condition test the Main Pump because of any of the
OFF before attempting these following reasons:
adjustments.
• Poor drilling performance while drilling under maximum load
• Drawing excessive amperage while drilling
• Metal particle contamination present in the main hydraulic filter
Procedure
1 Disconnect the pump case drain hose from the fitting on top of the hydraulic
reservoir.
Cap the exposed fitting.
tools for this operation. 2 Loosen the fitting on the case drain hose at the pump end and position
the open end of the hose through the side of the Power Pack. Retighten
the fitting at the pump end.
Rotation Manifold Block case drain hose

3 Position the open end of the case drain hose into a bucket or container,
ensure all levers are in neutral, and switch on the Power Pack.
4 Ensure the Drilling/Rod Handling/Back Reaming selector is in the Rod
Handling position and move the main feed level fully forward until the
Excessive case flow can carriage stalls and the circuit pressure gauge registers 285 bar.
cause the drain hose to
move suddently when testing 5 Lock the feed lever in the fully forward position.
— slowly operate the feed lever.
6 Measure the case drain flow going into the bucket.
The acceptable case drain flow is up to 10 lpm.
A higher flow than this would indicate the pump is internally worn or damaged,
the additional leakage giving an indication of whether or not you should
replace the pump.
The accuracy of this test is very dependent on the temperature of
the hydraulic oil. Therefore, bring the drill up to normal operating
temperature before beginning the test.
The Power Pack 7-
Main Pump Removal

Use the correct Personal 1 Remove the drain plug from the bottom of the hydraulic reservoir and allow
Protective Equipment and the reservoir to drain.
2 Loosen and remove the four split flange bolts at the bottom of the plenum
Use spill trays to capture any chamber and move the hose and fitting clear.
spent oil and dispose of in an
manner.
3 Disconnect the hose from the charge pressure gauge to the plenum
chamber at the chamber.
4 Disconnect the return hose from the heat exchanger to the plenum chamber
at the chamber.
5 Loosen and remove the four split flange bolts and remove the plenum
chamber.
6 Disconnect the following hoses at the Main Pump. Ensure all open hoses
and ports are plugged or capped.
a) Main pressure hose.
b) Case drain hose.
c) Load sensing hose from top of pump.
d) Open the dump valve to vent any stored pressure and remove the
accumulator hose to allow easier pump removal.
e) Pressure gauge hose from top of pump.
7 Remove main valve bank drain hose at the check valve between the two
filters and pull out the way.
8 Loosen the hose clamp on the hose going to the gear pump suction
manifold and remove the hose at the manifold.
9 Loosen and remove the bolts and split flanges at the gear pump discharge
side, leaving the hose connected at the absorption filter.
10 Disconnect the hose going to the accumulator.
The Power Pack 7-
11 Remove the four M20 hex head bolts which fasten the pump to the adapter
housing.
Protective Equipment and 12 Carefully and gently move the pump with the clamped geared drive hub
tools for this operation. fitted off the spigot in the adapter housing.
13 Remove the pump carefully through the side of the Power Pack.
Possible crush hazard due 14 Remove the recirculation pump.

to main pump weight and size 15 Measure the distance between the hydraulic pump bolt flange face and
— use the correct lifting the front face of the geared hub.
and support equipment.
The hub needs to be refitted onto the new pump at this dimension.
16 Remove the two socket head capscrews which clamp the hub to the splined
shaft and slide the hub off.
17 Note the hub set-up for reassembly.
The Power Pack 7-
Main Pump Reassembly

Use the correct Personal 1 Ensure that the big O-ring is correctly seated in the rear of the main pump
Protective Equipment when and fit the recirculation pump into position. Ensure that the recirculation
using cleaning fluids. pump is fitted so that the suction and discharge ports are positioned above
Use the correct tools for this the centreline of the pump shaft.
operation. Discharge
port
Possible crush hazard due

to main pump weight and size
— use the correct lifting
and support equipment.
Recirculation Pump assembly
2 Clean and check the mating surfaces of the pump and adapter housing.
3 Fit the geared drive hub onto the splined pump shaft and set up to the
dimension measured in para 15 in the previous section.
4 Apply Loctite to the two socket head capscrews, then fit and tighten the
hub onto the splined shaft.
5 Lift the preassembled pump into the Power Pack and carefully slide the
assembly through the adapter housing spigot.
6 Gently find the gear tooth alignment and slide fully into place. Do not
force the assembly with a sudden impact or by winding in with the bolts
as damage to the drive plate could occur.
7 Fit and tighten the four M20 bolts.
8 Reconnect hoses in the reverse of the disassembly order ensuring that
all split flange clamps are tightened securely and evenly.
9 Refill the hydraulic reservoir with an oil suitable for your operating
conditions. Refer to the Oil Selection Chart on page 3-3.
Note: The complete purging 10 Prime the main pump by removing the case drain connection and adding
procedure must be performed oil until the case is full.
after fitting a new pump.
See detailed description, 11 Prime the main pump plenum chamber by removing the cap nearest the
commencing on page 2-8. top of the chamber and ensuring oil is present up to this level.
The Power Pack 7-
Main Pump Pressure Setting

Ensure the drill is turned OFF 1 Ensure the Control Panel valves are in the following positions and switch
before these adjustments are on the Power Pack.
attempted.
a) The rotation control lever and the carriage control lever must be in the
Use the correct Personal neutral position.
b) The wireline hoist control lever (if fitted) must be in neutral.
c) The water pump speed control (if fitted) must be wound fully out
(anti-clockwise) to the zero speed position.
d) The Drilling/Rod Handling selector lever must be in the rod handling
position.
e) The Rod Pulling/Rod Feeding selector lever may be in either
position.
2 Check the charge pressure reading of 1 to 2 bar is indicated on the gauge
on the Power Pack.
3 Monitor the pilot pressure gauge on the Power Pack and adjust the main
pump stand-by pressure (if necessary) to 28-30 bar by adjusting the upper
main pump adjustment screw.
4 Ensure PT1 also reads 35–40 bar and PT4 reads 5–8 bar. PT2, PT3, and
PT5 should read zero bar.
5 Switch OFF the Power Pack.
6 Disconnect the two feed cylinder hoses from the Feed Frame and cap.
under pressure — vent the
hose by cycling the carriage
lever on the Control Panel.
Access to the pump adjustments is

through the top of the hydraulic module
Ensure the two hose ends are capped with 1 1/16” JIC plugs.
7 Turn ON the Power Pack.
8 Slowly move the carriage control lever fully forward and lock into position
to pressurise the main pump.
The Power Pack 7-
9 Adjust the lower adjustment screw on the main pump inwards until the
PT1 reading on the circuit pressure gauge reads 285 bar.
under pressure — vent the 10 Check that PT4 also reads 285 bar.
hose by cycling the carriage
11 Return the carriage control lever to neutral, switch off the Power Pack,
lever on the Control Panel.
and reconnect the two hoses to the feed frame.
Ports to L.S. port in

Standby adjustment
Use the correct Personal main valve bank
Protective Equipment and and pressure
gauge selector Pressure control adjustment
(Pump max. pressure)
The Power Pack 7-
Heat Exchanger
Cooling of the hydraulic oil is provided by a two pass, water to oil heat
exchanger.
Either connection may be used for inlet water connection. With an inlet
water temperature of +20 deg. C and a flow of 20 to 30 lpm, the hydraulic oil
temperature would normally be between 40 deg. C and 60 deg. C.
The only maintenance required is to periodically remove the end caps from
the cooler body and clean out the inside of the water tubes. Service intervals
Use the correct Personal would be largely dependent on the condition of the incoming water supply.
In areas where water contamination is a problem, e.g. rusty pipes, the use
of a water strainer should be considered.
Threaded plugs are fitted to one of the end caps. These can be used for
draining the heat exchanger or for fitting sacrificial anodes in areas where
very corrosive water is used.
Ensure that new gaskets are fitted each time the end caps are removed
and replaced.
Either connection may be used for inlet water

The Power Pack 7-10
Swagelok Connections
Important Swagelok Installation Instructions
Swagelok tube fittings are used
extensively on LM Series drills. New Swagelok Tube Fittings are installed in three steps.
1 Insert the tubing into the preassembled Swagelok fitting. Ensure that the
tubing rests firmly on the shoulder of the fitting and that the nut is finger-
tight.
Protective Equipment and 2 Scribe the nut at the 6:00 o’clock position.
3 Hold the fitting body steady with a back-up wrench. Tighten the nut one-
and-one-quarter turns using the scribe mark as an indicator.
Body Front Rear Nut

