Lm30 Ss Osm Ce June14

GLOBAL DRILLING PRODUCTS
Copyright © 2014 Boart Longyear. All rights reserved.
LM30 SKID STEER

OPERATIONS AND SERVICE MANUAL
June 2014
TABLE OF CONTENTS
Chapter 1: Safety
1.1 Reference Note for Users Manual ............................................................. 3
1.2 Important Safety Information ..................................................................... 4
1.2.1 Hazard Signal Indicators................................................................... 4
1.3 Safety Warnings and Guidelines ............................................................... 5
1.3.1 Before operating the drill rig.............................................................. 5
1.3.2 Whilst operating the drill rig............................................................... 6
1.3.3 After operating the drill rig................................................................. 9
1.3.4 General “Housekeeping”................................................................... 9
1.3.5 Cautions and Warnings................................................................... 11
1.4 General Safety Instructions...................................................................... 12
1.4.1 General Safety Requirements......................................................... 12
1.4.2 Operational Intervals ...................................................................... 17
1.5 Transportation — Skid Steer Rig............................................................. 18
1.5.1 Lifting............................................................................................... 18
1.5.2 Moving Whilst In Transit.................................................................. 18
1.5.3 Setting up the Drill........................................................................... 18
1.6 Moving a Disabled Machine ..................................................................... 20
1.6.1 Lifting the Machine.......................................................................... 20
1.6.2 Towing/Retrieving the Machine....................................................... 21
1.7 Storage of the Drill Rig and Accessories................................................ 22
1.8 Disposal of Equipment.............................................................................. 23
1.9 Personal Safety Equipment (PPE) .......................................................... 24
1.10 Airbourne Noise Emissions.................................................................... 24
1.11 Location of E-Stops and Operation of Guards ..................................... 26
1.11.1 Emergency Stop (E-Stop) push buttons........................................ 26
1.11.2 Safety Lanyard and E-Stop........................................................... 27
1.11.3 Battery Isolator Switch................................................................... 28
1.11.4 Feed Frame Guard........................................................................ 28
1.11.5 Residual Risks............................................................................... 29
1.11.6 Counter Balance Valves................................................................ 29
iii
Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
Table of Contents
1.12 Fire Fighting ............................................................................................ 30

1.12.1 Fire Classifications acc. EN2......................................................... 31
1.13 Safety Instructions for Drilling............................................................... 32
1.14 Skid Steer Dimensions and Cuddy Sizes.............................................. 33
Chapter 2: General Information

2.1 General Information .................................................................................. 37
2.1.1 Prior to First Use ............................................................................. 37
2.2 General Description................................................................................... 38
2.3 Ordering and Returning Parts ................................................................. 38
2.3.1 Ordering Parts ................................................................................ 38
2.3.2 Safety Related Components ........................................................... 38
2.3.3 Returning Parts ............................................................................... 39
2.4 Limited Warranty ...................................................................................... 39
2.5 EC Declaration of Conformity................................................................... 42
2.5.1 Location of Name (Type) Plates...................................................... 43
2.5.2 Recommended Tool Kit (p/n 56400)................................................ 45
Chapter 3: Drill Introduction and Operation

3.1 The LM30 Skid Steer Rig........................................................................... 49
3.2 The Control Panel...................................................................................... 51
3.3 Operating the Skid Steer Rig.................................................................... 54
3.3.1 Cooling Water.................................................................................. 55
3.3.2 Control Positioning.......................................................................... 55
3.3.3 Starting the Skid Steer..................................................................... 55
3.3.4 Stopping the Skid Steer................................................................... 57
3.3.5 Adjusting and Setting Rotation Motor Displacement....................... 58
3.3.6 Inserting the Core Barrel................................................................. 58
3.3.7 Running Rods into the Hole............................................................. 59
3.3.8 Rod Pulling...................................................................................... 60
3.3.9 Drilling.............................................................................................. 61
3.3.10 Rechucking.................................................................................... 62
3.4 Fault Light Indicators................................................................................ 63
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Table of Contents
Chapter 4: Options
4.1 Wireline Hoist............................................................................................. 67
4.1.1 Introduction...................................................................................... 67
4.1.2 Hoist Capacity................................................................................. 68
4.1.3 Wireline Maintenance...................................................................... 68
4.1.4 Checking and/or Changing the Oil................................................... 69
4.1.5 Changing the Wireline Cable........................................................... 71
4.2 Feed Frame Positioner (FFP).................................................................... 73
4.2.1 Setting up to Drill a Down Hole (0° to –90°).................................... 73
4.2.2 Setting up to Drill an Up Hole (0° to +90°)....................................... 74
4.3 Extending the Feed Frame........................................................................ 76
4.3.1 With Dump Cylinder Fitted............................................................... 76
4.4 Removing the Skid Steer from the Positioner Assembly...................... 77
4.5 Water Pump................................................................................................ 79
4.5.1 Introduction...................................................................................... 79
4.5.2 Water Pump Lubrication and Maintenance..................................... 80
Chapter 5: Drill Commissioning

5.1 Hose Connections..................................................................................... 85
5.2 Pre-Start Checks........................................................................................ 86
5.2.1 BEFORE OPERATION.................................................................... 86
5.2.2 OPERATING THE MACHINE.......................................................... 87
5.2.3 Oil Temperature Switch................................................................... 88
5.2.4 Control Panel................................................................................... 88
5.2.5 Drill Head......................................................................................... 89
5.2.6 Water Pump..................................................................................... 90
5.2.7 Positioner Assembly........................................................................ 90
5.3 Start Up....................................................................................................... 91
5.4 Purging (Flushing) and Pilot Bleeding..................................................... 91
5.4.1 Chuck Circuit................................................................................... 91
5.4.2 Rod Holder Circuit........................................................................... 92
5.4.3 Rotation (Hydraulic Motor) Circuit — Bleeding of Pilot Hoses
A and B........................................................................................... 92
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Table of Contents
5.4.4 Feed Cylinder Circuit — Bleeding of Pilot Hoses A and B.............. 93

5.4.5 Wireline Hoist Circuit — Bleeding of Pilot Hoses A and B............... 94
5.4.6 Feed Frame Dump Circuit — Bleeding of Pilot Hoses A and B....... 95
5.4.7 Positioner Tilt Circuit — Bleeding of Pilot Hoses A and B............... 95
5.4.8 Fine Feed Circuit............................................................................. 95
5.4.9 Water Pump Circuit......................................................................... 96
5.5 Function Checks........................................................................................ 97
5.5.1 Chuck/Rod Clamp........................................................................... 97
5.5.2 Rotation Direction............................................................................ 97
5.5.3 Feed Frame..................................................................................... 98
5.5.4 Drill Head — Alignment Check........................................................ 98
5.5.5 Drill Head — Thread Making/Breaking............................................ 99
5.5.6 Rod Handling................................................................................... 99
5.5.7 Water Pump................................................................................... 100
Chapter 6: Hydrostatic Explanation

6.1 Introduction.............................................................................................. 103
6.2 The Main Pump........................................................................................ 103
6.3 Main Manifold Block Assembly ............................................................. 103
6.4 Feed Manifold Assembly......................................................................... 108
6.5 Setting Pressures.................................................................................... 109
6.5.1 Chuck Load Sense Relief.............................................................. 109
6.5.2 Rod Holder Load Sense Relief...................................................... 110
6.5.3 Dump Cylinder Load Sense Reliefs............................................... 110
6.5.4 Tilt Cylinder Load Sense Reliefs................................................... 110
6.5.5 Wireline Hoist Load Sense Reliefs................................................ 111
6.5.6 Rotation Load Sense Reliefs......................................................... 111
6.5.7 Feed Load Sense Reliefs.............................................................. 112
6.5.8 System Relief Valve V2................................................................. 112
6.6 Setting Flow Rates................................................................................... 113
6.6.1 Rotation Circuit.............................................................................. 113
6.6.2 Feed Circuit................................................................................... 114
6.6.3 Water Pump Circuit....................................................................... 115
6.6.4 Wireline Hoist Circuit..................................................................... 115
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Table of Contents
6.6.5 Dump Circuit.................................................................................. 116

6.6.6 Positioner Tilt Circuit...................................................................... 116
Chapter 7: Electrical Schematics

Chapter 8: Maintenance
8.1 Hydraulic Oils........................................................................................... 125
8.1.1 Hydraulic Oil Hints......................................................................... 125
8.1.2 Oil Selection Chart......................................................................... 125
8.2 Hydraulic Filters....................................................................................... 126
8.2.1 Chuck Filter................................................................................... 126
8.2.2 Skid Steer Filter Elements............................................................. 126
8.2.3 Filter Hints..................................................................................... 127
8.3 BQ Rod Clamp.......................................................................................... 129
8.3.1 Rod Clamp Jaw Replacement....................................................... 130
8.3.2 Rod Clamp Guide Bushing Replacement...................................... 131
8.3.3 Spring Pack Replacement............................................................. 132
8.3.4 Rod Clamp Hydraulic Piston.......................................................... 133
8.3.5 Rod Holder Troubleshooting.......................................................... 135
8.4 HQ Mk2 Rod Holder................................................................................. 137
8.4.1 Rod Holder Jaw Replacement....................................................... 138
8.4.2 Rod Holder Guide Bush Replacement.......................................... 139
8.4.4 Rod Holder Hydraulic Piston......................................................... 142
8.5 BQ Rotation Unit and Chuck................................................................... 145
8.5.1 Chuck............................................................................................ 145
8.5.2 Rotation Unit.................................................................................. 145
8.5.3 Gearbox Lubrication and Maintenance.......................................... 146
8.5.4 Chuck Jaw Replacement............................................................... 147
8.5.5 Guide Bushing Replacement - Front............................................. 148
8.5.6 Guide Bushing Replacement - Rear.............................................. 149
8.5.7 Gear Set Replacement in Rotation Unit........................................ 150
8.5.8 Gear Replacement on Hydraulic Motor......................................... 152
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Table of Contents
8.5.9 Chuck Disassembly....................................................................... 153

8.5.10 Rotation Unit Disassembly.......................................................... 156
8.5.11 Rotation Unit Preassembly Checks............................................. 158
8.5.12 Rotation Unit Reassembly........................................................... 160
8.5.13 Rotation Unit Rotary Seal Test.................................................... 162
8.5.14 Break Out Device Operation........................................................ 165
8.5.15 Break Out Device Disassembly................................................... 166
8.5.16 Setting Sequence Valve Pressure............................................... 167
8.5.17 Rotation Unit Troubleshooting..................................................... 169
8.6 HQ Mk2 Rotation Unit and Chuck........................................................... 173
8.6.1 Chuck............................................................................................ 173
8.6.2 Rotation Unit.................................................................................. 173
8.6.5 Guide Bush Replacement.............................................................. 176
8.6.6 Oil Seal Replacement.................................................................... 177
8.6.8 Chuck Cylinder Overhauling.......................................................... 186
8.6.9 Breakout Device Servicing............................................................ 190
8.6.10 Breakout Device Operation......................................................... 194
8.6.12 Rotation Unit Maintenance.......................................................... 197
8.7 400 Series (Direct Coupled) Feed Frame............................................... 209
8.7.1 Introduction.................................................................................... 209
8.7.2 Assembling the Feed Frame......................................................... 210
8.7.3 Feed Frame Maintenance............................................................. 210
8.7.4 Adjusting the Carriage................................................................... 212
8.7.5 Replacing the Carriage Wear Strips.............................................. 214
8.7.6 Carriage Side Plate Disassembly.................................................. 216
8.7.7 Removing the Feed Cylinder......................................................... 217
8.7.8 Removing the Cylinder Trunnions................................................. 218
8.7.9 Replacing the Feed Cylinder......................................................... 219
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Table of Contents
8.7.10 Feed Cylinder Disassembly......................................................... 220

8.7.11 Cylinder Reassembly................................................................... 223
8.8 The Power Unit......................................................................................... 225
8.8.1 Introduction.................................................................................... 225
8.8.2 The Main Pump............................................................................. 225
8.8.3 Heat Exchanger............................................................................. 227
8.8.4 SAE/MS Straight Thread Positionable Elbows and Tees ............. 228
8.8.5 Troubleshooting............................................................................. 229
Chapter 9: Troubleshooting the Hydraulic System

9.1 Explanation of the Checking System..................................................... 233
9.2 Function Test Chart ............................................................................... 234
9.2.1 (Blank) Function Test Chart........................................................... 235
9.3 Hydraulic Circuit Diagrams..................................................................... 236
Chapter 10: Troubleshooting the Electrical System

