No.

S032013-02 Date: March 2013 Page: 1 of 6

Service Alert - LF90D Mainline Hoist Rope

Life
In an on-going effort to improve our capital The present hoist orientation dictates that the
equipment products, this service alert announces the mainline wire rope is routed off the bottom of the
availability of a new Mainline Hoist cable tensioner hoist drum close to the dump frame as shown in
for the LF90D. figure 1.
This service bulletin supersedes Service Alert #292 The hoist cable is forced to bend in opposite
issued in February 2008. directions as it runs over the crown block sheaves
from the hoist drum, affecting its lay on the drum as it

Units Affected is rewound.

This kit is recommended to upgrade all LF90D drills Due to the limited space available, the hoist

manufactured prior to s/n 2013-001. tensioner cannot be located at the rope entry
location, limiting its effectiveness.

Problem
Solution
The amount of wire rope on the mainline hoist drum
varies with mast position. The recommendation outlined in this service alert is

When operating the hoist with a second wrap, the to rotate the mainline hoist 180 degrees on the dump

additional rope negatively affects tensioner operation frame to allow the rope to come off the top of the

and under certain conditions the rope can make hoist.

contact with the hoist frame gusset, causing rope A new more robust tensioner is also included to help

damage when the rope is under load. control the cable at the entry point and allow for the
second wrap of rope on the drum (Figure 2).
The kit consists of a new wire rope assembly, hoist
pin, tensioner, and two (2) guards with mounting
bolts. It is available for sale under kit # 5402854.

Fig 1: Mainline rope spooling

Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specification and price without notice.
Copyright ©2013 Boart Longyear. All Rights Reserved
No. S032013-02 Date: March 2013 Page: 2 of 6

Instructions for ordering kits:

1. This service kit is an upgrade to your existing

mainline winch and is not covered by warranty
under any circumstances.
2. The kit is available for sale under part number
5402854.
3. If you wish to upgrade your drill, please purchase
the kit by contacting your Boart Longyear
Customer Service Representative and providing
the part number.
Figure 2: Updated Mainline Hoist Installation

If you have any questions or would like a quotation

Tools Required: on field installation, please contact your Boart
· Overhead lifting device 1500 lbs. capacity for Longyear Service Representative and refer to
bare winch Service Alert # S032013-02.
· Magnetic drill
· 1-1/8” drill bit
· 3/4” Torque wrench
· 1-1/2” , ¾ drive socket
· ¾” ratchet and 12” extension
· 7/8” thin wall socket
· Assorted metric and imperial open end
wrenches, including:
o 9/16” open end wrench
o 1-1/4”open end wrench

Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specification and price without notice.
Copyright ©2013 Boart Longyear. All Rights Reserved
No. S032013-02 Date: March 2013 Page: 3 of 6

Step by step instructions for installation:

1. Raise mast to vertical for hoist access.

2. Lower the head until the feed cylinders bottom
out.
3. Pay out mainline hoist rope to ground.
4. Remove existing hoist guard (x1).
5. Remove existing hoist tensioner (x1).
6. Loosen wire rope retaining set screws.
7. Lay the mast down to remove the mainline hoist
rope from the hoist drum.
8. Raise mast to provide best access for hoist
removal. (mast angle may vary with lifting
Figure 3: Updated Mainline Hoist Vent
equipment available to handle the hoist)
9. Stop engine and shut off power at master
15. Slot holes in dump frame using a portable
disconnect. Site specific “tag out, lock out”
magnetic drill to the dimensions shown in figure
procedures are required.
5 (page 6).
10. Disconnect hydraulic lines from hoist motor, and
16. Using sling, position hoist over mounting slots
cap all ports and hoses.
on dump frame. Make sure the hoist has been
11. Secure mainline hoist (224 kg) with a load rated
flipped with the motor on the right as per Figure
sling, and remove hoist mounting bolts.
4.
12. Remove hoist from drill rig.
17. Use a pry bar with a tapered end to temporarily
13. Remove hoist motor and rotate prior to re-
locate the hoist for bolt insertion. Never use
installation per figure 4.
your fingers to locate holes.
14. Relocate hoist vent per Figure 3.

Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specification and price without notice.
Copyright ©2013 Boart Longyear. All Rights Reserved
No. S032013-02 Date: March 2013 Page: 4 of 6

18. Install hoist mounting bolts with back up 26. Install winch guard.
washers behind nuts(x4). 27. Install tensioner guard.
19. Be sure to position the hoist at the extreme left 28. Restart drill, test mainline hoist direction.
of the slots, and torque hoist mounting nuts 29. Install hoist plug.
to 760 nm (560 ft. lb.). 30. Raise mast to vertical with the aid of a spotter
20. Remove bolts (x8) and top plate of winch frame. and check for any interference between the
21. Bolt the new tensioner on winch frame as seen mast raising cylinders and the guarding.
in Figure 2. 31. Wind in hoist cable until hoist clevis is at the top
of the mast.
32. Torque tensioner eye bolt nut to 27- 34 nm (20-
25 ft. lbs.).
33. Test hoist and tensioner function.
34. Record the rig serial number, date of repair and
mechanics name on this service alert and keep
on file for future reference.
35. Update your parts book with the attached parts
book information.