Ferrule Ferrule
Swagelok fitting components
6.00 o’clock
Installation
Retightening Instructions
Swagelok connections may be disconnected and retightened many times
and still maintain their seal.
1 Insert the tubing with its pre-swaged ferrules into the fitting, until the front
ferrule seats.
2 Hand tighten the nut then rotate it an extra one quarter turn with wrench
(or to its original one-and-one-quarter turn position).
Snug it slightly with the wrench.
90° only
Retightening
The Power Pack 7-11
SAE/MS Straight Thread Positionable Elbows and Tees
Installation Instructions
1 Lubricate the O-ring with a lubricant compatible with the system fluid,
environment and the O-ring material.
The standard O-ring material is Buna.
2 Turn the fitting into the straight thread boss until the metal back-up washer
contacts the face of the boss.
3 Position the fitting by backing it out (not more than one turn counterclockwise)
until the Swagelok or VCO end is oriented in the proper direction.
4 Hold the wrench pad with a back-up wrench and tighten the locknut until
the washer is against the face of the boss.
Elbow
Body
Wrench
Pad
Front Ferrule
Rear Ferrule
Nut
Locknut
O-ring
Elbow Swagelok fitting components
Screw in
Installation
Hold
Tighten
Position
Tightening
The Power Pack 7-12
Power Pack Troubleshooting

Symptom Action
Drill is shutting down on Low Oil Level Alarm

Add more oil of the correct grade to the hydraulic reservoir
and locate and correct source of leak.
Drill is shutting down on High Temperature Alarm

Allow the drill to cool down and locate source of heat.
Check that adequate flow of water is available across
heat exchanger and check that high temperature alarm is
correctly set.
Drill is shutting down on Overload Alarm.

Check that the overload relay in the starter cabinet has
been correctly adjusted to suit the maximum working
amps. Normally this would be 130 amps for a 75kw electric
motor.
These adjustments must be made by a qualified
electrician.
High Amperage when Rod Handling

1 Rod String tight in hole. 1 Disconnect rods from Chuck, repeat operation and
check amps.
2 Relief Valve venting. 2 Secondary relief valves in V3 should not vent until
PT4 reads 300 bar. Stall the carriage at each end of
its stroke and check the amps. If maximum amps
are being drawn, adjust the secondary relief valve
or valves as detailed in the pressure setting notes.
High Amperage when Rod Making or Breaking

1 Relief Valve venting. 1 The primary relief valve in the main valve bank should
not vent until PT4 reads 310 bar.
Stall the chuck in the forward and reverse directions,
ensure PT4 reads 285 bar and check the amps.
If maximum amps are being drawn, adjust the primary
relief valve in the main valve bank inlet section as
detailed in the pressure setting notes.
Circuit Pressure Gauge fails to respond to Drilling Conditions

1 PT selector incorrectly set. 1 Turn PT selector knob to position number 2 for
drilling.
2 Damaged pressure gauge. 2 Replace gauge.
The Power Pack 7-13
Symptom Action
Drill is shutting down on Low Fuel

Check the level of the fuel gauge. Fill if necessary.
Diesel Engine stalls when Rod Handling

1 Rod String tight in hole. 1 Disconnect rods from Chuck, repeat operation and
check if engine stalls.
2 Relief Valve venting. 2 Secondary relief valves in V3 should not vent until
PT4 reads 300 bar. Stall the carriage at each end of
its stroke and check again if the engine stalls. If it
does then adjust the secondary relief valve
or valves as detailed in the pressure setting notes.
Diesel Engine stalls when Rod Making or Breaking

1 Relief Valve venting. 1 The primary relief valve in the main valve bank should
not vent until PT4 reads 310 bar.
Stall the chuck in the forward and reverse directions,
ensure PT4 reads 285 bar and check if the engine
stalls. If it does then adjust the primary relief valve in
the main valve bank inlet section as detailed in the
pressure setting notes.
The Power Pack 7-14

SECTION 8
THE CONTROL PANEL

8-2 Introduction
8-3 Pilot Oil Unit
8-5 Directional Controls
8-6 Fine Feed Valve
Weight: Control Panel (complete) 50 Kg
(complete, with hoses) 90 Kg
Chapter Reference: Control Panel: P/N 3000004

The Control Panel 8-
Introduction
The Control Panel contains pilot control valves and gauges to monitor
hydraulic functions.
The hydraulic connections are located on the underside bulkhead and labelled
for easy connection.
A detailed explanation of the controls is located in Section 1 - Drill
Introduction.
Weight: Control Panel (complete) 50 Kg

(complete, with hoses) 90 Kg
Pilot Oil Unit

If the operation of the pilot oil unit levers become unsatisfactory it may be
necessary to relubricate and readjust the moving parts of the top cover
assembly.
Readjusting the Lever Locks

If the Rotation or Feed Levers slip back towards the neutral position when
locked forward, then they must be readjusted.
1 Return the lever to the neutral position and leave unlocked.
Prior to removing any 2 The adjusting screw can be reached by passing a 5 mm Allen key through
control lever ensure a hole in the bottom of the handle bracket.
the drill rig is turned OFF.
3 Screw the socket head capscrew out to tighten the locking mechanism.
4 Move the lever fully forward to check the locking mechanism.
5 Return the lever to the neutral position and make any final adjustments.
Access hole
for adjustment
Pilot Oil Unit assembly
Lever and Cover Disassembly

For each lever —
Prior to removing any 1 Remove the screw plug, sealing ring, compression spring, spring retainer
control lever ensure and bolt from the top of the cover.
the drill rig is turned OFF.
2 Turn the cover over and remove the spring pin retaining the detent quadrant
to the shaft.
3 Remove the shaft and the handle assembly.
4 Tap the shaft bush and dust seal out of the cover.
5 Slide the handle lock segment off the shaft.
6 Remove the nylon lock pad from the handle.
Reassembly of Levers and Cover

1 Clean and inspect all parts. Replace worn or damaged items. New dust
seals and O-rings should be used.
2 Reassemble in the reverse of the disassembly order, dipping all internal
components in clean hydraulic oil.
3 The shaft must be free to move in the cover bush. Use a lithium based
grease to lubricate all moving parts.
Directional Controls
Important Disassembly
The Drilling/Rod Handling and
Rod Feeding/Rod Pulling control 1 Lift the bottom of the rubber boot around the valve handle to expose the
valves are identical. retaining pin.
2 Carefully tap out the retaining pin through one side of the valve. Remove
the valve handle from the valve body.
3 Remove the valve end covers by removing the four socket head screws
at each end of the valve.
4 The spool can now be carefully removed from the handle end of the valve
body.
5 To separate the spool components, remove the retaining pin which fastens
the spool to the actuating fitting.
Reassembly
1 Clean and inspect all parts.
2 Replace the complete valve if the spool or the body of the valve is
damaged.
3 Replace all O-rings.
When assembling the valve onto sub-plate, ensure the four O-rings
between them are correctly positioned.
4 Tighten the bolts evenly and gradually.
Note carefully the direction of

orientation of the Valve Block
Fine Feed Valve

1 Remove the four M5 socket head capscrews from the top of the Fine Feed
Valve.
2 Lift the valve off the valve plate.
Note: No field repairs are possible Disassembly

to the adjustment knob section of
this valve. Repairs are limited to
1 Remove the hex head plug from the top of the valve and also remove the
the spool end of the valve only, as spring, spring retainer and ball.
listed below. 2 Remove the hex head, O-ring plug from the end of the valve body.
3 Carefully tap the open end of the valve body to extract the spool, being
careful not to damage the spool as it comes out.
4 Clamp the cylindrical section of the valve securely in a vice, using soft
jaws to prevent any damage.
5 Using a suitable-sized spanner, unscrew the body section of the valve.
6 The spring retainer and spring will now be free to be removed.
Reassembly
1 Clean and inspect all the components.
2 Replace the complete valve if the spool or bore of the valve is
damaged.
3 Replace the O-rings.
4 Reassemble in the reverse order to disassembly, dipping all internal parts
in clean hydraulic oil.
Ensure the four O-rings between the valve and the valve plate are in
the correct position.
5 Tighten the four mounting bolts evenly and gradually.
Plug
Spool
Spring retainer
Spring
O-rings Spring Guide
Adjusting knob assembly

Valve plate
SECTION 9
OPTIONS
9-2 Wireline Hoist
Introduction
Hoist Capacity
SAFETY WARNING
Freewheel Valve
Counter Balance Valve Adjustment
Chain Setting and Adjustment
Spooling Device Alignment
9-5 Wireline Hoist (Small)

9-6 Feed Frame Positioner (FFP)
Setting Up to Drill a Down Hole
Setting Up to Driil an Up Hole
Extending the Feed Frame
9-10 Air Blast Cooler