10.1 Introduction............................................................................................ 239
10.2 LM30 CAT246C Skid Steer Test Chart ................................................ 240
10.2.1 Fault Finding Test Example......................................................... 241
10.2.2 Standby Test 1 — STANDBY AUTO........................................................242
10.2.3 Standby Test 2 — STANDBY + ISOLATE...............................................242
10.2.4 Drill Mode Test 3 — DRILL MODE...........................................................243
10.2.5 Drill Mode Test 4 — DRILL MODE + ROTATION + FINE FEED..........243
10.2.6 Rod Handling Test 5 — ROD HANDLING + ROD PULLING.................244
10.2.7 Rod Handling Test 6
— ROD HANDLING + ROD PULLING + REVERSE CARRIAGE.............244
— ROD HANDLING + ROD PULLING + FORWARD CARRIAGE...........245
— ROD HANDLING + ROD PULLING + THREAD BREAKING...............246
10.2.10 Rod Handling Test 9 — ROD HANDLING + ROD FEEDING..............246
— ROD HANDLING + ROD FEEDING + FORWARD CARRIAGE........247
— ROD HANDLING + ROD FEEDING + REVERSE CARRIAGE..........248
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Table of Contents

— ROD HANDLING + ROD FEEDING + THREAD MAKING.................248
10.3 PLC Input/Output Descriptions............................................................ 249
10.4 Testing Procedure — Pressure Switches and Solenoid Valves........ 250
10.4.1 Testing a Pressure Switch........................................................... 250
10.4.2 Testing a Solenoid Valve............................................................. 251
x
Table of Contents
TABLE OF FIGURES
Chapter 1: Safety
Figure 1–1: 3 metre Danger Zone..................................................................... 13
Figure 1–2: CAT Skid Steer lifting points and weights....................................... 19
Figure 1–3: LM30 Control Panel lifting points and weight................................. 19
Figure 1–4: Positioner lifting points and weight................................................. 19
Figure 1–5: Feed Frame lifting points and weight.............................................. 20
Figure 1–6: Wireline lifting point and weight...................................................... 20
Figure 1–7: Front towing eyes........................................................................... 21
Figure 1–8: Rear towing eyes............................................................................ 21
Figure 1–9: Towing line configuration................................................................ 21
Figure 1–10: Layout Plan: A-weighted emission sound pressure levels........... 25
Figure 1–11: LM30 Control Panel E-Stop.......................................................... 26
Figure 1–12: LM30 Skid Steer Cab E-Stop....................................................... 27
Figure 1–13: Feed Frame Safety Lanyard and E-Stop...................................... 27
Figure 1–14: Battery isolator switch................................................................... 28
Figure 1–15: Feed Frame Guard and Magnetic Safety switch.......................... 29
Figure 1–16: Skid Steer Fire Fighting Equipment.............................................. 30
Figure 1–17: Fire Suppression activation switches........................................... 30
Figure 1–18: Skid Steer dimensions.................................................................. 34

Figure 2–1: Feed Frame name (type) plate....................................................... 43
Figure 2–2: Skid Steer name (type) plates and sound label.............................. 44

Figure 3–1: Skid Steer Rig — Front and Right Side View................................. 50
Figure 3–2: Skid Steer Rig — Left Side and Rear View.................................... 50
Figure 3–3: LM30 Control Panel controls.......................................................... 53
Figure 3–4: Hydraulic Oil Level Sight Gauge..................................................... 56
Figure 3–5: Engine Oil Level Dipstick and Filler Cap........................................ 56
Figure 3–6: Engine Start Switch........................................................................ 57
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Table of Contents
Figure 3–7: Rotation Motor Speed Control........................................................ 58

Figure 3–8: CAT Fault Lights............................................................................. 63
Chapter 4: Options
Figure 4–1: Counterbalance valves on Wireline Hoist....................................... 67
Figure 4–2: Typical examples of wire rope deterioration................................... 69
Figure 4–3: Wireline Hoist front cover............................................................... 69
Figure 4–4: Accessing the Wireline oil drain/fill plugs........................................ 70
Figure 4–5: Wireline Hoist Oil Selection Chart.................................................. 71
Figure 4–6: Laying the cable............................................................................. 72
Figure 4–7: CAT Skid Steer feed frame and positioner..................................... 73
Figure 4–8: Feed Frame Positioner components.............................................. 74
Figure 4–9: Feed Frame Positioner control valves and levers.......................... 75
Figure 4–10: Clamping plates............................................................................ 76
Figure 4–11: Rotation Unit hydraulic hose connections.................................... 77
Figure 4–12: Bridging plug................................................................................. 78
Figure 4–13: Positioner coupler pins................................................................. 78
Figure 4–14: 712 Water Pump........................................................................... 79

Figure 5–1: Hose Connections — Rotation Unit ............................................... 85
Figure 5–2: Hose Connections — Main Valve Bank.......................................... 85
Figure 5–3: Oil Temperature Switch.................................................................. 88
Figure 5–4: Fill to halfway point of sight glass................................................... 89
Figure 5–5: Side View of Main Manifold Block.................................................. 93

Figure 6–1: Chuck and Rod Holder Solenoid Valves...................................... 104
Figure 6–2: Valves on the rear/bottom of the Manifold block.......................... 106
Figure 6–3: Chuck and Rod Holder pressure switches................................... 107
Figure 6–4: Load Sense Valves in the Main Manifold assembly..................... 109
Figure 6–5: Main Valve Bank........................................................................... 113
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Table of Contents

Figure 8–1: BQ Chuck Filter location............................................................... 126
Figure 8–2: BQ Rod Clamp............................................................................. 129
Figure 8–3: BQ Rod Clamp jaw replacement.................................................. 130
Figure 8–4: BQ Rod Clamp guide bushing replacement................................. 131
Figure 8–5: Hydraulic Rod Clamp Piston assembly........................................ 134
Figure 8–6: HQ Rod Holder for 400 Series Feed Frames............................... 137
Figure 8–7: HQ Rod Holder jaw replacement.................................................. 138
Figure 8–8: HQ Rod Holder guide bush replacement...................................... 139
Figure 8–9: Spring Pack replacement............................................................. 141
Figure 8–10: Loosening and Torquing Sequence............................................ 142
Figure 8–11: Rod Holder Hydraulic Piston...................................................... 143
Figure 8–12: BQ Rotation Unit and Chuck...................................................... 145
Figure 8–13: Gearbox Service locations.......................................................... 146
Figure 8–14: Chuck Jaw replacement and torquing sequence........................ 147
Figure 8–15: Front Guide Bush replacement................................................... 148
Figure 8–16: Rear Guide Bush replacement................................................... 149
Figure 8–17: Removing the Retaining Sleeve and Guide Bush...................... 150
Figure 8–18: Hydraulic Motor removed........................................................... 150
Figure 8–19: Rear cover removed................................................................... 151
Figure 8–20: Gear replacement on Hydraulic Motor........................................ 152
Figure 8–21: BQ Chuck assembly................................................................... 153
Figure 8–22: BQ cylinder assembly................................................................. 155
Figure 8–24: Rotation Unit assembly............................................................... 158
Figure 8–25: Main Housing and Rotary Shaft.................................................. 159
Figure 8–26: Main Housing rotary seal and cir-clip......................................... 159
Figure 8–27: Rotary Seal ‘O’-rings and back-up washers............................... 160
Figure 8–28: Rotary seal testing...................................................................... 165
Figure 8–29: BOD Nomenclature.................................................................... 165
Figure 8–30: Break Out Device (cross-sectional view).................................... 166
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Table of Contents
Figure 8–31: HQ Rotation Unit and Chuck...................................................... 173

Figure 8–33: Chuck jaws removed and retightening sequence....................... 175
Figure 8–34: Front Guide Bush removed........................................................ 176
Figure 8–35: Rear Guide Bush removed......................................................... 177
Figure 8–36: Replacing the Rear Oil Seal....................................................... 178
Figure 8–37: Removing Gear Case and Hydraulic Motor ............................... 180
Figure 8–38: Removing Driven Gear, Locknut, Lockwasher, and 4 keys ....... 180
Figure 8–39: Removing Adaptor Plate, O-Ring, and Oil Seal.......................... 181
Figure 8–40: Removing Chuck Retaining Plate............................................... 183
Figure 8–41: Removing Rear Chuck Sub Plate............................................... 183
Figure 8–42: Replacing the Front Oil Seal....................................................... 184
Figure 8–43: Gear Replacement on Hydraulic Motor...................................... 185
Figure 8–44: Removing the Chuck Jaws......................................................... 186
Figure 8–45: Removing the Chuck Cylinders.................................................. 188
Figure 8–46: HQ Chuck assembly — exploded view...................................... 188
Figure 8–47: Torquing Sequence.................................................................... 189
Figure 8–48: Breakout Device oil seals........................................................... 190
Figure 8–50: Removing Gear Housing and O-Ring......................................... 198
Figure 8–51: Exploded view of main housing components............................. 198
Figure 8–52: Main Housing oil groove............................................................. 199
Figure 8–55: Chuck Retaining Plate and Spindle ‘O’-rings.............................. 202
Figure 8–57: 400 Series Feed Frame.............................................................. 209
Figure 8–58: Fit and tighten the four M12 bolts............................................... 210
Figure 8–59: Direct Coupled Feed Frame — working position........................ 210
Figure 8–60: Feed Frame service and maintenance points............................ 211
Figure 8–61: Loosen in two places on each side............................................. 212
Figure 8–62: Feed Cylinder hex. nut............................................................... 212
Figure 8–63: Adjusting the Carriage slides...................................................... 213
Figure 8–64: Carriage Assembly..................................................................... 214
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Table of Contents
Figure 8–65: Tighten nine M10 bolts to 44 Nm (30 lbft) torque....................... 215
Figure 8–66: Carriage Side Plate disassembly................................................ 216
Figure 8–67: Feed cylinder removal................................................................ 217
Figure 8–68: Removing the Cylinder Trunnions.............................................. 218
Figure 8–69: Feed cylinder disassembly......................................................... 220
Figure 8–70: Piston rod assembly................................................................... 222
Figure 8–71: Rod end gland and End cap gland............................................. 223
Figure 8–72: The LM30 Skid Steer Power Unit............................................... 225
Figure 8–73: Main Pump pressure setting....................................................... 226
Figure 8–74: Heat Exchanger location and hose connections........................ 227
Figure 8–75: Elbow fitting components............................................................ 228
Figure 8–76: Elbow installation........................................................................ 228
Figure 8–77: Elbow tightening......................................................................... 229

Figure 9–1: Troubleshooting the Hydraulic System......................................... 233
Figure 9–2: Hydraulic Component Symbols used in Circuit Diagrams............ 236

Figure 10–1: PLC and Expansion Module....................................................... 239
Figure 10–2: Electrical troubleshooting — control settings.............................. 240
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Table of Contents
THIS PAGE INTENTIONALLY LEFT BLANK
xvi
Chapter 1: Safety
Contents
1.1 Reference Note for Users Manual ............................................................. 3
1.2 Important Safety Information ..................................................................... 4
1.2.1 Hazard Signal Indicators................................................................... 4
1.3 Safety Warnings and Guidelines ............................................................... 5
1.3.1 Before operating the drill rig.............................................................. 5
1.3.2 Whilst operating the drill rig............................................................... 6
1.3.3 After operating the drill rig................................................................. 9
1.3.4 General “Housekeeping”................................................................... 9
1.3.5 Cautions and Warnings................................................................... 11
1.4 General Safety Instructions...................................................................... 12
1.4.1 General Safety Requirements......................................................... 12
1.4.2 Operational Intervals ...................................................................... 17
1.5 Transportation — Skid Steer Rig............................................................. 18
1.5.1 Lifting............................................................................................... 18
1.5.2 Moving Whilst In Transit.................................................................. 18
1.5.3 Setting up the Drill........................................................................... 18
1.6 Moving a Disabled Machine ..................................................................... 20
1.6.1 Lifting the Machine.......................................................................... 20
1.6.2 Towing/Retrieving the Machine....................................................... 21
1.7 Storage of the Drill Rig and Accessories................................................ 22
1.8 Disposal of Equipment.............................................................................. 23
1.9 Personal Safety Equipment (PPE) .......................................................... 24
1.10 Airbourne Noise Emissions.................................................................... 24
1.11 Location of E-Stops and Operation of Guards ..................................... 26
1.11.1 Emergency Stop (E-Stop) push buttons........................................ 26
1.11.2 Safety Lanyard and E-Stop........................................................... 27
1.11.3 Battery Isolator Switch................................................................... 28
1.11.4 Feed Frame Guard........................................................................ 28
1.11.5 Residual Risks............................................................................... 29
1.11.6 Counter Balance Valves................................................................ 29
1
Chapter 1: Safety
1.12 Fire Fighting ............................................................................................ 30

1.12.1 Fire Classifications acc. EN2......................................................... 31
1.13 Safety Instructions for Drilling............................................................... 32
1.14 Skid Steer Dimensions and Cuddy Sizes.............................................. 33
Table of Figures
Figure 1–1: 3 metre Danger Zone..................................................................... 13
Figure 1–2: CAT Skid Steer lifting points and weights....................................... 19
Figure 1–3: LM30 Control Panel lifting points and weight................................. 19
Figure 1–4: Positioner lifting points and weight................................................. 19
Figure 1–5: Feed Frame lifting points and weight.............................................. 20
Figure 1–6: Wireline lifting point and weight...................................................... 20
Figure 1–7: Front towing eyes........................................................................... 21
Figure 1–8: Rear towing eyes............................................................................ 21
Figure 1–9: Towing line configuration................................................................ 21
Figure 1–10: Layout Plan: A-weighted emission sound pressure levels........... 25
Figure 1–11: LM30 Control Panel E-Stop.......................................................... 26
Figure 1–12: LM30 Skid Steer Cab E-Stop....................................................... 27
Figure 1–13: Feed Frame Safety Lanyard and E-Stop...................................... 27
Figure 1–14: Battery isolator switch................................................................... 28
Figure 1–15: Feed Frame Guard and Magnetic Safety switch.......................... 29
Figure 1–16: Skid Steer Fire Fighting Equipment.............................................. 30
Figure 1–17: Fire Suppression activation switches........................................... 30
Figure 1–18: Skid Steer dimensions.................................................................. 34
2
Chapter 1: Safety
1.1 Reference Note for Users Manual
THE AVAILABLE MANUAL CONSISTS OF TWO PARTS.