It is recommended that this work be

carried out in a properly equipped shop

Figure 4: Tensioner Installation with lifting equipment by trained

maintenance personnel.
22. Re-connect hoses to motor.
23. Locate the new hoist rope supplied with the kit, If you have any questions or would like a quotation
and examine the cut end. Note that the butt of on field installation, please contact your Boart
the cut end has been welded. This is necessary Longyear Service Representative and refer to
for max rope life. Never install a freshly cut rope Service Alert # S032013-02.
on the hoist without this preparation.
24. Lower mast and thread new hoist rope through
mainline sheaves and over the top of the hoist
drum as shown in Figure 2. Insert the free end
of the rope into the drum rope socket.
25. Tighten wire rope retaining set screws.

Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specification and price without notice.
Copyright ©2013 Boart Longyear. All Rights Reserved
No. S032013-02 Date: March 2013 Page: 5 of 6

Regional CSR Contact Information

Region Country Contact Name Contact tel # Contact email address

LAM Peru Karina Hernandez +51 1 2034250 khernandez@boartlongyear.com
LAM Peru Leonel Sanchez +51 1 2034383 leonel.sanchez@boartlongyear.com
LAM Chile Rodrigo Vargas +56 2 5953336 rodrigo.vargas@boartlongyear.com
LAM Chile Miguel Carreño +56 2 5953340 miguel.carreno@boartlongyear.com
LAM Argentina Paulina Perinetti +54 2 614053049 paulina.perinetti@boartlongyear.com
LAM Colombia Juan Garzon +57 4 6046390 juan.garzon@boartlongyear.com
LAM Brazil Viviane Oliveira +55 3 1304866 viviane.oliveira@boartlongyear.com
NAM Mexico Chris Romero +1 801 977 3344 chris.romero@boartlongyear.com
NAM US Paul Bambrick +1 801 977 3319 paul.bambrick@boartlongyear.com
NAM Canada Carol Parfitt +1 705 474 2800 canada.orderdesk@boartlongyear.com
EMEA EU Aida Chaouachi +41 22 7090887 aida.chaouachi@boartlongyear.com
EMEA Russia Evgeniya Ivanova +79 2 50054236 evgeniya.ivanova@boartlongyear.com
EMEA Zambia Abraham London +26 0966858150 abraham.london@boartlongyear.com
EMEA South Africa Sandra Kruger +27 117679399 sandra.kruger@boartlongyear.com

Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specification and price without notice.
Copyright ©2013 Boart Longyear. All Rights Reserved
No. S032013-02 Date: March 2013 Page: 6 of 6

Figure 5: Dump Frame Rework

Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specification and price without notice.
Copyright ©2013 Boart Longyear. All Rights Reserved
2
Printed in Canada Copyright © 2012 BOART LONGYEAR
 1 5403924 1 HOIST REWORK ( Page 4 )
2 3547862 REF WIRE ROPE 15mm x 75' LG
3 5403474 1 TENSIONER ASM, HOIST ( Page 14 )
4 5402949 1 GUARD, LF90D WINCH
5 5402961 1 GUARD, LF90D TENSIONER
6 5004233 4 C/SCR, FH M10 x 1.5 x 20

3
Printed in Canada Copyright © 2012 BOART LONGYEAR
4
Printed in Canada Copyright © 2012 BOART LONGYEAR
 1 3546537 1 HOIST, PLANETARY 16000 LB BARE C/W MOTOR
2 5404001 1 ADAP, HYD REDUCER 8ORB 1/8 NPT
3 5002780 1 ADAP, HYD PLUG 1/8 NPT

5
Printed in Canada Copyright © 2012 BOART LONGYEAR
14
Printed in Canada Copyright © 2012 BOART LONGYEAR
 1 5403475 1 FRAME, TENSIONER
2 5400815 1 RETAINER, TENSION
3 5403477 1 SUSPENSION UNIT, TENSIONER
4 5403476 1 SHAFT, TENSIONER
5 5403478 2 TUBE 50 X 5 X 39
6 5400802 2 BUSHING, SQUARE HOLE 39MM
7 5403479 1 ARM, TENSIONER
8 5403480 1 ARM, TENSIONER
9 5403481 1 ROLLER, TENSIONER
10 5400808 1 ROD END, (5/8)
11 5403030 1 C/SCR, SH SHOULDER 5/8 X 1-3/4
12 5403792 1 C/SCR, SH SHOULDER 3/4 X 9-1/2
13 46098 2 C/SCR, HH 3/4 UNC x 1 1/2 Lg.
14 44525 1 NUT, HEX 1/2-13 UNC
15 102222 1 NUT, HEX 5/8 UNC NYLOCK
16 44621 1 WASHER, FLAT 1/2"
17 44587 1 WASHER, FLAT 5/8"
19 5400807 2 WASHER, FENDER (3/4)

15
Printed in Canada Copyright © 2012 BOART LONGYEAR