Introduction
Operation
Service
9-12 Water Pump

Introduction
Water Pump Lubrication and Maintenance
9-14 Transportation
9-16 Cuddy Sizes
9-17 Lanyard
9-18 Feed Frame Guard
9-19 Accumulator (Pilot Pressure)
Options 9-
Wireline Hoist
Introduction
The hydraulic hose connections The hydraulically powered wireline hoist is designed to connect directly to
for the wireline hoist must the power pack via the interconnecting hoses provided.
be correctly made so that
For most applications the hoist is fastened to the wireline extension on the
the counter balance valve is
feed frame positioner. Operation of the hoist is by way of the wireline control
metering the oil flow exiting
from the hydraulic motor when
valve on the control panel.
the hoist is in the cable out
mode. Hoist Capacity
This will prevent the hoist from
Capacity is dependent on the diameter of the cable used:
overspeeding when lowering
the overshot into a deep hole. Cable size Capacity
5mm 1400 m (4600 ft)
6mm 1000 m (3280 ft)
1/4 in 895 m (2930 ft)
3/16 in 1550 m (5080 ft)
Wireline Hoist shown with optional spooling device
Weight: Wireline Hoist assembly 452 Kg

(complete with 1000m of 6mm cable)
Chapter Reference: Wireline Hoist p/n 3003816

Options 9-
Freewheel Valve
Opening this valve permits the hoist drum to be freewheeled when using pump
in QU overshots. It works by forming a loop which allows the oil to circulate
between the two motor ports.
When the valve is opened, the ability to brake the hoist by returning the control
valve to neutral is no longer applicable. Therefore always ensure that the valve
is closed when using gravity descent overshots or with pump in overshots
where the possibility exists that braking will be a requirement.
Counter Balance Valve Adjustment

1 Set the pressure gauge selector on the power pack to PT1.

2 Gradually move the wireline control lever into the cable out position and
operation. note the circuit pressure when the hoist drum starts to rotate. The correct
pressure is 60–70 bar.
3 If adjustment is necessary the valve adjustment screw is wound inwards
to increase the pressure setting.
Chain Setting and Adjustment

1 When using 3/16 in or 5 mm cable, set the drive chain onto the small
sprocket. For 1/4 in or 6 mm cable set the chain onto the larger
Possible pinch point between sprocket.
the chain and sprocket
— keep hands well clear. 2 First loosen the chain tension by slackening the adjustment on the idler
sprocket. This is achieved by loosening the four 8 mm hex head bolts.
Protective Equipment at all 3 After relocating the drive chain, adjust the idler sprocket to tension the chain
times. so that there is approximately 10–15 mm total up and down movement.
Options 9-
Spooling Device Alignment

1 The spooling device should be angled as close as possible to enable the
cable to be directed in a straight line to the sheave on the end of the feed
frame.
2 Alignment is achieved by loosening the two lockbolts and then swivelling
the assembly into the optimum position.
Spooling device may drop
under its own weight when 3 Relocate and tighten the lockbolts when complete.
bolts are removed — use
appropriate lifting equipment. Drive
Sprockets
Idler
Spooling Device adjustment locations

Options 9-
Wireline Hoist (Small)

Introduction
The hydraulic hose connections The hydraulically powered wireline hoist is designed to connect directly to
for the wireline hoist must the power pack via the interconnecting hoses provided.
be correctly made so that
For most applications the hoist is fastened to the wireline extension on the
the counter balance valve is
feed frame positioner. Operation of the hoist is by way of the wireline control
metering the oil flow exiting
valve on the control panel.
from the hydraulic motor when
the hoist is in the cable out The wireline hoist is fitted with a pilot operated brake assembly which operates
mode. by way of the Wireline control valve on the Control Panel.
This will prevent the hoist from
The hoist assembly has counterbalance valves fitted on both port connections
overspeeding when lowering to stop the load from running away in the event of a loss of pressure.
the overshot into a deep hole. This valve is proportional, meaning the flow through the valve is proportional
to spool movement, which in turn controls the speed of the wireline hoist.
The counterbalance valves are pre-set to 210 bar.
Hoist Capacity
Capacity is dependent on the diameter of the cable used:
Cable size Capacity
5mm 500 m (1575 ft)
6mm 300 m (980 ft)
Drum Speed 150 rpm
Line Pull 500 Kg
Counterbalance valves
Wireline Hoist
Weight: Wireline Hoist assembly 200 Kg

(complete with 500 m of 5 mm cable)

Chapter Reference: Wireline Hoist p/n 3003453
Options 9-
Feed Frame Positioner (FFP)

When using the optional positioner, it is strongly recommended that the
supplied face mounting bracket be used to fasten the front of the feed frame
Failure to adequately anchor to the rock face.
the drill can cause unsafe
working conditions, and will
Mounting holes in the positioner base are for the fitment of additional anchor
result in higher than normal
bolts into the floor.
wear of components.
Setting up to Drill a Down Hole (0° to –90°)
1 Locate the base of the positioner so that it is sitting evenly on the ground,
Possible hazard when pinning using timber bearers if necessary. Fit four 5 ft (minimum) rock bolts through
the base — refer to site-specific the holes in the positioner base and tighten firmly.
procedures for pinning.
2 Ensure that the clevis end of the tilt cylinder piston rod is pinned to the
Ensure the drill is switched forward clevis of the cradle base. Reposition it if necessary.
OFF before connecting wireline
hoses to the diverter valve.
3 Connect the wireline hoist hoses to the diverter valve fittings on the
positioner and ensure the diverter valve is switched to the ‘Lift Cylinder’
Possible injury whilst packing mode.
bearers under positioner
— personnel must keep clear 4 Loosen and remove the rear cradle clamp cap and move them clear.
when setting up the drill.
5 Start the power pack and move the wireline hoist control lever to the raise
position to lift the feed frame.
6 To stop the raising of the feed frame, return the wireline lever to neutral.
Support
poles Front
cradle
clamps
Rear cradle
clamps Face
mounting
bracket
Hose bulkhead
connections for
dump and
tilt cylinder
Anchor bolts
Typical set-up for Down Hole Drilling — Feed frame types will vary.
Options 9-
7 When the required angle has been set, fit one of the supplied support
poles horizontally into the cradle clamps.
8 Using the clamps provided, fasten two of the remaining support poles
between the stubs on the cradle and the lower support pole mounted
Possible injury whilst horizontally.
tightening scaffolding
clamps at height — refer to
9 The Feed Frame can be raised from horizontal to vertical in the one
site-specific procedures operation. Fit the support poles in place when the required angle is
regarding operators achieved.
working at height. 10 Disconnect the wireline hoist hoses from the diverter valve and refit them
to the hoist.
11 Use an airleg drill to drill two anchor bolt holes in the rock face.
12 Fit two 5 ft rock bolts through the mounting bracket and tighten down
firmly.
Setting up to Drill an Up Hole (0° to +90°)

Possible injury whilst packing 1 Locate the base of the positioner so that it is sitting evenly on the ground.
bearers under the positioner Dependent on the hole angle and collar, it may be necessary to raise the
— personnel must keep clear positioner above floor level with timber bearers (see illustration). Fit the
when setting up the drill. required length rock bolts once this is done.
Possible hazard when pinning 2 Ensure that the clevis end of the tilt cylinder piston rod is pinned to the
the base — refer to site-specific
rear clevis on the cradle base. Reposition it if necessary.
procedures for pinning.
Cylinder repositioning for up holes
3 Connect the wireline hoist hoses to the diverter valve fittings on the
positioner and ensure the diverter valve is switched to the ‘Lift Cylinder’
Ensure drill is switched OFF mode.
before connecting wireline
hoses to the diverter valves. 4 Loosen and remove the front cradle clamp caps and move them clear.
5 Start the power pack, and move the wireline hoist control lever to the raise
position to lift the feed frame.
6 To stop the raising of the feed frame, return the wireline lever to neutral.
7 When the required angle has been set, fit one of the supplied support
poles horizontally into the cradle clamps.
Options 9-8
8 Using the clamps provided, fasten two of the remaining support poles
between the stubs on the cradle and the lower support pole mounted
Possible injury whilst horizontally.
tightening scaffolding
clamps at height — refer 9 The Feed Frame can be raised from horizontal to vertical in the one
to site-specific procedures operation. Fit the support poles in place when the required angle is
regarding operators achieved.
working at height.
10 Disconnect the wireline hoist hoses from the diverter valve and refit them
to the hoist.
11 Use an airleg drill to drill two anchor bolt holes in the rock face.
12 Fit two 5 ft rock bolts through the mounting bracket and tighten down
firmly.
Typical set-up for steep Up Hole Drilling — Feed frame types will vary.
Extending the Feed Frame

Ensure the area is clear
1 Connect the wireline hoses to the diverter valve and ensure the valve is
of personnel before switched to the ‘Dump Cylinder’ mode.
extending the Feed Frame. 2 When extending the Feed Frame forward or reverse ensure that there is
Ensure a clear line of sight a clear line of sight between the operator and helper at all times. This is
exists. so that injury cannot occur.
Options 9-
3 Loosen the bolts on the six clamps which are holding the Feed Frame to
the cradle, then turn on the Power Pack.
4 To extend the Feed Frame towards the rock face, move the Wireline control
lever into the ‘raise’ mode. The Feed Frame is retracted by moving the
Wireline control lever into the ‘lower’ mode.
Diverter Valve
Lift cylinder ‘Far’ port Dump cylinder valve V2 port
Lift cylinder ‘Near’ port Dump cylinder valve V1 port
Wireline hose connections
Diverter Valve assembly
5 When the desired position is achieved, tighten the bolts on the clamps.
Always ensure that the Feed Frame is gripped by a minimum of four
clamps.
6 Switch off the Power Pack and remove the Wireline hoses, then reconnect
them to the Hoist.
7 Check the carriage travel along the Feed Frame for any obstruction or
hose fouling.
Options 9-10
Air Blast Cooler