Part 1 contains the general Safety and Operating Guidlines
Part 2 contains spare parts catalogue.
IMPORTANT!
The manual may not cover every possible operating situation.
IMPORTANT!
The drill owner must ensure that all personnel who are responsible
for LM30 operation and maintenance were instructed and trained
in appropriate way and know all of the relevant informations that is
indicated in the machine documentation.
Parts 1 and 2 of this manual must be stored in a protected place on the

machine and must always be readily available.
If this manual gets lost or damaged a new one can be ordered from
BOART LONGYEAR by supplying the part no. of the manual and also
the serial no. of the drill rig. (The serial no. can be found at the first
page of the manual or on the type plate on the drill rig.)
When the machine is sold the address of the new owner must be
communicated to BOART LONGYEAR so that customer contact with
the new user can be maintained.
PLEASE NOTE
This handbook is a general description of the LM30 Skid Steer drill rig.
Pictures, descriptions, and technical data may therefore not match every
aspect of your specific drill rig.
BOART LONGYEAR is constantly striving to improve its products

and must therefore reserve the right to change designs, materials,
specifications without notice.
3
Chapter 1: Safety
1.2 Important Safety Information

ALL SAFETY REGULATIONS FOLLOW THE VALID LAWS AND
REGULATIONS OF THE EUROPEAN COMMUNITY.
FURTHERMORE, ANY ADDITIONAL NATIONAL REGULATIONS

SHOULD STILL BE CONSIDERED.
IF THE DRILL RIG IS APPLIED BEYOND THE FEDERAL

REPUBLIC OF GERMANY THE NATIONAL LAWS AND REGULATIONS
OF THE RESPECTIVE USER COUNTRY ARE VALID.
1.2.1 Hazard Signal Indicators
This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury and death.
Warning and Caution indicators are located throughout the manual

at specific points of interest, and are intended to alert the reader to the
existence and relative degree of a hazard.
Indicates an imminently hazardous situation which, if not avoided, could

result in death or serious injury, or property damage.
Indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury, or property damage.
Indicates a potentially hazardous situation which, if not avoided, MAY

result in minor or moderate injury, and property damage. It may also be
used to alert against unsafe practices.
These notices are given to prevent personal injury, death and/or

equipment damage. These indictors must be followed to reduce the
possibility of personal injury, damage to the equipment, or improper
service. Always heed these notices, and practice common sense when
performing any maintenance or repair procedure.
Notes: are indicated to draw attention to detailed instructions. These

notes are intended to give further important information regarding the
machine and/or a step in a procedure.
4
Chapter 1: Safety
1.3 Safety Warnings and Guidelines

Due to the wide range of safety regulations in existance around
the world, Boart Longyear Pty Ltd can only design its equipment to
satisfy basic safety considerations. The customer and/or operator is
responsible to ensure that their Boart Longyear drill and its accessories
fully comply with all applicable local safety and health regulations.
The customer is also responsible to take the necessary safety

precautions to operate the drill and its accessories in a safe manner.
Boart Longyear Pty Ltd will gladly assist the customer in this respect.
Familiarity and proper training are required for the safe operation of
this equipment. Failing to follow these instructions may result in serious
injury or death.
Safety is the most important element of any procedure. Preparation is

essential to complete a procedure in a safe and efficient manner.
Read the operating instructions and familiarise yourself with the location
and proper use of all controls.
Follow the general safety practices listed below to reduce exposure to

potential hazards:
1.3.1 Before operating the drill rig

DO / ALWAYS
●● read and understand this manual and all labels fixed to the machine.
●● be sure the machine is positioned on a firm, level surface and will not
tip, roll, slide, or fall while operating.
●● know where you are drilling! Make sure that you will not drill into any
utilities, such as buried electric cables, gas, or water mains. Also you
must check for overhead powerlines.
●● read all instruction manuals carefully and make sure that you
understand their content and implications before you attempt
to operate the equipment. If you have any doubts or questions,
particularly with respect to safety matters, please call for assistance.
●● wear personal protective equipment that satisfies all worksite-specific
safety procedures, such as a hard hat, safety glasses, and steel-
capped work boots.
●● prepare the required parts and materials. Gather all necessary parts
and materials before beginning any procedure.
●● prepare proper tools and equipment. Always use the correct tool for
the job. Improper or homemade tools can cause injury or machine
damage.
5
Chapter 1: Safety
●● ISOLATE all energy sources before servicing any equipment.

●● ensure that all commissioning checks and adjustments have been
thoroughly carried out before operating the machine.
●● before operating any hoist, ensure the rope is free and clear to travel.
●● ensure that the drill is properly stabilised (and anchored, if
necessary). Take all necessary precautions regarding potential
hazards (such as high-tension electric wires, for example).
●● ensure all persons are clear of the drill rig before moving, or starting
any drilling operation.
●● develop work procedures that are specific to each work site.
DO NOT / NEVER
●● start a drill rig in need of repair.
●● attempt to operate the drill rig unless you are fully familiar with all
rig controls, gauges, functions, operational sequences, and the
ramifications of each function to be performed.
●● operate equipment while under the influence of drugs, alcohol, or
medication.
BEWARE
●● dry nitrogen is the only gas used to charge accumulators on drifters
and rotary heads. Never use oxygen to charge accumulators
because an ignition of an oxygen/oil mixture may produce an
explosion.
Ensure that accumulators are always in perfect condition. Inspect
regularly and thoroughly to ensure that accumulator components
have no cracks or show signs of excessive wear.
1.3.2 Whilst operating the drill rig

DO / ALWAYS
●● wear an approved hard hat, safety shoes or boots, safety glasses or
mask and hearing protection, when near an operating drill rig.
●● keep clear of rotating equipment. Wear proper clothing because
loose or baggy clothing can become tangled in moving parts.
●● operate the drill rig from the operator Control Panel position.
●● be prepared for emergencies. Accidents can happen, even under the
best conditions. Fire extinguishers and first aid kits should be well
maintained and easily accessible.
●● wear a certified full-body harness with the shortest possible lanyard
attached to a certified fall arrestor system while working on the
platform.
6
Chapter 1: Safety
●● keep hands, feet, and loose clothing away from all moving parts on
the drill, generator, engine, and drilling accessories. Failure to comply
could result in physical injuries or even death.
●● follow all procedures and safety warnings. Service procedures are
written to be as safe and efficient as possible.
●● use a mirror for inspection if the bit cannot be removed for checking.
●● check that all helpers are well outside the swing/slewing radius of the
drill rig, prior to moving or setting up.
●● be sure to have the drill string guard closed and secured when
drilling. Never work with the guard open or over ridden.
●● relieve the pressure of flushing fluid in the drill string when breaking
joints.
●● be aware of the following when using spanners to break and
uncouple threaded joints on drill strings:
○○ note the drection of rotation to break joints, and
○○ use a wrench of the correct size.
●● remember to secure the rig with wedges if it is parked on a slope or
incline.
●● secure the rig against inadvertent movement. Inadvertent or
unauthorised start up must be avoided if the motor has stopped so
lock and secure the isolator switch.
●● keep the thread connection clean and well lubricated. The time spent
on this is regained many times over, when it comes to tripping out of
the hole.
●● keep guards installed and maintained in good working order.
●● ensure that all casing and rod joints are screwed together completely.
DO NOT / NEVER
●● rotate drill rods without a water swivel attached to the drill string.
(Ensure the hoisting cable is attached to the water swivel bail.)
●● climb on top of the machine or work under suspended drill rods.
●● rotate the drill rods with a rod joint located behind or above the
Chuck.
●● use multiple part lines on the Main Hoist.
●● exceed the rod rack derating weights.
●● attempt to loosen or remove any high-pressure hydraulic line without
relieving the pressure beforehand.
●● take shortcuts, and never operate this machine when any person
(including the operator) is under or in the operational envelope of the
loading/unloading process.
7
Chapter 1: Safety
●● walk alongside the rig when it is being moved, not even for short
distances i.e. to the next hole. You could become crushed between
the rig and the wall.
●● stand beneath the drill bit to inspect it. Material or debris may shoot
out or the bit may drop out and cause injury.
●● hit drill bits with a hammer as the bit material may break and cause
severe injuries to personnel.
●● place excessive feed pressure on the drill because this may cause
several problems including:
○○ the drill rig will be pushed by its own force from the hole, and
○○ wear of all components, drill string, and head is increased.
BEWARE
●● when hoisting/lowering rods, make sure the hoisting cable is in
complete tension before releasing the Chuck.
●● sliding parts can create pinch points, and tilting parts can create
crush points.
●● rotary heads, drifters, shank adapters, couplings, drill steels, casing,
bits and crowns may get hot during drilling.
Do not touch these parts with your bare hands. Be sure to wear
working gloves when handling any of the above components. Severe
burns may result if these components are touched with bare hands.
●● drills have many moving components. Keep yourself and all other
persons clear of moving drill heads, feed mechanisms, drill strings
and moving tools.
●● the drill equipment includes several hoses that lay on the floor.
These hoses are a trip hazard, so always be aware of hoses.
●● exhaust fumes from internal combustion engines are deadly.
Be sure to only operate the drill rig in well ventilated areas.
If the rig must be operated in a confined area, consult Boart Longyear
for assistance in safe operation.
●● be aware of the travelling hoist plug at all times.
●● be careful not to drop any tools when working on the platform.
●● care must be taken when handling drill string sections. Drill string
sections are cumbersome and very heavy. Be sure to watch for
adequate foot holds (Mud-sludge).
●● of volatile solvents. Some parts cleaning solvents used to remove oil
and grease can develop dangerous fumes when they evaporate. Be
sure to only use such solvents in a well-ventilated area.
●● the operator must never leave the Control Panel whilst the drill is in
progress.
8
Chapter 1: Safety
1.3.3 After operating the drill rig

DO / ALWAYS
●● allow the machine to cool. Many components can get hot during
operation. Be sure to allow enough time for components to cool
before beginning service.
●● use only qualified service technicians. Failure to do so could cause
severe damage to the machine or the operator, and may void your
warranty.
●● check that all hoses are cleared from the path before moving the rig.
DO NOT / NEVER
●● adjust the hydraulic system before consulting a Boart Longyear
Technician.
●● change or alter the drill, its components, optional equipment, or
accessories without prior approval from Boart Longyear.
●● attempt any repairs until you determine the cause of the problem.
Unless you know the correct cause, your repairs may be useless.
Make a list of all probable causes, and check the simple ones first.
BEWARE
●● When pressurised, a damaged accumulator could burst scattering
metal fragments throughout the area, which could severely injure
personnel.
●● Be sure to bleed accumulators before any accumulator disassembly
is attempted and use only tested and approved accumulators for
replacement.
1.3.4 General “Housekeeping”