Introduction
The Air Blast Cooler has been offered as an option to allow full operation of
the Power Pack without the need for a supply of cooling water.
The Air Blast Cooler has been fitted in series with the water cooler so that
the Power Pack can still use water cooling if the need ever arises.
The cooler fan is driven by a hydraulic motor using the gear pump in the
recirculation circuit. A bypass check valve has been fitted to allow oil to
bypass the cooler during cold start ups. This protects the cooler core from
possible over pressurisation.
A relief valve has also been fitted to the pressure port of the fan motor (set
to 100 Bar) to protect the gear pump from over pressurisation should there
be a mechanical fault with the fan or motor.
Operation
Return oil is passed through the core of the cooler after passing through the
return filter and the existing shell and tube water cooler. The hydraulically
driven fan draws cool air from below and passes it over the core. As the air
passes over the core heat is transfered from the core surface to the air which
is exhausted from the top of the cooler.
Options 9-11
Service
The effectiveness of the Air Blast Cooler is dependent on the ambient air
temperature entering the cooler and the cleanliness of the core.
Cooler cores can foul in an undeground environment reducing cooling capacity
and leading to possible high operating temperatures. It is therefore important
that the core is cleaned on a monthly basis.
Remove the core by disconnecting the three hoses to the fan motor and the
two hoses connected to the cooler core. Take care to ensure these ports
are plugged and capped to prevent contamination. The cooler assembly is
retained by six bolts. Two bolts on the left hand side can be accessed from
the underside of the mounting brackets and remaining four bolts are on
the opposite side. Take care to support the assembly and core during this
process. Remove the cooler assembly. Remove final two bolts securing the
cowling to the core. Remove the cowling complete with motor and fan to gain
access to the core. Clean core by spraying with degreaser, hosing out and
then blowing out with air.
Ensure you wear the appropriate personal protective equipment when
servicing the core.
Replace cowling and secure.
Refit cooler asssembly to mounting brackets and re connect hoses. Take
care to ensure hoses are correctly fitted. Incorrect fitting of hoses to the core
could lead to damage to the core. Refit hoses to motor ensuring that the fan
direction is correct on start up.
Options 9-12
Water Pump
Introduction
The water pump provides controlled water flow to the drill string and for
flushing the hole.
The Triplex piston pump is directly coupled to a hydraulic motor, which is
variably controlled by flow from the Control Panel.
Two pump options are available:
• The 520 Water Pump assembly delivers 20 U.S. gpm (76 Lpm) at a working
pressure of 500 psi (34 bar).
• The 535 Water Pump assembly delivers 35 U.S. gpm (132 Lpm) at a
working pressure of 500 psi (34 bar).
Model 535 Water Pump
Weight: 520 Water Pump 200 Kg
Chapter Reference: Water Pump p/n 3000866
Weight: 535 Water Pump 265 Kg
Chapter Reference: Water Pump p/n 3000327

Options 9-13
Water Pump Lubrication and Maintenance

1 Stop the water pump motor before checking or adding oil.
2 Before checking clean around the oil level tap, which is located on the rear
cover.
3 Open the tap and check if oil flows out. If not, top up through the top oil
filler cap.
It is recommended that the lubricating oil be changed after the first
200 hours service, Thereafter the oil should be changed after every
2500 working hours.
4 Drain the oil from the unit by unscrewing either of the two magnetic plugs
located either end of the water pump.
Ensure the correct Personal
Protective Equipment and tools 5 Fill with SAE 30 grade oil. Do not over fill. Refer to Section 3 for related
are used at all times. Material Safety Data Sheets.
Dispose of spent oil in an 6 Use only clean oil that has been stored in unopened containers.
7 Check oil daily.
manner.
Filler cap
Drain plug
Options 9-14
Transportation
Lifting
• The Power Pack, Positioner, and Feed Frame assembly should not to be
loaded (or unloaded) using a forklift from either end of the equipment as
the load will make the forklift unstable.
• The designated lifting slots must be utilised if a forklift is to be used.
• Alternately, if these components are to be lifted using slings then the
designated lifting points provided on each piece of equipment must be
used (see graphics below).
• Due to its weight, it will be necessary to use an appropriate mechanical
lifting device and correct lifting procedures when removing the Control
Panel from the Power Pack.
Moving whilst in transit

• To stop the drill assembly moving whilst it is being transported, the rudd
links and designated tie-down points must be used. These points are
clearly marked on the Power Pack, Feed Frame, Wireline Hoist, Water
Pump, and Positioner Assembly (see graphics below).
• When connecting or disconnecting the Power Pack and/or the Positioner to
the towing vehicle, the jack leg must be lowered and adjusted to the correct
height. This height should allow the hands to be free when connecting to the
vehicle, thereby maintaining a clear line of sight with the operator/driver.
• When the Power Pack or Positioner is being reversed into the drill site,
there is a potential for a crush injury between the wall and the vehicle.
Personnel are to maintain a clear line of sight with the driver/operator at
all times. DO NOT stand between the vehicle and the wall.
Mass 900 Kg
Mass 425 Kg
Options 9-15
Mass
(Diesel Power Pack)
1800 Kg
(Electric Power Pack)
1190 Kg
Mass
(Model 520) 200 Kg
Mass (Model 535) 265 Kg
(with hoses) 90 Kg
(without hoses) 50 Kg
Mass
(complete) 452 Kg
with 1000m of 6mm cable
Options 9-16
Cuddy Sizes
The recommended Cuddy Size for the LM Series Drill assembly varies with
the actual drill configuration being used.
As a guide, the 1300 Series Feed Frame and Positioner have been selected
to show the maximum required Cuddy Size.
It is nominally 7.5m wide x 6.7m high x 11m long.
7500 (Nom)
6800 (Nom)
5270 (Nom) Wireline extension closed
6765 (Nom) Wireline extension fully open 6300 (Nom) Down hole - Wireline extended
4800 (Nom) Down hole - Wireline closed
6650 (Nom)
1100 (Nom)
Options 9-17
Lanyard
The Lanyard is fitted to the Feed Frame as a safety device.
In the event of personnel becoming entangled in rotating or moving parts
when drilling or rod handling, the drill can be shut down by pulling the lanyard
cable.
Rotation will stop, the Rod Holder will close, and the Power Pack will shut
down.
When the cable stop has been activated it will be necessary to reset the ‘Stop’
switch located on the front of the feed Frame. To do this, manually move the
switch back to the ‘ON’ position.
If the Rod Holder is isolated open when the drill shuts down then the rods will drop.
Under no circumstances is the Rod Holder to be isolated ‘Open’ when drilling or rod
handling. Always have the selector valve in the ‘Automatic’ mode and the rod holder
lock-out fitted to the ‘Auto’ mode.
The only time the Rod Holder is to be used in thge ‘isolate’ mode is when inserting the
core barrel through the Chuck and Rod Holder.
Emergency
STOP Lanyard
Manual Reset Emergency

(when activated) STOP Button
Options 9-18
Feed Frame Guard

The Feed Frame has been fitted with a physical guard which covers the
rotating and moving components when drilling.
This guard is interlocked so that if the guard is removed when in Rod Handling,
pilot pressure is still available to the Control Panel.
When the guard is removed whilst Drilling mode is selected the magnetic
safety switch will de-energise and open valve V31. The pilot signal to the
Control Panel will drain the tank and all drill functions will cease.
If the Rod Holder is isolated open when the drill shuts down then the rods will drop.
Under no circumstances is the Rod Holder to be isolated ‘Open’ when drilling or rod
handling. Always have the selector valve in the ‘Automatic’ mode and the rod holder
lock-out fitted to the ‘Auto’ mode.
The only time the Rod Holder is to be used in thge ‘isolate’ mode is when inserting the
core barrel through the Chuck and Rod Holder.
Magnetic Safety Switch location

Options 9-19
Accumulator (Pilot Pressure)

The Power Pack is fitted with a 0.3 litre accumulator which is plumbed into
the PP7 pilot pressure line to the Control Panel.
Stored Pressure —
It is pre-charged at a nominal pressure of 30 bar, which assists in maintaining
DO NOT attempt to check
or re-charge the accumulator
a constant pilot pressure at all times.
unless you have the correct A dump valve has been plumbed into the accumulator line. In the event of
equipment and instructions the accumulator needing to be removed the stored pressure can be vented
to do so. to tank.
Accumulator
Options 9-20

SECTION 10
HYDROSTATIC EXPLANATION
10-2 Introduction
The Main Pump
10-3 The Recirculation Pump
10-4 Main Valve Bank
10-7 Valve Manifold Blocks
Feed Circuit Manifold Block
Rotation Circuit Manifold Block
Diesel Valves (Optional)
10-11 Valve Module Schematic

10-12 Check Valves
10-14 Setting Valve Pressures
Valves V7, V9, V11, V20 and V21
Main Valve Bank
10-19 Setting Flow Rates
Hydrostatic Explanation 10-
Introduction
The Hydraulic System comprises a low pressure control circuit and a high
pressure, load sensing function circuit.
The low pressure control circuit allows for the use of small diameter, low
pressure hoses between the Control Panel and the Power Pack, which
increases the manoeuvrability of the Control Panel.
The high pressure system is controlled by pilot operated valves in the Hydraulic
Module in the Power Pack, and directs oil from the Main Pump to the Drill
Head when, and as required.
The hydraulic system is pre-set in the factory and tested on a dynamometer
to ensure that all settings are correct. No attempt should be made to alter
them in the field. The maximum oil flows and pressures are set to ensure the
full load current of the electric motor is not exceeded.
The Main Pump

The mechanical drive group consists of one main pump which is directly
coupled to a power unit. The pump is a swash-plate axial piston type with a
load sensing control which allows different diesel/electric motor speeds to
be accommodated by flow control adjustment.
The Suction Chamber of the main pump is maintained at a charge pressure
of 1–2 bar by a tandem mounted gear pump. The main pump produces:
• 140 cc/rev which results in approx.
• 200 Lpm for 50 Hz electric supply,
• 245 Lpm for 60 Hz electric supply, or
• 160 Lpm for diesel engine operating at 2000 rpm.
The pump is right hand rotation when looking at the shaft end which makes
it suitable for direct connection to a diesel engine.
The Recirculation Pump

This Recirculation Pump is used for oil treatment purposes. The discharge
is passed through a 10 micron return filter, oil cooler and thence to the main
pump suction chamber. Here it discharges any unwanted make-up oil across
an integral check valve back to the oil reservoir.
This arrangement means that the hydraulic circuit is essentially a ‘closed
loop’ type.
The recirculation pump produces:
• 63 cc/rev which results in approx.
• 91 Lpm for 50 Hz electric supply,
• 110 Lpm for 60 Hz electric supply, or
• 126 Lpm for diesel engine operating at 2000 rpm.

Standby adjustment
main valve bank
and pressure
Recirculation Pump
Main Valve Bank

The discharge from the Main Pump is delivered to the Main Valve Bank located
in the Hydraulic Module. This is a load sensing valve consisting of a central
inlet section, tank section, and four valve sections. When viewing from the
bulkhead end of the Power Unit, the individual components are numbered
from left to right as follows:
Inlet Section
The Inlet Block contains a ‘P’ port to which the output from the Main Pump
is connected.
Two compensators and a relief valve are inbuilt into this block. The relief
valve is the primary relief valve and is set to 310 bar. This protects the main
pump from pressure spikes. The two non-adjustable compensators ensure
that independent, simultaneous operation of valves on either side of the Inlet
Block can take place.
The ‘M’ port on top of the Inlet Block is internally connected to the ‘P’ port and
is used to transmit pump pressure to the valves ‘V9’ and ‘V10’.
The load sense (LS) port is connected to the load sense connection on the
Main Pump The ‘X’ port is connected to the ‘A’ port of valve V7 which is
mounted on the rotation manifold.
Valve V4
Valve V4 controls the water pump option and is operated by a pilot signal,
WP1, from the Control Panel.
Pilot lines must be connected if the water pump is not used.
Valve V3
Valve V3 controls the fast feed mode of the feed cylinder and is operated by
pilot signals:
• PP4 for rapid rearward movement of Carriage
• PP6 for rapid forward movement of Carriage.
Valve V2
Valve V2 controls the speed of the Rotation Unit and is operated by pilot
signals from the Control Panel:
• PP1 for forward rotation
• PP2 for rearward rotation.
Valve V1
Valve V1 controls the speed of the Wireline Hoist and is operated by pilot
signals from the Control Panel:
• WL2 for lowering the cable (power down)
• WL1 for raising the cable (power up).
If Wireline Hoist is not used pilot lines must be looped.
Proportional Control
All valves in the main valve bank are proportional valves. This means the
flow through the valve is proportional to the spool movement which, in turn,
is proportional to the pilot pressure applied.
The pilot pressure required to start the spool movement is 6 bar while 18 bar
is required to move the spool to the full flow position. e.g. a 12 bar pilot signal
would result in a flow of half the full flow.
Flow Limiters
All valves have maximum flow rate adjustment screws at the top and bottom
of each valve section which can be used to reset the maximum flow the valve
can pass in either direction when the spool is at its maximum flow position.
These are set in the factory and normally should require no further adjustment
on site.
Valve 4 Valve 2
Water Rotation
Pump Circuit
Circuit Valve 3 Valve 1
Feed Wireline
Circuit Circuit
TOP VIEW
V3 Feed Wireline
Secondary Secondary
Relief Relief
(‘A’ Port) (‘A’ Port)
Primary
Relief
FRONT VIEW
Inlet Section - consisting of V3 Feed Wireline

Pressure (‘P’ Port), Secondary Secondary
Tank (‘T’ Port), Relief Relief
Load Sense (‘LS’ Port), (‘B’ Port) (‘B’ Port)
and Pressure (‘M’ Port)
Secondary Relief Valves

These are fitted to valves V1 and V3 and protect the Wireline Hoist and
Feed Cylinder from pressure spikes when the valve is centred quickly after
lowering a load.
Load Sensing in V1, V2, V3 & V4

As the spool of these valves is shifted from the neutral position, an oil flow
occurs from the P port to either the A or B port.
The pressure generated from this oil movement is transmitted to the load
sensing port, via internal passages in the Valve Bank. It is then transmitted
to the Main Pump which then senses the pressure of the A or B port. i.e. the
‘load pressure’. This pressure can be measured at the PT4 tapping.
If all four valves produce a load pressure at the respective A or B ports, then
the highest load pressure is transmitted to the Pump by the selective action
of the shuttle valves.
Valve Manifold Blocks

Important Feed Circuit Manifold Block
There are two manifold blocks:
— Feed circuit manifold block The flows from the A and B ports of valve V3 (feed cylinder valve) pass directly
— Rotation circuit manifold block. through the two main passages in this block to the hose connections on the
front of the Power Pack. The following valves are mounted on this block:
V5 Cylinder Float
This valve is installed for floating the feed cylinder during thread making or
breaking. It is spooled by pilot pressure at the V5Y port for thread making and
at the V5X port for breaking. The spool position then allows oil at reduced
pressure into the appropriate side of the feed cylinder to provide a power
assisted head float.
V6 Cylinder Fine Feed

This valve is installed for the fine feed operation of the feed cylinder during
drilling. When the valve has no pilot signal applied, the A and B ports are
blocked. A PP8 pilot signal moves the spool to connect the cylinder ‘A’ line
to the adjustable feed pressure valve and, simultaneously, connects the
cylinder ‘B’ line to the feed flow control valve.
Oil at a controlled pressure (P1) is admitted into the feed cylinder and the
flow of oil out of the cylinder is controlled i.e., the rate of movement of the
piston (and carriage) is controlled by the throttling action of the feed flow
control valve.
Should P1 be set high enough to cause the pressure P2 to exceed 30 MPa,
then the secondary relief valve in the valve V3 will vent and the rate of advance
of the piston will increase.
Pressure P2 will decrease to zero as the piston reaches the end of its
stroke.
V8 Pilot Logic
This valve is installed to provide appropriate pilot signals to either of valves
V3 and V6 for rapid cylinder feeding or controlled cylinder feeding. When the
carriage control lever is moved forwards a PP3 pilot signal is applied to the
P port of valve V8.
This pilot signal is converted by V8 into either:

a) PP6 pilot signal which spools V3 if the Drilling/Rod Handling selector
is in the Rod Handling position i.e., V8 is in the spring-offset or de-
pressurised position. In this case the carriage control lever will be able
to move the feed cylinder quickly forward via Valve V3.
OR
b) PP8 pilot signal which spools the valve V6 if the Drilling/Rod Handling’
selector is in the Drilling position i.e V8 is in the pilot off-set or
pressurised position.
In this case the carriage control lever will be able to move the feed cylinder
with controlled fine-feed.
V20 and V21 Carriage Float

These valves are adjustable and are calibrated so that the power assisted
carriage float moves in correct relation to the rod thread pitch.
V22 and V23 Pilot Logic

These valves sequence the correct pilot signal to either V5X or V5Y for either
thread making or breaking.
Rotation Circuit Manifold Block