DO / ALWAYS
●● use only Boart Longyear replacement parts. This includes such items
as cables, gears, hydraulic hoses and components, as well as all
mechanical parts. Failure to do so could cause severe damage to the
machine or the operator, and may void your warranty.
●● ensure the drill and its accessories fully comply with applicable local
safety and health regulations.
●● replace the safety devices and guards after repairs and maintenance.
●● refer to this manual for detailed operating instructions.
Failure to comply could result in physical injury or even death.
●● use extreme caution when tramming or setting up on uneven ground.
Always ensure that the stability of the rig is not impaired.
●● use only the purpose made craneage lugs when lifting the rig.
9
Chapter 1: Safety
●● keep the work area clean and avoid dangerous working

environments.
●● be aware of the operating zones and recommended areas for safe
operation. Keep visitors a safe distance away from the work area.
DO NOT / NEVER
●● exceed the rated capacity of any piece of equipment.
●● remove or disable guards and safety devices — they are for your
protection. These accident prevention devices require particular
attention so make sure they are always fully functional.
●● use defective devices. It can lead to delays, stopping the rigs
functioning, and may cause severe personal injuries or even death.
●● change or alter the drill, its components, optional equipment, or
accessories without PRIOR APPROVAL from Boart Longyear.
Unauthorised alteration may void the warranty, render the equipment
unsafe, or result in decreased performance.
●● change any of the factory settings on hydraulic systems without fully
understanding the system.
●● attempt field repairs on complicated and/or precision-made parts
such as hudraulic pumps and motors. This may void your warranty.
Complicated repairs should only be made by qualified personnel
working in shops equipped with the correct/proper tools.
●● attempt any adjustments or repairs. Call for assistance If you do not
fully understand the equipment and how it operates.
●● make unauthorised alterations. It may void the warranty, render the
equipment unsafe, or result in decreased performance.
For additional information on training or start-up contact your Boart
Longyear representative.
10
Chapter 1: Safety
1.3.5 Cautions and Warnings
STOP WARNING — Stop and observe CRUSH HAZARD — This part of the machine
surrounding warning decals. has a rotating crush potential.
EXTEND/RETRACT — Component extends and

retracts unguarded.
DO NOT CLIMB — No climbing activity
to occur without appropriate PPE.
HOT SURFACE — Surface adjacent to this

warning can be too hot to touch.
BODY CRUSH HAZARD — Moving parts of the
machine have the potential for crush injury.
PRESSURE VESSEL — This component

is pressurised.
MANUAL — Indicates to refer to this manual

before proceeding with any activity.
11
Chapter 1: Safety
HEARING PROTECTION — Must be worn HARD HAT — Must be worn

when near this machine. when near this machine.
LOADED SPRINGS — Warning that springs

inside component are loaded and disassembly
EYE PROTECTION — Must be worn should be done with caution.
when near this machine.
1.4 General Safety Instructions

1.4.1 General Safety Requirements
1. Safety Valves
The settings of pressure limiting valves in the drill rig hydraulic circuits
must be changed only by Boart Longyear approved personnel.
2. Static Components
Welding of static and bearing components in the drill rig is to be carried
out only by the manufacturer or by Boart Longyear approved personnel.
3. Hydraulics
The rig,s hydraulic system must be checked regularly. Replacement
hoses or hydraulic components must be original Boart Longyear parts.
This requirement must be complied with for safety reasons, and it also
applies to all static and bearing components such as:
●● Screws and Bolts
●● Springs and Washers
●● Feed Frame Components
●● Drill Mast Components
●● Positioner Components.
12
Chapter 1: Safety
4. Replacement of Worn Parts

Repairs and replacement of worn parts can be carried out by qualified
personnel. In addition, all standard maintenance and service intervals
must be complied with. If in doubt contact Boart Longyear.
5. Safety Devices
Safety devices and protective equipment on moving machine
components should only be opened, removed, or disabled with the
engine stopped and secured against inadvertent or unauthorised start-
up. Safety devices include engine covers, lids, caps, doors, gratings,
guards, and panels. All safety devices and protective equipment must
be reinstalled after completing any maintenance service and repairs.
6. Safety Distance
A safety clearance of 500 mm (20”) must be maintained from buildings,
scaffolding, and other equipment to prevent the danger of being
crushed. Keep in mind the rigs slewing facilities. If the safety distance
cannot complied with, the area must be cordoned off.
7. Danger Zone
A 3 metre radius Danger Zone exists all round the rig.
Figure 1–1: 3 metre Danger Zone
13
Chapter 1: Safety
Be sure that no one is within the danger zone. This is the area around
the drill rig within which persons may be endangered by the rig’s slewing
range or movement of some of its components.
The operator must work the rig only if no one is within the danger zone.
In case of danger the operator must give warning signals,and these

signals are generally given with the horn. Pre-determined hand warning
signals must be used if onsite noise is louder than the audible signals.
If persons do not leave the dangerous zone, despite having been

warned, the operator must terminate all operations immediately and
inform the site supervisor.
8. Directive of Application
Boart Longyear drill rigs must be used only as directed and described in
the operators manual.
9. Operation
The drill rig functions must be activated only from the control console.
10. Operating Instructions

All instructions for the drill’s operation, maintenance, service, repair, and
transport must be complied with. The contractor is obliged to satisfy all
safety regulations and local requirements. Amendments to operating
instructions must be kept securely at the work site.
11. Transport of Persons

The transport of persons on the drill rig is strictly forbidden.
12. Tramming and Operating

The independent and unassisted operation, and maintenance of the
LM30 drill rig must only be entrusted to persons who:
●● Are at least 18 years of age
●● Have been instructed in operating and maintaining the LM30 drill rig
and have proven their ability to the contractor
●● Can be expected to perform responsibly and are designated for the
job by the contractor.
13. Stability
The stability of the LM30 drill rig must always be assured. It may be
affected by excessive load, unsecured ground, jerky acceleration and
stopping during tramming, slewing movements, slopes.
The operator is responsible for the rig’s stability and must, if necessary,
modify procedures to allow for specific site conditions.
14. Securing Against Fall

To forestall danger of falling and crashing, the drill rig must always keep
a safe distance from ledges, pits and slopes.
14
Chapter 1: Safety
It is the contractor’s responsiblity to assess the ground bearing capacity,

and dictate a safety distance for the rig. Check the bearing capacity of
bridges, floors, and structure prior to moving the rig onto them.
15. Signaling
If the operator’s vision is obscured during tramming and operation of
the drill rig, someone must give signals for assistants, or the tramming/
working area must be cordoned off. Only suitably qualified persons must
be designated to give signals, and they must be instructed in this role.
Communication must be co-ordinated and exclusively used between

the operator and the person giving the signals. The signalling person’s
attention must not be diverted by being given additional tasks.
16. Utility Lines

It is the contractor’s responsibly to determine if any utility/service lines,
ducts, or pipes are buried on the drilling site. The site owner is obliged
to supply this information.
If utility lines are present their location must be clearly marked. Plans
clearly detailing the location (including run and depth) of utility lines
must be kept for reference on the work site.
The operator must stop working immediately and inform the site
manager if a utility line or its protective cover is found or has been
damaged. Uncovered utility lines must be secured against swaying or
slipping.
15
Chapter 1: Safety
LM30 SKID STEER RIG

ONLY TRAINED OPERATORS ARE TO USE THIS MACHINE READ MANUAL PRIOR TO OPERATING
TRAMMING SETTING UP
REMOVE FEED FRAME GUARD APPLY PARK BRAKE BY RAISING SEAT BAR
POSITION FEED FRAME HORIZONTAL AND CENTRAL RUN ENGINE AT IDLE SPEED ONLY
PRIOR TO TRAMMING KEEP CLEAR OF MOVING PARTS AT ALL TIMES
PLACE POSITIONER AS LOW AS PRACTICAL TO GROUND ENSURE FEED FRAME IS SECURELY CLAMPED TO CRADLE
SECURE HOSES AND KEEP OFF GROUND ONCE POSITIONED.
KEEP PERSONNEL CLEAR OF MOVING RIG
DRILLING
TRAMMING SPEED: Less than 6 km/hour
RIG MUST BE SECURED TO FACE PRIOR TO COMMENCING
IFTRAMMING BARE RIG DRILLING
(i.e. DRILL AND COUNTERWEIGHT REMOVED),
SAFE TRAMMING ANGLE IS: Less than 5 deg. SET ENGINE SPEED TO 2000 rpm
TOWING MAINTENANCE
RIG CAN BE TOWED IN EMERGENCY SITUATIONS ONLY WARNING ONLY TRAINED MAINTENANCE PERSONNEL ARE TO
OPERATE
CONNECT TO TOWING ATTACHMENT PROVIDED
SKID STEER IS POTENTIALLY UNSTABLE WHEN DRILL RIG IS
CONSULT CAT OPERATORS MANUAL AND CHAPTER 1 MOVED. REFER TO MANUAL PRIOR TO TRAMMING
OF THIS MANUAL WHEN MOVING A DISABLED MACHINE
POSITION RIG ON FLAT GROUND FOR ANY MAINTENANCE,
MAXIMUM TOWING SPEED: 1.6 km/hour DISCONNECT RIG FROM SKID STEER, AND UNPLUG CABLES
MAXIMUM TOWING DISTANCE: 15 m PRIOR TO TILTING CAB
ENGAGE SAFETY STAY WHEN ARMS ARE ELEVATED
WARNING IF SKID STEER IS TO BE MOVED WITHOUT DRILL
ATTACHED THEN COUNTERWEIGHT MUST BE REMOVED.
16
Chapter 1: Safety
1.4.2 Operational Intervals

1. Operational Intervals
The operator must not leave the site if the drill rig and tools are not
secured. The operator must set all the operating levers in OFF position
prior to leaving the Control Panel.
2. Safety Requirements for Hydraulic Lines

2.1. Markings
Hydraulic hoses must carry continuous markings at intervals not greater
than 500 mm. These markings must be clearly readable, and supply the
following data:
●● Name of the Manufacturer (e.g. HANSA FLEX)
●● Type
●● Nominal Diameter
●● Working Pressure (Max. permissible dynamic pressure is 4 times
more)
●● Date of Manufacture (e.g. “1Q 06”= First Quarter 2006).
2.2. Storage
Hydraulic hoses must be stored tension-free, in a dry and clean
environment. Direct sunlight and UV-radiation must be avoided. Storage
time should not exceed four years.
2.3. Operational Hydraulic Lines

After 6-year’s operation all hydraulic lines must be exchanged for safety
reasons, even is there are no apparent technical faults. Hoses are
subject to a natural ageing process, so their lifetime is limited. Hoses
that have been operated as part of a hydraulic system must not under
any circumstances be reused.
2.4. Inspection
Hydraulic lines must be inspected by qualified personnel to assess their
operational safety. This should occur before the initial start up, and
subsequently, at least once every year. Defective and faulty lines must
be replaced immediately.
17
Chapter 1: Safety
1.5 Transportation — Skid Steer Rig

Refer to the CAT Operation and Maintenance Manual for further
details.
1.5.1 Lifting
●● Under no circumstances is the Skid Steer assembly to be loaded or
unloaded using a forklift. The load will make the forklift unstable.
●● The Skid Steer must be either craned or driven off the transport.
●● The designated lifting points must be used when loading or unloading
the Skid Steer assembly.
●● Correctly rated slings and qualified riggers must be used.
1.5.2 Moving Whilst In Transit

●● To stop the Skid Steer moving whilst it is being transported, the Rudd
links and designated tie-down points must be used.
These are clearly marked on the Skid Steer and Positioner assembly
(see graphics below on adjacent pages).
●● The load must be regularly checked whilst in transit to prevent it from
moving around.
●● Fully clamp the feed frame and cradle in the transport position when
tramming.
1.5.3 Setting up the Drill

●● When tramming the drill, the Positioner assembly should be as low
as possible to the ground to maximise visibility.
●● Beware of the possibility of injuring other personnel whilst tramming.
●● At all times be aware of the surrounding area, vehicles, and
personnel.
●● Operators should always drive forwards wherever possible to
minimise any risk of injury to other personnel in the immediate
vicinity.
●● When the Skid Steer is being moved within the drill site there is a
potential for a crush injury between the wall and the drill assembly.
Personnel are to maintain a clear line of sight with the driller/operator
at all times. Do not stand between the Skid Steer and the wall.
●● Moving the Control Panel is a two-man lift, due to a potential tripping
hazard from hoses on the ground.
18
Chapter 1: Safety
Without Counterweight With Counterweight and Drill

Mass: 4,000 Kg Mass: 5,600 Kg
Figure 1–2: CAT Skid Steer lifting points and weights
Mass: 40 Kg
Figure 1–3: LM30 Control Panel lifting points and weight
Mass: 400 Kg
Figure 1–4: Positioner lifting points and weight
19
Chapter 1: Safety
Mass: 535 Kg
c/w HQ Rotation Unit

and HQ Rod Holder
Figure 1–5: Feed Frame lifting points and weight
Mass: 120 Kg
Figure 1–6: Wireline lifting point and weight
1.6 Moving a Disabled Machine
Use the correct Personal Protective Equipment and tools for this
operation.
1.6.1 Lifting the Machine

If the machine is disabled it should ideally be lifted onto a trailer or truck
in order to be transported.
For details of the correct lifting procedure refer to the previous section
of this manual and “Lifting and Tying Down the Machine” in the CAT
Operations and Maintenance Manual.
20
Chapter 1: Safety
1.6.2 Towing/Retrieving the Machine

If the machine cannot be lifted the following guidelines are to be used in
order to retrieve the machine.
●● Attach a line to the towing eyes. Two towing eyes (A) are located at
the front of the machine, and two towing eyes (B) are located at the
rear.
Figure 1–7: Front towing eyes
Figure 1–8: Rear towing eyes
●● DO NOT attach a line to any other point on the machine.