The flows from the A and B ports of the valve V2 (rotation circuit control) pass
directly through the two main passages in this block to the hose connections
on the front of the Power Pack.
The following valves are mounted on this block:
SV1
This shuttle valve is a spool-type valve and directs oil from the higher pressure
line of the rotation circuit to tapping PT2. The oil is further transmitted to SV2
and to the chuck, only during thread making or breaking operations.
SV2
This shuttle valve is identical to SV1 and directs oil to the chuck from either
the rotation circuit (PT2) or the rod holder circuit (PT3).
During drilling operations, the pressure at PT3 will always be higher than PT2
and oil will be directed to the chuck via V10 and SV2.
V10
On application of a pilot signal, this valve directs oil to the chuck and rod holder,
thereby opening the rod holder and simultaneously closing the chuck. In
the spring-offset position, the rod holder circuit PT3, is vented directly into
the oil reservoir, i.e. the T port of V10 is directly connected to the top of the
oil reservoir.
This valve receives a pilot signal by either of two control modes:
a) The Drilling/Rod Handling selector is placed in the Drilling position i.e.,
a PP9 pilot signal is transmitted from the control panel.
OR
b) A combination of the carriage control lever and the Rod Feeding/Rod
Pulling selector results in a PP5 pilot signal being transmitted from the
control panel. This is known as a ‘working’ stroke of the feed cylinder
wherein the chuck is closed and the rod holder is open as the carriage
moves, i.e. either forward carriage control lever movement in the Rod
Feeding mode or rearward carriage control lever movement in the Rod
Pulling mode.
V9 Pressure Reducing Valve

This valve is set to give a controlled outlet pressure of 40–45 bar for the pilot
pressure supply to the control panel through PP7.

When Valve V10 receives a pilot signal, the rod holder should open and the
chuck should close as V10 directs oil into the PT3 circuit. The pressure at
PT3 therefore increases. A load sensing signal is taken from the PT3 circuit,
through valve V7 and then to the pump via the ‘X’ and ‘LS’ ports of the main
valve bank.
This load sensing signal causes the pump pressure PT1 and the PT3 circuit
pressure to increase. If it were not for the pressure reducing characteristic
of valve V7, then the PT1 and PT3 pressures would increase until the pump
cut-off pressure was reached at PT1 and PT3 both read 28.5 MPa. Valve V7
limits the PT4 load sensing signal to 140 bar.
Should the pump be required to produce a higher pressure for another circuit
e.g. rotation, then the load sensing shuttle valve chain in the main valve bank
enables PT1 to increase above 140 bar.
The PT3 circuit pressure will then also increase and valve V7 will no longer
control the PT3 pressure.

This valve is installed to reduce the pressure to the chuck and is set to
6–7 MPa.
The maximum controllable pressure is limited to approximately 8 MPa by
the valve spring.
Hydrostatic Explanation 10-10
V12 Threading Speed

This valve controls the thread making speed during rod handling. The valve
is located on the bulkhead plate on the Power Pack.
Adjust inward to increase to a suitable threading speed.
V13 Rod Holder Delay Valve

This valve adjusts the delay for the rod holder operation. Adjustments are
required if chuck jaws do not secure the drill rod before the rod holder
opens.
SV3
This shuttle valve is a low pressure ball type, used for transferring pilot signals
PP8 and/or PP5 to Valve V10.
Diesel Valve Options
Dump Valve
In the event of the accumulator needing to be removed, the stored pressure
in the accumulator line can be vented via this valve.
V30 Float
This valve produces a pilot signal to open the check valves, allowing a bypass
of oil at the counter balance valves (when fitted to the feed cylinder) during
threadmaking and breaking.
V31
This valve acts as a safety interlock in conjunction with the rod guard magnetic
safety switch and the drilling pressure switch.
When Drilling mode is selected, the safety guard must be in place to activate
the magnetic safety switch. This energises the guard and safe relays, allowing
power to go to the V31 valve.
This gives a full pilot signal to the Control Panel.
When in Rod Handling mode, the magnetic safety switch is de-energised and
the rod handle relay closes. This allows power to the V31 valve, giving a full
pilot signal to the Control Panel.
When drilling, if the guard is removed the V31 valve will dump the pilot signal
at the Control Panel to tank and drill functions will cease to operate.
Valve Module Schematic
Valve module
Check Valves
CV1
This valve has a one bar spring to ensure positive seating of the poppet. It is
located between the two filters and is installed to prevent tank pressures from
valves V3 and V4 being reflected to the tank ports of valves V1 and V2.
Check Valve CV1
CV2 and CV3

These two valves are combined into a single assembly and are located inside
the main pump plenum chamber.
CV2 is normally in the closed position, but will open and allow unrestricted
make-up oil to flow to the main pump suction chamber. This is an anti-
cavitation safe-guard for the main pump.
CV3 acts as a relief valve and allows surplus charge oil to flow from the
main pump suction chamber to the oil reservoir. It has a spring tension of
approximately 1.5 bar.
 Main Pump
 Section


CV3
Reservoir CV2
CV4
This valve prevents the loss of oil in the pilot pressure supply system (PP7)
which may occur whenever the pump pressure PT1 is reduced below
the accumulator storage pressure i.e., it maintains a steady pilot supply
pressure.
Check Valve CV4

Setting Valve Pressures

Valves V7, V9, V11, V20 and V21
This section explains how to correctly set the pressures of the individual
valves in the Hydraulic Module should the need arise.

1 Ensure that the adjusting screw on V9 is wound fully out and switch on
the Power Pack.
Protective Equipment is worn at
2 Move the Rod Handling/Drilling selector lever on the Control Panel to the
all times, and the correct tools Drilling position.
are used for this operation. 3 Using a 10mm spanner, wind in the adjustment screw on V9 while
monitoring the PT6 pilot pressure gauge on the Power Pack.
4 Stop when the indicator on the gauge reads 40–45 bar and lock the
locknut.
5 This completes the setting of V9.

the Power Pack.
Protective Equipment is worn at 2 Move the PT selector knob on the Power Pack to position No. 3.
all times, and the correct tools
3 Ensure all the valves on the Control Panel are in the neutral position and
are used for this operation.
switch on the Power Pack.
4 Move the Rod Handling/Drilling selector lever to the Drilling position.
5 Using a 10mm spanner, wind in the adjusting screw on V7 while monitoring
the circuit pressure gauge on the Control Panel.
6 Stop when indicator reaches 140 bar and lock locknut.

8 Reset the PT selector knob to position number 2 ready for drilling.

the Power Pack.
Protective Equipment is worn 2 Move the PT selector knob on the Power Pack to position number 5.
at all times. 3 Ensure all the valves on the Control Panel are in the neutral position and
Use the correct tools for this switch on the Power Pack.
operation.
4 Move the Rod Handling/Drilling selector lever to the Drilling position.
5 Using a 10mm spanner, wind in the adjustment screw on V11 while
monitoring the circuit pressure gauge on the Control Panel.
6 Stop when the indicator on the gauge reads 70 bar and lock the locknut.
V20 and V21 Head Float Calibration

A reduced system pressure is applied to the appropriate side of the feed
cylinder depending on whether the rod is being “made up” or “broken”. This
circuit overcomes the combined effects of head mass and carriage resistance
when the drill is in float mode.
Precise adjustment of the head float circuit is not required. Place two rods in
the feed frame and rotation unit. During making and breaking, notice when
Wear the correct Personal the rod joint is fully undone, and ensure the carriage speed is sufficient to
Protective Equipment at all allow the box and pin to separate. Adjust V20 slightly to achieve separation
times. of the box and pin if necessary.
Ensure the immediate area Wind flow control cartridge adjustment fully anticlockwise to close flow off
is clear before fitting rods completely.
through the Rotation Unit
Wind flow control cartridge adjustment fully clockwise to open flow
and Rod Holder.
completely.
Note: These adjustments are To adjust V20, select rod handling and full reverse motion. Adjust V20 so that
normally only required when
the carriage is approximately synchronised to the rod thread pitch.
changing down hole or up hole
angles greater than 45 degrees. To adjust V21, select rod handling and full forward motion. Adjust V21 so that
the carriage is approximately synchronised to the rod thread pitch.
Main Valve Bank

The following adjustments must be made to the main valve bank:
a) Primary relief valve — inlet block
b) Secondary relief valve — V1 and V3
c) Maximum flow limiters — V1, V2, V3 and V4.
Primary Relief Valve
Ensure the Correct Personal 1 Wind the pressure control adjustment screw on the main pump fully in
Protective Equipment is worn. (bottom screw).

Standby adjustment
main valve bank
and pressure
Ensure the drill is switched OFF
before these adjustments are
attempted.
2 Move the PT selector knob on the Power Pack to position number 1.

3 Disconnect the two hoses going to the rotation motor and plug the open
ends with 1 1/16” JIC plugs. Cap open fittings on the motor.
under pressure — vent hose 4 Ensure all valves on the Control Panel are in the neutral position and
at Control Panel by cycling switch on the Power Pack.
Rotation control lever. 5 Move the rotation control lever on the Control Panel fully forward and lock
into position.
6 Using a 5mm Allen key, either increase or decrease the primary relief
valve setting until the gauge indicator reads as follows:
• LM45/55/75 — 310 bar.
• LM90 — 330 bar
7 Lock the locknut on the primary relief valve.
8 Decrease the lower pressure control adjustment screw on the main pump
until the gauge indicator reads as follows:
• LM45/55/75 — 285 bar.
• LM90 — 310 bar.
9 Tighten the locknut and re-fit the cap to the adjustment screw.
10 Return the rotation control lever to the neutral position and switch off the
Power Pack.
Secondary Relief Valves — V1

Ensure the Correct Personal 1 Disconnect the two big hoses going to the Wireline Hoist and plug the
protective Equipment is worn. ends with 3/4” JIC plugs.
Cap the open hose connections on the Hoist.
2 Move the PT selector knob on the Power Pack to position number 4.
Ensure the drill is switched OFF
attempted.
4 Move the Wireline Hoist control lever fully into the raise position.
5 Using a 5mm Allen key, adjust the top relief valve adjusting screw on V1
Possibility of hydraulic oil until the circuit pressure gauge reads:
at Control Panel by cycling
• for 5mm diameter cable — 165 bar
Wireline Hoist control lever. • for 6mm diameter cable — 210 bar.
6 Lock the locknut on the relief valve and return the wireline hoist lever to
the neutral position.
7 To set the bottom relief valve on V1 move the wireline hoist lever to the
lower position and repeat this procedure.
8 Switch off the Power Pack and re-set the PT selector to position number
2 ready for drilling.
Top Top
Secondary Secondary
Primary Relief Valve Relief Valve
Relief Adjustment Adjustment
Valve for V3 for V1
Adjustment
Ensure the drill is switched OFF Secondary Relief Valves — V3

1 Disconnect the two feed cylinder hoses going to the Feed Frame or
attempted.
Positioner and ensure the hose ends are plugged by the quick release
Possibility of hydraulic oil couplings.
If quick release couplings are not being used, plug the ends with 1 1/16”
JIC plugs.
Feed control lever.
2 Move the P.T. selector knob on the Power pack to position number 4.
3 Wind the pressure control adjustment screw on the main pump fully in
Ensure the Correct Personal (bottom screw).
protective Equipment is worn.
5 Move the carriage control lever fully forward and lock in position.
6 Using a 5mm Allen key adjust the top relief valve adjusting screw on V3
until the circuit pressure gauge reads 300 bar.
If 300 bar cannot be reached, check the main relief valve has been
correctly set to:
• LM45/55/75 — 310 bar.
• LM90 — 330 bar.
7 Lock the locknut on the relief valve.
8 Reset the pressure control adjustment screw on the main pump until the
circuit pressure gauge reads as follows:
• LM45/55/75 — 285 bar.
• LM90 — 310 bar.
Lock the locknut and refit the cap to the adjustment screw.
9 Return the carriage control lever to the neutral position.
10 To set the bottom relief valve on V3 move the carriage lever fully rearward
and repeat this procedure.
11 Switch off the Power Pack and reset the PT gauge selector to position
number 2 ready for drilling.
Setting Flow Rates

Valves V1, V2, V3 and V4
Ensure the correct Personal A hydraulic flow meter capable of measuring flow rates up to a maximum of
Protective Equipment and tools 200 Lpm is a necessity for setting these adjustments.
are used for this operation.
V1 — Wireline Hoist Circuit

1 Disconnect the two 1/2” ID hoses going to the Wireline Hoist at the Hoist
end. Cap the open connection on the Hoist.
Ensure the drill is switched
OFF before attempting these 2 Connect the flow meter to the wireline hoist hoses with the hose from the
adjustments. Power Pack ‘A’ port connected to the inlet of the flow meter.
3 Ensure load valve on the flow meter is fully open and the Drilling/Rod
Handling selector lever on the Control Panel is in the Rod Handling
position.
4 Wind the maximum flow adjustment screw at top of V1 fully out and switch
on the Power Pack.
5 Slowly move the wireline hoist control lever on the Control Panel fully into
the raise position and allow the hoses to purge for 10 minutes.
under pressure — vent hose 6 Wind the top maximum flow adjustment screw inwards until the flow
at Control Panel by cycling reduces to 58 Lpm. Lock the adjustment screw.
Wireline Hoist control lever. 7 Return the wireline hoist control lever to neutral and move the control lever
into the reverse position. Allow to purge for 10 minutes.
8 Wind the bottom maximum flow adjustment screw inwards until the flow
reduces to 58 Lpm. Lock the adjustment screw.
9 Return the Wireline control lever to neutral and switch off the Power
Pack.
10 If necessary set the secondary relief valves on V1. Refer page 10-17.
Rotation
Reverse
Feed Wireline
Forward Forward
Feed Wireline
Water Pump Reverse Rotation Reverse
Forward Forward
V4 V3 V2 V1
Water Feed Rotation Wireline
Pump Circuit Circuit Circuit
V2 — Rotation Circuit
Possibility of hydraulic oil 1 Disconnect the two 3/4” ID hoses going to the rotation motor at the motor
under pressure — vent hose end. Cap the open connections on the motor.
2 Connect the flow meter to the rotation motor hoses with the hose from the
Rotation control lever.
Power Pack ‘A’ port connected to the inlet of the flow meter.
Protective Equipment is worn
3 Ensure the load valve on the flow meter is fully open and the Drilling/Rod
for this operation. Handling selector lever on the Control Panel is in the Drilling position.
4 Wind the flow adjustment screw at the bottom of V2 fully out and switch
on the Power Pack.
5 Slowly move the rotation control lever on the Control Panel fully forward
and lock into position.
Allow the hoses to purge for 10 minutes.
6 Several combinations are possible for power packs and rotation units,
which also vary dependent on the connection to the hydraulic system of
hydraulic powered water pumps. The larger capacity hydraulic water pumps
require the oil flow in the rotation circuit to be reduced to compensate for
the additional power demand on the circuit.
Refer to the table below for the correct oil flow value:
Power Rotation V2 Oil Flow Setting

Pack Unit without Water Pump with Water Pump
BQ 82 Lpm À 82 Lpm
LM45
HQ 82 Lpm 82 Lpm
HQ45 — Á 82–85 Lpm

LM55 HQ55 100 Lpm Not recommended
HQ55 H/T 100 Lpm Not recommended
HQ55 — Â 100–110 Lpm

HQ55 H/T — 100–110 Lpm
LM75
HQ75 140 Lpm Not recommended
HQ75 H/T 140 Lpm Not recommended
HQ55
HQ55 H/T
LM90 160 Lpm 160 Lpm
HQ75
HQ75 H/T
À based on 712 capacity water pump

Á based on 520 capacity water pump
Â based on 520/535/835 capacity water pump
Independent electric powered water pumps require no reduction in oil

flow within the V2 rotation circuit.
7 Return the rotation control lever to neutral.

8 Slowly move the rotation control level fully rearward and lock it into
position.
9 Adjust the flow adjustment screw at the top of V2 inwards until the flow
rate is approx. 20 Lpm.
10 Return the rotation control level to neutral and switch off the Power
Pack.
V3 — Feed Circuit
Possibility of hydraulic oil 1 Disconnect the two 3/4” ID hoses going to the feed cylinder or
under pressure — vent hose Positioner.
2 Connect the flow meter to the feed cylinder hoses with the hose from the
Feed control lever.
Power Pack ‘A’ port connected to the inlet of the flow meter.
Protective Equipment is worn
3 Ensure the load valve on the flow meter is fully open and the Drilling/
for this operation. Rod Handling selector lever on the Control Panel is in the Rod Handling
position.
Ensure that the Rod Pulling/Rod Feeding selector lever is in the Rod
Pulling position.
4 Wind the adjustment screw at the top of V3 fully out and switch on the
Power Pack.
5 Slowly move the Carriage control lever on the Control Panel fully forward
and lock into position. Allow the hoses to purge for 10 minutes.
6 Monitor the oil flow through the flow meter and adjust the screw at the top
of V3 until the correct flow is obtained, then lock the adjustment screw:
Power Feed
V3 Oil Flow Setting
Pack Frame
LM45 400 Series 90 Lpm
400 Series 90 Lpm

LM55
700 Series 120 Lpm
400 Series 90 Lpm

LM75/90 700 Series 120 Lpm
1300 Series 120 Lpm
7 Return the Carriage control lever to neutral.