●● DO NOT attach a towing line to only one towing eye when you are
retrieving the machine.
●● If a single line is used to pull the machine then it must be a minimum
length of 3m (10 ft). If two lines are used then each must be a
minimum length of 1.5m (5 ft).
Each of these line lengths must
be a minimum of 1.5m (5 ft)
Figure 1–9: Towing line configuration
21
Chapter 1: Safety
●● Do not exceed a maximum pull angle of 20 degrees in any direction.

●● The strength of the line used should be at least 1.5 times the gross
weight of the machine.
●● Provide shielding in order to protect the operator if the line breaks.
DO NOT drag the machine for long distances

— damage to the tyres may occur.
Maximum Towing Speed: 1.6 km/hour
Maximum Towing Distance: 15 m
1.7 Storage of the Drill Rig and Accessories

If the machine is to be left in storage for an extended period of time then
it is advisable to:
1. Remove the balls from the ports in the water pump (beam pump),
fill with oil and cap.
2. Spray exposed parts of the rig with lanolin or a suitable corrosion

inhibitor.
3. Any hydraulic rams should be fully retracted and exposed areas

wrapped in Denso tape (or similar anti-corrosion and sealing tape).
4. Cover the equipment with a canvas tarpaulin.
5. Take appropriate care of the hydraulic hoses to prevent damage.
6. All hydraulic hoses are to be capped securely to prevent leakage

and ingress of foreign material.
A full service of the equipment must be carried out before use, following
periods of storage.
22
Chapter 1: Safety
1.8 Disposal of Equipment

When the drilling rig comes to the end of its useful life, care should be
taken over the disposal of this equipment:
1. Some components such as hydraulic rams, hoses and

accumulators may still be pressurized and can contain residual
hydraulic oil.
Care should be taken to relieve this pressure before dismantling
this equipment using appropriate tools and safe working
procedures, or before sending it away for disposal in accordance
with local regulations. The accumulators are pre-charged a nominal
pressure of 30 bar, but will vary depending upon their intended use;
whereas the system pressure maybe in the order of 300 bar.
2. Hydraulic hoses may contain residual hydraulic oil and must be
disposed of in an appropriate manner through an authorized
disposal route, in accordance with local regulations.
3. Some parts are heavy and care should be taken when

maneuvering these items. The use of appropriate lifting aids is
recommended.
4. Use of appropriate personal protection equipment (PPE) i.e. eye,

head, hand, and foot protection is recommended when handling
oils, rusty, and heavy items.
5. If any of the equipment has been in a fire then extreme caution

should be exercised when handling seals and hoses.
During combustion, hydrogen fluoride is generated in many
fluorine-containing compounds such as products containing Viton
and polytetrafluoroethylene (Teflon). These additives are often
used to prolong the life of seals and hoses.
Hydrofluoric acid (HF) is a solution of hydrogen fluoride in water.
Once absorbed into blood through the skin, it reacts with blood
calcium and may cause cardiac arrest. However, because it
is absorbed through the skin, immediate medical treatment is
necessary as rinsing off is not enough.
6. When dismantling a hydraulic cylinder or motor fitted with a
counterbalance valve, the pressure trapped between the valve
and cylinder/motor must be relieved by slightly undoing the valve
mounting bolts.
7. Drain oil from hoses and other hydraulic components. Used hoses
and components are to be disposed of in an appropriate manner
through an authorized disposal route, and in accordance with local
regulations.
23
Chapter 1: Safety
1.9 Personal Safety Equipment (PPE)

Operators, assistants, and service personnel must use suitable
protective clothing, depending upon requirements and the machine
employment.
A Hard hats are worn to protect personnel

from falling objects.
Safety glasses and masks prevent
B
fragments of stray material and dust from
affecting personnel.
(A dust trap should be used when
compressed air is used for cleaning.)
C
Refer to site-specific requirements for
appropriate gloves, safety footwear (and
other PPE).
Ear protection (i.e. plugs or headphones)

should be used if the sound level ot the
worksite exceeds 80 dB.
D
Furthermore, work clothes must fit snugly.
Bracelets and neckllaces should be avoided
— they can be easily grasped by the
machine’s moving parts.
Hairnets are to be carried and worn by
personnel with long hair.
1.10 Airbourne Noise Emissions

The following are extracts from a noise survey carried out for Boart
Longyear by Health Safety Environment Australia in order to satisfy the
requirements of the Machinery’s directive.
For the test it was run at its maximum operational speed under no load
conditions.
24
Chapter 1: Safety
Figure 1–10: Layout Plan: A-weighted emission sound pressure

levels as measured
Table 1: Results summary
Workstation / Bystander L’pA LpA Upper Boundary

Postion (dB) (dB) (dB)
Workstation 1: Rig Operator’s position
83.2 82.0 87.3
at rig controls
Workstation 2: Rig Offsider’s position
88.5 88.2 93.6
at rod handler
Bystander position 1: Rig Offsider at
79.6 76.4 81.3
standby position behind rig controls
L’pA = A-weighted emission sound pressure levels as measured.
LpA = emission values corrected for background noise corrections, K1A and local environment
correction K3A.
Upper boundary values are best estimate levels that the sound pressure will not exceed given 95%
probability, a normal distribution, a coverage factor of 1.6 and assessment accuracy grade 3.
No C-weighted instantaneous peak levels measured exceeded 130 dB.
Sound Power Level LWA = 107 dB.
25
Chapter 1: Safety
Table 2: Reference measurement surface A-weighted emission

sound pressure levels
L’pA
Postion
(dB)
East of feed frame end 86.3
North of feed frame 84.5
North of midpoint of skid steer 90.4
North-west of skid steer 90.8
West of skid steer 88.1
South-west of skid steer 83.0
South of skid steer 82.8
South of feed frame end 81.0
Average sound pressure 87.1
L’pA = A-weighted emission sound pressure levels as measured 1m off reference box.
1.11 Location of E-Stops and Operation of Guards

There are a number of ways in which it is possible to stop the drill rig in
an emergency:
1.11.1 Emergency Stop (E-Stop) push buttons

All functions of the hydraulic system and the diesel engine will stop after
any of the three Red E-Stop switches is pressed:
●● on the Control Panel
●● inside the Skid Steer cab
●● on the Rod Holder end of the Feed Frame.
Figure 1–11: LM30 Control Panel E-Stop
26
Chapter 1: Safety
Figure 1–12: LM30 Skid Steer Cab E-Stop
To reset an E-Stop Switch to allow operation of the hydraulic system,

pull the button up and twist as indicated by the direction arrow on the
button itself.
1.11.2 Safety Lanyard and E-Stop
1
2
1–Safety Lanyard 2–E-Stop button
Figure 1–13: Feed Frame Safety Lanyard and E-Stop
The Safety Lanyard is an E-Stop device fitted to the Feed Frame, in

case the operator becomes entangled in moving rods, hoses, etc.
Should this situation arise 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 Unit will shut down.
27
Chapter 1: Safety
After the cable stop has been activated it will be necessary to reset
the E-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.
Always have the Rod Holder selector valve in ‘Automatic’ mode when
drilling.
(The only time the Rod Holder is to be used in ‘Isolate’ mode is when
inserting the core barrel through the Chuck and Rod Holder.)
1.11.3 Battery Isolator Switch

A battery isolator switch is located near the rear left corner of the skid
steer.
After isolating the system it can be can be restarted by resetting this

switch and following the defined startup procedure.
Figure 1–14: Battery isolator switch
1.11.4 Feed Frame Guard
At all times be aware of (and avoid damaging) the magnetic switch cable
connected to the feed frame.
Keep immediate area clear when dumping the feed cylinder.
The Feed Frame has been fitted with a physical guard that covers the
rotating and moving components when drilling/rod handling. This factory
fitted guard is a safety device and the drill must not be used without it.
It incorporates a magnetic safety switch that allows the drill to operate
normally during drilling operations. When it is removed only rod handling
is permitted, and the head will not rotate at full speed. If the guard is
damaged it must be repaired/replaced before operating the drill.
28
Chapter 1: Safety
The illustration below shows the current guard. But designs may vary or
change, depending upon the customer’s requirements.
1–Feed Frame Guard 2–Magnetic Safety Switch
Figure 1–15: Feed Frame Guard and Magnetic Safety switch
1.11.5 Residual Risks

Unguarded rotating machinery, if not avoided,will result in serious injury
or death.
The drill is only guarded from one side of the Feed Frame and under all
circumstances, no one should be allowed to go to the unguarded side of
the feed frame while the drill is running.
The rig must be stopped before entering the cab.
1.11.6 Counter Balance Valves

Counterbalance (or load holding) valves are fitted directly to the feed,
positioner (2 off- dump and tilt) cylinders and wireline hoist as safety
interlocks in the event of a pressure loss in the feed circuit, to prevent
loads from moving.
29
Chapter 1: Safety
1.12 Fire Fighting

When fighting fires and for other associated activities:
●● Use available fire extinguishers
(Simple operating procedures are listed on each fire extinguisher.)
●● Prevent people on fire from running away. Extinguish the fire by
using a fire blanket/cover or dry powder fire extinguisher.
●● Fight the fire together with other people if possible in order to
minimize the risk to your own personal safety.
●● Do not force your way into rooms already filled with smoke.
Keep unauthorized persons away from the danger area. Remove items
in peril and any important documents. Turn off mains and media, as far
as this is safely possible. Inform the fire brigade and auxiliary workers
about the state of affairs and about potential dangers. Always follow the
instructions or commands given by fire brigade officers.
1–Fire Suppression system 2–Fire Extinguisher

Figure 1–16: Skid Steer Fire Fighting Equipment
(mounted on rear of RHS mudguard)
If the Skid Steer catches fire, the Fire Suppression Unit can be activated
by turning one of the two available switches:
●● attached to the RHS front pillar inside the cab and in front of the
driver’s seat
●● externally, on the left rear corner of the skid steer.
Figure 1–17: Fire Suppression activation switches

30
Chapter 1: Safety
1.12.1 Fire Classifications acc. EN2

Fire Classification A — solid substance fires, mainly of organic nature,
which normally cause fires to glow, e.g. car tyres, wood, coal, some
plastics, paper, straw, textiles.
Fire Classification B — fires of liquid substances or substances

becoming liquid, e.g. ether, alcohol, petrol, varnishes, oils, fats, resinous
substances, the majority of plastics, tar, waxes.
Fire Classification C — gas fires, e.g. acetylene, methane, propane,

town gas, hydrogen.
Fire Classification D — metal fires, e.g. aluminium, potassium, lithium,

magnesium, sodiem, and their alloys.
Fire Safety Actions

1. Alarm
2. Rescue
3. Extinguish
The correct fire extinguishing tactics are:
●● Extinguish with the wind !
●● Extinguish at the flame root, from front to back !
●● For fires of solid substances, extinguish by fits and starts !
●● For liquid fires, extinguish the fire low, above the fire area in one
step!
31
Chapter 1: Safety
1.13 Safety Instructions for Drilling

●● The drill is only guarded on one side of the feed frame. No one
should be allowed to go to the unguarded side of the feed frame
under any circumstances while the drill is running.
●● The rig must be stopped before going to the skid steer side of the
feed frame and entering the cab.
●● The feed frame must be anchored to the rock face before starting the
drill.
●● The feed frame positioner must be on the ground surface or
bedlogged/chocked before starting the drill. This is to ensure the load
is taken off off the skid steer arms.
●● Never walk alongside the rig when being moved, not even for short
distances i.e. to the next hole. You could become crushed between
the rig and the wall.
●● Always check that all helpers are well outside the swing/slewing
radius of the drill rig, prior to moving or setting up.
●● Work procedures need to be developed to suit each site.
●● Check that all hoses are cleared from the path before moving the rig.
●● Be sure to have the drill string guard closed and secured when
drilling. Never work with the guard open or over ridden.
●● Care must be taken when handling drill string sections. Drill string
sections are cumbersome and very heavy. Be sure to watch for
adequate foot holds (Mud-sludge).
●● Be sure to always relieve the pressure of flushing fluid in the drill
string when breaking joints.
●● Be sure to always comply with the following, when using spanners to
break and uncouple threaded joints on drill strings:
○○ Direction of rotation to break joints
○○ Wrench of the correct size.
●● Never stand beneath the drill bit for inspection. Material or debris
may shoot out or the bit may drop out and cause injury.
●● Use a mirror for inspection if the bit cannot be removed for checking.
●● Do not hit drill bits with a hammer, the material may break and cause
severe injuries to personnel.
●● Some cleaning solvents used to remove oil and grease produce
dangerous fumes when they evaporate. Only use these solvents in a
well-ventilated area.
●● The operator must never leave the control panel whilst drilling is in
progress. The rig must be secured against inadvertent movement.
Inadvertent or unauthorised start up is avoided if the motor is
stopped; the isolator switch is locked and secured.
●● If the drill rig is parked on a slope or incline, the rig must be secured
using wedges.
32
Chapter 1: Safety
●● Do not place excessive feed pressure on the drill. This causes

several problems:
○○ The drill rig will be pushed by its own force from the hole.
○○ Wear of all components, drill string, and head is increased.
●● Always keep thread connection clean and well lubricated. The time
spent on this is regained many times over, when it comes to tripping
out of the hole.
●● Make sure that all casing and rod joints are screwed together
completely.
1.14 Skid Steer Dimensions and Cuddy Sizes

These four illustrations show the dimensions of the drill when operating
in the vertical up, vertical down, and horizontal positions. This data may
be used to assist when setting up the cuddy site for drilling.
2310
2010
1450
226
350 1286 1249 1083
3968
2423
2820
2037
33
Chapter 1: Safety
2507
2820
2423.5
2533
3634.2
3540.3
2037
Figure 1–18: Skid Steer dimensions
34
Contents
2.1 General Information .................................................................................. 37
2.1.1 Prior to First Use ............................................................................. 37
2.2 General Description................................................................................... 38
2.3 Ordering and Returning Parts ................................................................. 38
2.3.1 Ordering Parts ................................................................................ 38
2.3.2 Safety Related Components ........................................................... 38
2.3.3 Returning Parts ............................................................................... 39
2.4 Limited Warranty ...................................................................................... 39
2.5 EC Declaration of Conformity................................................................... 42
2.5.1 Location of Name (Type) Plates...................................................... 43
2.5.2 Recommended Tool Kit (p/n 56400)................................................ 45
Table of Figures
Figure 2–1: Feed Frame name (type) plate....................................................... 43
Figure 2–2: Skid Steer name (type) plates and sound label.............................. 44
35
36
2.1 General Information

The purpose of this manual is to furnish the operator with detailed
information that will enable him to achieve the maximum operating
performance from the drill.
It will also give information necessary to perform preventative

maintenance tasks, and make minor repairs and adjustments.
Parts lists, with corresponding views to aid in ordering parts, are also
included.
Boart Longyear is backed by more than 100 years of experience in the

design, manufacture, and operation of core drilling equipment. Many of
the accepted industry practices in use today were pioneered by Boart
Longyear.
To obtain the utmost in performance and life of the equipment, it should

be given regular care and operated in accordance with the instructions.
Read this manual carefully before attempting to operate the drill and
keep this book handy at all times for reference when any question
arises.
2.1.1 Prior to First Use

After the arrival of your new Boart Longyear LM30 Skid Steer drill rig a
quick inspection should be done:
●● Visually inspect the drill for any loose hoses, fittings, or bolts, or any
damage that may have occurred during shipping.
●● Take extreme caution when a loose hose or fitting has allowed oil to
leak, as this will create a hazard.
●● Make sure that any oil leak has not drained the tank too low for
proper operation.
●● Check oil levels and fill with recommended lubricants.
●● Visually inspect all electrical connections.
●● Refer to the relevant chapters in this manual for proper and safe
movement of the drill rig.
37
2.2 General Description

The LM30 SS (Skid Steer) drill rig uses a CAT 246C Skid Steer carrier
to power and transport the drill components. It is a compact, mobile unit
that ensures quick set up time and ease of moving from site to site.
The rig is powered by the 54 kW, CAT 3044C DIT diesel engine.
The skid steer rig drill comes with an integrated water pump, feed frame
positioner, and a 360 degree turntable which enables it to drill holes in
all angles from vertically up to vertically down.
●● Direct drive feed frame with 40kN pullback and 1.1 m feed stroke
●● BQ (HQ optional) Rotation Unit and Chuck assembly
●● BQ (HQ optional) foot clamp; spring close and hydraulic open
●● Automatic fire suppression unit for CAT skid steer
●● Optional 500m (1,640 ft) wireline winch.
2.3 Ordering and Returning Parts

2.3.1 Ordering Parts
The following procedure will expedite the filling of your parts order,
eliminate delays, and ensure correct replacement parts are received:
1. List the model and serial number of the drill.
2. State the exact quantity required.
3. Specify the description and part number as shown in the Parts

Manual.
4. Specify the method of shipment: i.e., Parcel Post, Express, Freight;

and for Overseas shipment: Air Freight, Air Parcel Post, or Sea
Freight.
All parts are priced F.O.B., our factory, and separate charge will be
made for transportation and export packing.
2.3.2 Safety Related Components

For the replacement of safety-related parts such as E-Stops, lanyards,
light guards and guards, please refer to the parts manual, which
accompanies this manual.
38
2.3.3 Returning Parts

1. If you wish to return parts, whether for repairs, replacement, or
warranty, a letter should first be sent to:
Boart Longyear Poland or Boart Longyear Pty Ltd
Spolka z o.o 26 Butler Boulevard
ul. Popieluszki 30 Burbridge Business Park
Katy Wroclawskie Adelaide Airport SA 5950
Poland Australia
Telephone: +48 7136 30200 + 618 8375 8375
Fax: +48 7136 30201 + 618 8375 8498
This letter should specify the quantity 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.
2.4 Limited Warranty

a. Consumables. Boart Longyear warrants for a period of one
(1) year after the date of shipment of the consumable products
manufactured by it, or the performance of related services, under
the Contract, that such consumable products are free from defects
in materials and workmanship and such services are performed in
a professional and workmanlike manner; provided, however, with
respect to consumable products purchased through an authorized
Boart Longyear distributor, the warranty period shall commence on
the date of purchase by the end-user.
b. 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.
c. 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.
39
As a condition to Boart Longyear’s warranty obligations, the

purchaser must:
(i) contact Boart Longyear and request authorization to return any
goods claimed to be defective promptly upon Purchaser’s discovery
of the alleged defect,
(ii) upon receipt of an approved authorization code from Boart
Longyear, return any goods claimed to be defective under
the foregoing warranty, at Purchaser’s expense, to the facility
designated by Boart Longyear, and
(iii) 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 confirmed
to be non-conforming as a result of Boart Longyear’s examination
and according to Boart Longyear’s warranty as set forth herein. All
removal and installation of goods shall be at Purchaser’s expense;
provided, however, Boart Longyear will reimburse the Customer
for an amount equal to the reasonable expenses incurred by the
Customer and attributable to the removal and shipment of any
defective goods.
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;
40
(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.
d. 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 Global Headquarters

10808 South River Front Parkway
Suite 600
South Jordan, Utah 84095
United States of America
Info@boartlongyear.com
Tel: +1 801-972-6430
Fax: +1 801-977-3374
41
2.5 EC Declaration of Conformity

Manufacturer : Boart Longyear Poland
Spolka z o.o , UL. Popieluszki 30,
55-080 Katy Wroclawskie, Poland
Type of unit: Underground Coring Drill

Model and Serial No:
Year of manufacture:
Power: 54kW
Measured sound level: 107 dB Lwa
The undersigned hereby declares, on behalf of Boart Longyear, that

the above-referenced product, to which this declaration relates, is in
conformity with the provisions of:
●● Machinery’s Directive (2006/42/EC)
●● Pressure Equipment Directive (97/23/EC)
●● Noise emission in the environment by equipment for use outdoors
Directive (2000/14/EC) amended by Directive 2005/88/EC (June 17,
2006)
Harmonised Standards:
●● EN ISO 11200:2009 Acoustics – Noise emitted by machinery and
equipment
●● EN ISO 791:1995+A1:2009 Drill rigs – Safety
●● EN ISO 4413:2010 – Hydraulic Power
●● EN ISO 12100:2010 - Machinery Safety - Risk Assessment and
Reduction
The Technical Construction File required by 2006/42/EC is maintained

by:
Responsible person: Pawel Jarecki
Address: Boart Longyear, UL. Popieluszki 30, 55-080
Katy Wroclawskie, Poland
This declaration of conformity is only valid for the type of machine

and series number, in accordance with the order number and the
specifications contained within it. Changes made by the owner/operator
to this machinery can invalid this declaration. If such changes are made
to the machinery, then the owner/operator confirms to ensure that such
changes are in compliance to the above standards and directives.
________________________
Piotr Wierzbicki
Plant Manager
Boart Longyear Poland Date:
42
2.5.1 Location of Name (Type) Plates

Boart Longyear LM30 Skid Steer drill rigs are supplied with name (type)
plates for distinct identification with the following data as a minimum
requisite: machine type, model, serial number, date of manufacture and
these plates can be found in the following locations.
Figure 2–1: Feed Frame name (type) plate
43
Figure 2–2: Skid Steer name (type) plates and sound label
44
2.5.2 Recommended Tool Kit (p/n 56400)
SOCKET SET HEX 1/2” SQ DRIVE 94554

ALLEN KEY SET - 1.27 TO 10 A/F 93765
BAR SOCKET EXTENSION 1/2” SQ DRIVE 56402
HANDLE OFF SET SOCKET 1/2” SQ DRIVE 56403
SPANNER COMBINATION 10 A/F 56404
SPANNER COMBINATION 5/16” A/F 56408
SPANNER COMBINATION 1” A/F 56412
SPANNER COMBINATION 1-1/4” A/F 56414
SPANNER ADJUSTABLE 15” 82496
SPANNER OPEN END 1-1/16” X 1-1/8” A/F 82497
KEY ALLEN 1/2” A/F 56415
SPANNER OPEN END 9/16” A/F X 1/2” A/F 56416
SOCKET DRIVE 1/2” SQ 19 A/F 82498
BOX TOOL KIT 56417
OPTIONS
KIT GEAR PULLER BQ ROTATION UNIT 94637
KIT GEAR PULLER HQ ROTATION UNIT 59484
KIT FITTING 56445
KIT FLOW METER - HYDRAULIC COMMISSIONING 80594
COMPRESSION TOOL ROD HOLDER - BQ 602655
COMPRESSION TOOL ROD HOLDER - HQ 602650
SPANNER - OPEN END 61.2 A/F 88915
45
46
Contents
3.1 The LM30 Skid Steer Rig........................................................................... 49
3.2 The Control Panel...................................................................................... 51
3.3 Operating the Skid Steer Rig.................................................................... 54
3.3.1 Cooling Water.................................................................................. 54
3.3.2 Control Positioning.......................................................................... 55
3.3.3 Starting the Skid Steer..................................................................... 55
3.3.4 Stopping the Skid Steer................................................................... 57
3.3.5 Adjusting and Setting Rotation Motor Displacement....................... 57
3.3.6 Inserting the Core Barrel................................................................. 58
3.3.7 Running Rods into the Hole............................................................. 59
3.3.8 Rod Pulling...................................................................................... 60
3.3.9 Drilling.............................................................................................. 61
3.3.10 Rechucking.................................................................................... 62
3.4 Fault Light Indicators................................................................................ 63
Table of Figures
Figure 3–1: Skid Steer Rig — Front and Right Side View................................. 50
Figure 3–2: Skid Steer Rig — Left Side and Rear View.................................... 50
Figure 3–3: LM30 Control Panel controls.......................................................... 53
Figure 3–4: Hydraulic Oil Level Sight Gauge..................................................... 55
Figure 3–5: Engine Oil Level Dipstick and Filler Cap........................................ 56
Figure 3–6: Engine Start Switch........................................................................ 56
Figure 3–7: Rotation Motor Speed Control........................................................ 58
Figure 3–8: CAT Fault Lights............................................................................. 63
47
48
3.1 The LM30 Skid Steer Rig

1 ROD HOLDER
Has two jaws which are hydraulically opened and spring closed to hold
the drill rods. The jaws open when drilling, and Rotation Unit sequences
allow for Rod Feeding/Rod Pulling.
2 ROTATION UNIT and CHUCK

The Chuck has three jaws which hydraulically close and spring open.
The Rotation Unit is fitted with a variable displacement motor which
drives a hollow spindle, allowing the rods to pass through and rotate the
drill string.
3 FEED FRAME ASSEMBLY