8 Slowly move the Carriage control lever on the Control Panel fully rearward
and lock in position. Allow the hoses to purge for 10 minutes.
9 Adjust the flow adjustment screw on the bottom of V3 until the correct flow
is obtained, then lock the adjustment screw.
10 Return the Carriage control lever to neutral and switch off the Power
Pack.
V4 — Water Pump Circuit

Possibility of hydraulic oil 1 Disconnect the two hoses going to the hydraulic motor on the water pump
under pressure — carefully at the pump end.
disconnect hoses. Cap the open connections.
Ensure the correct Personal 2 Connect the flow meter to the water pump hoses with the hose from the
Protective Equipment is worn Power Pack. ‘A’ port is connected to the inlet of the flowmeter.
for this operation.
3 Ensure the load valve on the flow meter is fully open and the Drilling/
Rod Handling selector lever on the Control Panel is in the Rod Handling
position.
4 Slowly wind fully inwards (turn clockwise) the knob on the water pump
speed control on the Control Panel. Allow the hoses to purge for 10
minutes.
5 Monitor the oil flow through the flowmeter and adjust the screw at the
bottom of V4 inwards until the flow is:
• for a 520 size pump — approximately 27 Lpm,
• for a 535 size pump — approximately 40 Lpm, or
• for a 712 size pump — approximately 15 Lpm.
Lock the adjustment screw.
6 Wind out the water pump speed control and switch off the Power Pack.
Valve 4 Valve 2
Water Rotation
Pump Valve 3 Circuit Valve 1
Feed Wireline
Circuit Circuit
Inlet
Section
SECTION 11
Troubleshooting the Hydraulic System

11-2 Explanation of Inbuilt Checking System
IMPORTANT NOTE
11-4 LM45/55/75 Design Circuit Pressures and

Amperes
11-5 LM45/55/75 Circuit Test Chart
11-6 LM90 Design Circuit Pressures and Amperes
11-7 LM90 Circuit Test Chart
11-8 Hydraulic Circuit Diagrams
Explanation of Symbols Used
Troubleshooting the Hydraulic System 11-
Explanation of Inbuilt Checking System

The task of trouble shooting the hydraulic system is simplified by an inbuilt
pressure testing system.
Two pressure gauges are permanently installed on the Power Pack:
• PT6 Pilot Pressure supply to the Control Panel.
• PT7 Charge Pressure i.e., the pressure in the suction manifold of the
main pump.
A gauge selector is mounted on the power unit adjacent to the PT6 and PT7
gauges. This selector has 5 positions which monitor the circuit pressure at
locations designated:
PT1 Main pump discharge pressure.
PT2 Rotation circuit pressure.
PT3 Rod holder circuit pressure.
PT4 Load sensing pressure.
PT5 Chuck supply pressure.
PT Pressure Gauges
The read-out of the pressure at any of these 5 selected locations, is presented

on the middle pressure gauge on the control panel, the graduations of which
are in MPa. (1MPa equals 10 bar)

Whilst drilling it is recommended that the PT2 pressure location be selected
so that an indication of the torque generated by the head may be continuously
monitored at the control panel.
IMPORTANT NOTE
• Before any work is commenced on any part of the Hydraulic System, the
area to be worked on must be thoroughly cleaned.
• All exposed fittings and hoses must be capped or plugged with the correct
cap or plug fitting.
• All exposed components or assemblies must be covered and protected.
• All oil entering the Hydraulic System must be filtered.
• Oils of different brands or grades should not be mixed. Use the correct
grade of oil to suit the operating conditions.
• The hydraulic system is factory flushed to the following code:
ISO 4406 CLEANLINESS CODE 15/11
LM45/55/75 Design Circuit Pressures and Amperes

Be aware of moving hoses and components at all times
— ensure immediate area is clear before conducting any tests.
LM45/55/75 Circuit Test Chart

LM90 Design Circuit Pressures and Amperes

LM90 Circuit Test Chart

Hydraulic Circuit Diagrams

The colour coded schematics following, are provided to help you troubleshoot
the hydraulic system should the need arise.
Each separate circuit drawing is represented on the pressure checking table.
protective Equipment and tools
By combining the two together, you will be able to set the controls for each
operation and then check both the pilot pressures and main circuit pressures
in your circuit, against the design pressures in the manual.
HINT: Note that these are design pressures and actual pressures may vary slightly
Always check pilot pressures first! from those shown.
Explanation of Hydraulic Component Symbols

Used in Circuit Diagrams
Troubleshooting the Hydraulic System 11-10
Hydraulic circuit diagrams for LM Series drills are included on the following pages:
Circuit Circuit
1. Stand By — Chuck Open 7. Rod Feeding — Return Stroke
2. Stand By — Chuck Closed 8. Thread Making
3. Drilling — Forward Feed 9. Thread Breaking
4. Rod Pulling — Pull Stroke 10. Wireline Hoist — Power Up
5. Rod Pulling — Forward Stroke 11. Water Pump
6. Rod Feeding — Feed Stroke

SECTION 12
Drill Rig Service Schedule

12-2 Service Schedule
Drill Rig Service Schedule 12-
Drill Rig Service Schedule

LOCATION: LM 45 / 55 / 75 / 90 Rig No.
For OK (  ) Defective (  ) DATE
WEEKLY: Weekly Weekly Weekly Monthly
ROTATION UNIT AND ROD CLAMP
Check jaws and bushings
FEED FRAME
Grease rollers and sheaves
Adjust wear strips
Check tension and lubricate chain
FEED FRAME POSITIONER
Grease
WIRELINE HOIST
Grease bearings and lubricate chain
WATER PUMP(S)
Check oil level
MONTHLY:
POWER PACK
Change hydraulic filters
Check tyre pressure
WIRELINE HOIST
Check bolts and guards
Check chain tension
WATER PUMP(S)
Check relief valve
Check coupling
Change pump oil
ROTATION UNIT
Check all bolts
Change breather
Change gearbox oil
ROD CLAMP
Check all bolts and angle bracket
FEED FRAME
Check hinge pin and bushings
Check Vee slides
Check cylinder support slides
Remove brass adjusting screws, clean, replace
Check cylinder support blocks
Check front and rear sheaves
SUPERVISOR'S RESPONSIBILITY NAME
TO ORDER PARTS SIGNATURE
NOTE: CHECK ALL HYDRAULIC AND WATER ASSEMBLIES DAILY
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Operations and Service Manual

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LM45/55/75/90

Operations and Service

• These two accumulators must be fitted to the Power Pack before

• The 0.35L accumulator is connected to the pilot pressure line PP7.

Capital Equipment. Boart Longyear warrants that the capital equipment

Boart Longyear Pty Ltd

© Boart Longyear 2008

1 List the model and serial number of the drill.

Hazard Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided,

WARNING indicates a potentially hazardous situation which, if not avoided,

CAUTION indicates a potentially hazardous situation which, if not avoided,

Section 2 Commissioning Procedure

Section 3 Servicing the Hydraulic System

Section 4 BQ Rod Clamp

Section 4 HQ Mk2 Rod Holder

Section 4 PQ Rod Holder

Section 5 BQ Rotation Unit and Chuck

Section 5 HQ Mk2 Rotation Unit and Chuck

Section 6 400 Series (Direct Coupled) Feed Frame

Section 6 700 Series (Direct Coupled) Feed Frame

Section 6 700 Series (Chain Coupled) Feed Frame

Section 6 1300 Series Feed Frame

Section 7 The Power Pack

Section 8 The Control Panel

Section 10 Hydrostatic Explanation

Section 11 Troubleshooting the Hydraulic System

Section 12 Drill Rig Service Schedule

DRILL INTRODUCTION and OPERATION

1-11 Operating the Electric Power Pack

1-13 Operating Both Power Packs

1-17 Rod Handling

1-23 Drilling Operations

Weight: Electric Power Pack 1190 Kg

Chapter Reference: LM55 Stub Shaft Assembly p/n 602380

LM75 Stub Shaft Assembly p/n 602031

LM90 Stub Shaft Assembly p/n 3002778

LM75D Stub Shaft Assembly p/n 30002918

The Power Pack

Diesel Power Pack

Diesel Power Pack

Diesel Power Pack

Electric Power Pack

Electric Power Pack

Electric Power Pack

The Electric Starter — Diesel Motor

The Electric Starter — Electric Motor

The Control Panel

Control Panel (fully optioned)

PT Gauge WL1 PP1 WP1 FC4 PP4 PP5 T WP

Bulkhead — Underside View

1 1/16” JIC 1 1/4” AF

14 ROTATION SPEED CONTROL — Used to adjust the displacement of

Operating the Diesel Power Pack

Starting the Diesel Power Pack

Before starting the equipment

Stopping the Diesel Power Pack

Operating the Electric Power Pack

Limit switches will not allow the

Starting the Electric Power Pack

Stopping the Electric Power Pack

Operating Both Power Packs

Motor adjustment point

CHEVRON EP HYDR OIL 3 H V 8 H V 100

FINA HYDRAN H V 3 H V H V 8 100

TEXACO RANDO OIL HD A- HD AZ-3 HD CZ-8 HD E-100

LM DRILL OIL TANK L

L09 WATER PUMP L (¼ U.S. quarts) SAE 30