Is a fabricated chassis that incorporates ‘Vee’ slides, a carriage
assembly, and a cushioned cylinder assembly. The Carriage is
connected directly to the Feed Cylinder, which allows the rod string
to be manually rod handled, and ensures a controlled feed rate when
drilling.
4 POSITIONER ASSEMBLY
Supports the Feed Frame assembly, allows for all angle holes to be
drilled. With its turntable base, the stem section can rotate on its axis.
5 HEAT EXCHANGER
Provides cooling of hydraulic oil whenever water flow occurs across the
heat exchanger.
6 ELECTRICAL ENCLOSURE
Contains the Programmable Logic Controller (PLC) which runs the
control system from a 24V DC supply.
7 COUNTER WEIGHT
Offsets the Positioner assembly, so as to keep the Skid Steer in balance
when tramming or drilling.
8 FLASHING LIGHT
A strobe light illuminates and flashes inside the cab when tramming, as
a safety beacon.
9 WORK LIGHTS
These are fitted to assist the skid steer operator when tramming.
10 FIRE SUPPRESSION UNIT and FIRE EXTINUISHER

If the Skid Steer catches fire, the fire suppression unit can be activated
by turning one of the two available switches. One is located near the
top left hand corner, behind the driver’s seat, and the other is mounted
externally on the left hand side of the skid steer.
A fire extinguisher is mounted beside the fire suppression unit cylinder
on the rear of the right hand side mudguard.
49
11 WATER PUMP
Provides controlled water pressure to the drill string when drilling and for
flushing the hole.
12 CONTROL PANEL
Contains pilot control valves and gauges to monitor hydraulic functions,
as well as the control box containing switches and the Emergency
STOP button.
10
3
4
11
Figure 3–1: Skid Steer Rig — Front and Right Side View
1
2
5
7
6
Figure 3–2: Skid Steer Rig — Left Side and Rear View
50
3.2 The Control Panel

1 WIRELINE DIRECTION CONTROL
Hoist moves when lever is moved, so keep area clear of personnel before
raising and lowering the wireline cable.
Controls the hoisting and lowering operations of the Wireline Hoist. The
speed range in both directions is variable and depends on control level
movement. Braking of the hoist is achieved by returning the control lever
to neutral.
2 ROTATION DIRECTION CONTROL
Rotation occurs when the lever is moved. Potential for personnel to be

trapped in rotating equipment — ensure the area is kept clear around the
Rotation Unit.
Controls clockwise or anti-clockwise rotation of the Chuck. When in

Drilling mode and moved to the fully-forward position provides maximum
chuck rpm.
During threadmaking and threadbreaking operations there

is maximum pressure available in the Rotation circuit, hence
operators should use proportional lever movement to avoid
overtightening and damaging drill rod threads.
Lift to operate type controls are fitted to avoid unintentional operation

of the lever, and magnetic switches are also fitted to allow sequencing
when rod handling.
3 FEED DIRECTION CONTROL
Feed occurs when lever is moved. Potential for personnel to be trapped

between moving parts — ensure the area is kept clear around the Feed
Frame.
Controls forward and reverse traverse for Rotation Unit Carriage. When
tripping rods, the Carriage speed is proportional to the lever movement.
In Drilling mode the direction of feed is dependent on the position of this

lever. Actual feed rate is controlled with the feed flow control valve and
the feed pressure control valve. Fast pull-back is available in Drilling
mode simply by moving the Feed lever rearwards.
Lift to operate type controls are fitted to avoid unintentional operation

of the lever, and magnetic switches are also fitted to allow sequencing
when rod handling.
51
4 DRILLING/STANDBY/ROD HANDLING SELECTOR SWITCH

●● In DRILLING, the Chuck is closed and the Rod Holder is open.
●● In STANDBY, the Rod Holder remains closed, and the Chuck is
open, allowing the Rotation Unit to move freely over the rod string.
●● The ROD HANDLING position is for rod tripping or rechucking. In this
mode the Rod Holder and Chuck are both closed onto the rod string
until the Feed Lever moves, thus opening or closing the Chuck.
5 FEED SEQUENCE CONTROL SWITCH

Set to either Rod Feeding or Rod Pulling, it controls the correct
clamping sequence of the Chuck and Rod Clamp when tripping rods.
6 ROD HOLDER SELECTOR SWITCH
Ensure the selector switch is in AUTOMATIC at all times.

It may only be isolated OPEN when inserting the core barrel between the
Chuck and Rod Holder
This switch should be set to AUTOMATIC for all normal drilling functions.
It should only set to Open for passing a Core Barrel through the Chuck
and Rod Holder.
Beware of falling parts and crush hazard.
This switch is used in conjunction with Confirm button (11).

To close the Rod Holder, return this switch to the Auto position.
The Rod Holder can only be isolated when the Drilling/Standby/Rod

Handling selector switch is in STANDBY mode.
7 CIRCUIT PRESSURE GAUGE

Monitors Rotation Circuit pressure or Torque whilst drilling.
8 WATER PRESSURE GAUGE

Connected to the Flush Pump discharge, it indicates the pressure at
which the flushing fluid is being pumped into the hole.
9 FEED PRESSURE GAUGE

Displays the pressure in the Feed Cylinder which is controlled by the
Feed Pressure Control Valve.
10 HOLDBACK PRESSURE GAUGE

Displays the holdback pressure in the feed cylinder when using the feed
flow control valve.
52
11 ROD HOLDER “ISOLATE OPEN” PUSH BUTTON

Chuck and Rod Holder.
When the rod holder selector switch is moved into the “isolate open”
mode the red light will flash.
Pushing the button will immediately open the rod holder.
12 11
13
8 9
4 5 6 14
7 10
1 2 3
15 16 17 18
15a
(under)
Figure 3–3: LM30 Control Panel controls
12 FAULT LIGHT INDICATORS

Each of the solid Red lights indicate an identified fault that shuts down
the drill, and the fault must be rectified before the rig can be restarted.
(See section 3.4 for further details about the fault light indicators.)
13 EMERGENCY STOP BUTTON

When pressed this button will stop the LM30 at the power source and an
audible alarm will sound until the key is turned OFF at the Start switch.
The button is lifted to RESET.
53
14 FINE FEED CONTROL SWITCH

When switched on, this activates the Feed Pressure and Holdback
valves, allowing the drill to Fine Feed.
15 FLUSH PUMP CONTROL
Hose can ‘whip’ when commencing full pump flow — ensure the hose is
firmly restrained.
Regulates the speed of the hydraulic motor for the Flush Pump
via a metered control valve, which includes a ‘stop’ to avoid motor
overspeeding.
Beneath the Water Pump Section is the Test Port (labelled 15a above),
which is used to connect any external gauges. It is a ‘Minimess’ type
fitting, marked “MP”.
16 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.
17 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 the drill bit and to hold back when drilling deep down
holes.
18 FEED PRESSURE CONTROL VALVE

Chuck and Rod Holder.
Controls the pressure at which oil is fed into the Feed Cylinder whilst
drilling.
3.3 Operating the Skid Steer Rig
Refer to the site specific ‘Pre-Start Procedures’ and the Skid Steer
Operators Manual for a detailed description of this procedure before
starting the drill.
54
3.3.1 Cooling Water

A cooling water flow of 20–30 Lpm must be circulating through the oil
cooler. Either connection can be used for the water inlet.
The water flow must be controlled by throttling the incoming water

supply. The flow must not be controlled by restricting the outgoing water
flow as the water pressure limit in the water tubes may be exceeded.
The maximum allowable pressure in the tubes is 10 bar.
3.3.2 Control Positioning

1. The Wireline, Rotation, and Carriage control levers must be in
neutral.
2. The Drilling/Standby/Rod Handling switch must be in STANDBY.
3. The Rod Pulling/Rod Feeding switch can be in either position.
3.3.3 Starting the Skid Steer
Wear the correct Personal Protective Equipment for this operation.

Before starting the equipment, ensure that nobody is standing in the
immediate vicinity of the Engine or the Drill Assembly.
1. Follow any predefined site-specific start-up procedure.
2. Check the sight glass and add hydraulic oil until the fluid level is to
the middle of the sight gauge.
FIRE HAZARD — Do not smoke while filling the hydraulic reservoir.

Do not fill near open flames.
Refer to the site specific procedures for refilling precautions.
3. Ensure the fuel level is adequate. If additional fuel is required, turn

the Key to the ON position and check the fuel gauge in the cab. Fill
until the high mark is reached.
4. Check the Engine Oil Dipstick and top up with the correct grade of
engine oil if required.
55
1 – Hydraulic Oil Tank Cap 2 – Sight Gauge
Figure 3–4: Hydraulic Oil Level Sight Gauge and Tank Cap
1 – Oil Filler Cap 2 – Dipstick 3 – Oil Filter
Figure 3–5: Engine Oil Level Dipstick and Filler Cap
5. Insert the Key into the Engine Start Switch from the OFF position
and turn it clockwise to the ON position.
6. Release the Key as soon as the engine fires.
56
Figure 3–6: Engine Start Switch
3.3.3.1 Engine Start Switch — Switch Positions

OFF — Insert the Key only from the OFF position ,
and remove the Key only when in the OFF position.
Turn the Key to the OFF position to stop the engine.
In the OFF position there is no power to most
electrical circuits. However, the cab lights, panel
lights, tail lights, working lights (f fitted) and fuel
gauge light are operational even when the switch
is in the OFF position.
ON — Turn the Key clockwise to the ON position in order
to activate all of the cab circuits.
START — Turn the Key clockwise to the START position
in order to crank the engine. Release the Key after
the engine starts, and the Key returns to the ON
position.
Note: If the engine fails to start the Key must be returned to the OFF position
before attempting to start the engine again.
3.3.4 Stopping the Skid Steer

1. Turn the Fine Feed Selector switch to OFF and return all control
levers to neutral.
2. Turn the Drilling/Standby/Rod Handling switch to STANDBY.
3. Ensure the engine speed is set to ‘idle’.
4. Turn the Key counterclockwise to the OFF position.
57
If necessary, the diesel engine can also be stopped by pressing one of

the three Red E-Stops or by pulling the Safety Lanyard.
3.3.5 Adjusting and Setting Rotation Motor Displacement

The LM30 Control Panel has a Rotation Speed control that permits the
maximum available chuck speed to be selected and set. Always use this
control to limit chuck speed — not the Rotation Directional control as
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.
Figure 3–7: Rotation Motor Speed Control
3.3.6 Inserting the Core Barrel
Use the correct Personal Protective Equipment for this operation.

Possibility of core barrel falling — use the correct manual handling
procedures.
Keep personnel clear from around front and rear of Feed Frame.
1. Ensure the Wireline, Rotation, and Carriage Feed control levers

are in neutral.
3. Turn the Rod Holder switch to ISOLATE OPEN and press the push
button to open the Rod Holder.
The Rod Holder and Chuck are both now open.
Ensure the safety guard is well clear for this operation.
58
4. Remove the safety guard (if fitted) and insert the core barrel
through the Chuck and Rod Holder.
5. With the core barrel positioned so that the core bit and reamer
are clear of the Rod Holder, move the Rod Holder switch into the
AUTOMATIC mode.
The Rod Holder will grip the core barrel.
Do not grip on the core bit or reamer shell.
3.3.7 Running Rods into the Hole
Use the correct manual handling procedures and Personal Protective

Equipment for this operation.
Ensure the immediate area is clear of personnel before moving the
carriage or rotating the head.
1. Ensure the Wireline, Rotation, and Carriage Feed levers are in

neutral.
2. Turn the Rod Pulling/Rod Feeding switch to ROD FEEDING.
3. Turn the Drilling/Standby/Rod Handling switch to ROD HANDLING.

Ensure the safety guard is well clear for rod handling.
4. Manually thread an additional drill rod.
5. Move the Carriage Feed lever rearward and position the Chuck so
that the rod joint is between the Chuck and Rod Clamp.
6. Return Feed lever to neutral.
7. Move 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 the 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.
59
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.
You are now ready for another feed cycle.
3.3.8 Rod Pulling

Ensure the immediate area is clear of personnel before moving the
carriage or rotating the head.

neutral.
2. Turn the Rod Pulling/Feeding switch to ROD PULLING.
3. Turn the Drilling/Standby/Rod Handling switch to ROD HANDLING.
4. Move the Carriage Feed lever rearward at which time the chuck will
close, the rod clamp will open and the rods will be withdrawn from
the hole.
5. Position the rod joint between the Rod Clamp and 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 75mm remains behind the
Rotation Unit carriage. This allows the carriage to float rearwards
as the rod joint is unscrewed.
75mm
L L
6. Return the Feed lever to neutral.

60
7. Move Rotation lever rearward to break and partially unscrew the

rod joint.
Do not completely separate the rods, especially on angled holes, as the

rods will fall through the Chuck — manually unscrew the rod.
8. Return the Rotation lever to neutral.
9. Move the Carriage Feed lever forward until rotation unit passes
over the rod joint.
10 Return the Feed lever to neutral.
11 Manually unscrew and remove the rod.
3.3.9 Drilling

Beware of rotating drill string — ensure all personnel are cleared from the
immediate area before starting.
Also, be aware of moving hoses and rotating rods during fast pull-back.
Note: 1. If thin kerf core barrels are being used, ensure that recommended
maximum bit weights are not exceeded.
Note: 2. Always ensure that the Feed Pressure control valve is screwed in far
enough to provide enough pressure to penetrate the formation being drilled.

neutral.
2. Turn the Rod Pulling/Feeding switch to ROD FEEDING.

Ensure the safety guard is in place.
3. Turn the Drilling/Standby/Rod Handling switch to ROD HANDLING
and ensure the safety guard is reinstalled (if fitted).
4. Move the Feed lever rearward and move Carriage to the rear end
of the Feed Frame.
5. Return the Feed lever to neutral.
61
6. Turn the Drilling/Standby/Rod Handling switch to DRILLING.
7. Start up Flushing Fluid circulation by winding out the Pump control

valve on the Control Panel.
8. Close the Feed Flow control valve on the Control Panel by winding
fully inwards.
9. Move the Rotation lever fully forward.
10. If necessary, adjust the Rotation Speed control to reset the free
running speed of the Chuck to suit the drill rod size being used.
11. Turn the Fine Feed selector switch to the ON position.
12. Wind in the Feed Pressure control on the Control Panel until the
pressure reading on the Feed Pressure gauge indicates a suitable
pressure for the formation being drilled.
13. Adjust the Feed Flow control valve by turning counterclockwise and
let the core bit come into contact with the rock face. There will be
a small delay after opening the valve before feeding commences,
due to hydraulic hose expansion.
14. Adjust the Feed Flow control valve further open to select the
penetration rate best suited for the conditions.
15. If a core blockage occurs, move the Carriage Feed lever rearwards
for fast pull-back off bottom.
3.3.10 Rechucking
Be aware of moving carriage and hoses — clear the immediate area

before starting this operation.
1. Turn the Fine Feed selector switch to the OFF position.
2. Move the Rotation lever to neutral.
4. Move the Carriage Feed lever rearward and position the Chuck in
the required position.
5. Turn the Drilling/Standby/Rod Handling switch to DRILLING.
You are now ready to drill again.
62
3.4 Fault Light Indicators

A bank of six fault lights are positioned across the top of the Control
Panel. Each light indicates an identified fault that shuts down the drill.
1 2 3 4 5 6
Figure 3–8: CAT Fault Lights
The following solid Red light sequences remain illuminated until the fault
is corrected. (The fault must be rectified before the rig can be restarted.)
1. Forward or Reverse Feed pressure switch fault.
2. Chuck pressure switch fault.
3. Rod Holder pressure switch fault.
4. Low Hydraulic Oil Level and the level needs to be checked.

Refer to the Operators Manual for further details.
5. High Hydraulic Oil Temperature in the Drill circuit.
6. Engine Fault — an automatic shutdown has occurred due to a high

temperature thermistor trip in the electric motor.
63
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Chapter 4: Options
Contents
4.1 Wireline Hoist............................................................................................. 67
4.1.1 Introduction...................................................................................... 67
4.1.2 Hoist Capacity................................................................................. 68
4.1.3 Wireline Maintenance...................................................................... 68
4.1.4 Checking and/or Changing the Oil................................................... 69
4.1.5 Changing the Wireline Cable........................................................... 71
4.2 Feed Frame Positioner (FFP).................................................................... 73
4.2.1 Setting up to Drill a Down Hole (0° to –90°).................................... 73
4.2.2 Setting up to Drill an Up Hole (0° to +90°)....................................... 74
4.3 Extending the Feed Frame........................................................................ 76
4.3.1 With Dump Cylinder Fitted............................................................... 76
4.4 Removing the Skid Steer from the Positioner Assembly...................... 77
4.5 Water Pump................................................................................................ 79
4.5.1 Introduction...................................................................................... 79
4.5.2 Water Pump Lubrication and Maintenance..................................... 80
Table of Figures
Figure 4–1: Counterbalance valves on Wireline Hoist....................................... 67
Figure 4–2: Typical examples of wire rope deterioration................................... 69
Figure 4–3: Wireline Hoist front cover............................................................... 69
Figure 4–4: Accessing the Wireline oil drain/fill plugs........................................ 70
Figure 4–5: Wireline Hoist Oil Selection Chart.................................................. 71
Figure 4–6: Laying the cable............................................................................. 72
Figure 4–7: CAT Skid Steer feed frame and positioner..................................... 73
Figure 4–8: Feed Frame Positioner components.............................................. 74
Figure 4–9: Feed Frame Positioner control valves and levers.......................... 75
Figure 4–10: Clamping plates............................................................................ 76
Figure 4–11: Rotation Unit hydraulic hose connections.................................... 77
Figure 4–12: Bridging plug................................................................................. 78
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Chapter 4: Options
Figure 4–13: Positioner coupler pins................................................................. 78

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Chapter 4: Options
4.1 Wireline Hoist

4.1.1 Introduction
The hydraulic hose connections for the wireline hoist must be correctly
made so that the cable spools off the drum when the Wireline lever is
pushed forward.
Potential for crush or entanglement injury — Under NO circumstances
should the cover be opened or the Freewheel control knob engaged/
disengaged whilst the wireline hoist is rotating.
The hydraulically powered wireline hoist is designed to connect directly

to the power pack via the interconnecting hoses provided.
For most applications the hoist is fastened to the wireline extension on

the feed frame positioner. Operation of the hoist is by way of the wireline
control lever on the control panel.
The wireline hoist is fitted with a pilot opened, spring closed brake
assembly that opens by way of a signal from either the A or B port,
depending on direction of hoist rotation.
The hoist assembly has counterbalance valves fitted on both port

connections to stop the load from running away in the event of a loss of
pressure. They are pre-set to 250 bar.
Figure 4–1: Counterbalance valves on Wireline Hoist
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Chapter 4: Options
4.1.2 Hoist Capacity

Capacity is dependent on the diameter of the cable used:
Cable size Capacity
5mm 500 m (1640 ft)
6mm 300 m (984 ft)
Drum Speed 150 rpm
Line Pull 500 Kg
Weight: Wireline Hoist assembly,

c/w 500m of 5mm cable: 200 Kg
Chapter Reference: Wireline Hoist p/n 3003453
4.1.3 Wireline Maintenance
Mechanical damage due to rope movement

over sharp edge projection whilst under load.
Localised wear due to abrasion on supporting

structure, e.g. vibration of rope between drum
and jib head sheave.
Narrow wear path, resulting in fatigue

fractures caused by working in a grossly
oversized groove, or over small support
rollers.
Severe wear in Lang’s Lay, caused by

abrasion at crossover points on multi-layered
coiling application
Corrosion to severe degree caused by

immersion of rope in chemically treated
water.
Typical wire fractures as a result of bend

fatigue.
Wire fractures at the strand, or core interface

(as distinct from ‘crown’ fractures), caused by
failure of core support.
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Chapter 4: Options
Typical example of localised wear and

deformation created at a previously kincked
portion of rope.
Multi-strand rope has ‘bird caged’ due to

torsional inbalance — typical of build-up
seen at anchorage end of a multi-fall crane
application.
Protrusion of IWRC resulting from shock

loading.
Figure 4–2: Typical examples of wire rope deterioration

(The above information has been supplied by A. Noble & Sons Pty Ltd.)
●● Wireline hoses should be visually checked each week for damage, so

as to minimise the potential for burst hoses.
●● The Wireline cable should be visually inspected each month, looking
for corrosion, frayed wiring, surface wear, or strand distortion. This
can be done by observing the cable whilst lowering and raising the
overshot assembly when pulling the inner tube.
4.1.4 Checking and/or Changing the Oil
application.
Remove all personnel from the immediate area before moving the hoist.
Stop the Power Pack and isolate the power supply during this procedure.
Dispose of any spent oil in an environmentally responsible manner.
When checking or changing the oil in the hoist the following procedure
should be observed:
1. Ensure the wireline hoist is stationary, there is no load on the cable,

and open the front cover.
Figure 4–3: Wireline Hoist front cover
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Chapter 4: Options
2. To check the oil level, disengage the hoist drum by pushing on the
knob located in the centre of the hub, rotate 90 degrees into detent
to keep disengaged.
Carefully rotate the drum until one of the access plugs in the hub is
in the 3 or 9 o’clock position when looking at the front of the hoist
assembly.
Re-engage the hub by turning the centre knob 90 degrees, and it
should spring outwards. The drum may have to be rotated slightly
to engage.
Figure 4–4: Accessing the Wireline oil drain/fill plugs
Note: In the above figure, the Oil Level access plug is at the 3 o’clock position
inside the hub.
3. Remove the plug (at 3 or 9 o’clock), and oil should just dribble out
at this location when the level is correct. Fill or drain as necessary.
Clean up any oil spills.
It is recommended that the gear oil be changed after the first
100 hours of service. Thereafter, it is recommended that the gear
oil be changed every 1500–2000 hours, or every 12 months.
4. To drain the oil, first take off the drum guard by removing the
M10x40 fasteners (8 off), spring washers, and guard retaining ring.
5. Disengage the hub as described above, and rotate it until a plug is

located at the bottom of the gearbox (6 o’clock position).
Re-engage the hub.
6. Remove the higher plug which will act as a breather.

Remove the bottom plug and drain the oil into a receptacle.
Oil volume is approximately 0.3L.
Replace the lower plug.
7. Refer to the above chart for the correct oil grade selection.
Do not mix different oil types as that will shorten the life of the
gearbox.
Use only clean oil that has been stored in clean containers.
8. Disengage the hub and rotate it until the open plug hole is located
at the 3 or 9 o’clock position. Re-engage the hub.
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Chapter 4: Options
Fill with the appropriate oil, no higher than the centerline of the hub.
9. Refit the plug, clean up any oil spills.
10. Refit the Drum guard, retaining ring, and fasteners.

Take care when fitting the Wireline Extension to the positioner.
Fit the extension to the positioner before the wireline hoist
assembly is fitted to the extension.
Figure 4–5: Wireline Hoist Oil Selection Chart
4.1.5 Changing the Wireline Cable
Use the correct manual handling and lifting procedures for this operation.
Use the correct Personal Protective Equipment and tools when handling
wireline cable.
Remove all personnel from the immediate area before operating the hoist.
Dispose of cable in a responsible manner.
The procedure for changing the wireline cable is as follows:
1. Remove the cover weldment from the hoist to access the cable.
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Chapter 4: Options
The cover is retained by M10 x 40 fasteners (8 off), spring washers,

and a retaining ring.
2. Move the Wireline control lever on the Control Panel slowly
forwards to feed out the cable from the drum.
Once all the cable is off the drum, undo the clamp plate to release
the cable end.
If the clamp plate is on the motor side of the drum due to the lay of
the cable, the hoist drum will need to be removed first.
3. Dispose of the faulty cable in an environmentally conscious

manner.
4. Fit the new cable roll onto the shaft and supports so it can rotate
freely.
5. Fit the end of the new cable through the hole in the side of the
wireline drum and securely clamp it with the plate.
Select the appropriate mounting location to suit the lay of the cable.
Refer to the following figure.
R.H. ROPE OVERWOUND R.H. ROPE UNDERWOUND
L.H. ROPE OVERWOUND L.H. ROPE UNDERWOUND
Figure 4–6: Laying the cable
6. Move the Wireline control lever slowly into reverse to feed the new
cable onto the drum.
The cable should be fully greased as it is wound onto the cable
using a general purpose grease.
IMPORTANT
Ensure the clamp fastening bolts do not protrude through into the cable
area.
Note: The drum may need to be separated from the gearbox to access the
cable clamp, as determined by the lay of the cable.
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Chapter 4: Options
4.2 Feed Frame Positioner (FFP)
Failure to adequately anchor the Drill can cause unsafe working

conditions, and will result in higher than normal wear on components.
When using the Positioner, it is strongly recommended that the supplied

face mounting bracket be used to fasten the front of the Feed Frame to
the rock face.
Figure 4–7: CAT Skid Steer feed frame and positioner
4.2.1 Setting up to Drill a Down Hole (0° to –90°)
Possible hazard when pinning the base — refer to site specific

procedures for pinning.
Potential for injury when packing bearers under positioner — other
personnel must keep clear when setting up the drill.
Potential for injury when tightening scaffolding clamps at height — refer
to site specific procedures regarding operators working at heights.
Possible pinch point injury when tilting the cradle to set-up drill angle.
Ensure the immediate area is clear of personnel before operating.
Always use an airleg drill to drill anchor holes. Using the rig to drill
anchor holes is not recommended.
Strain injury can happen while maneuvering positioner for azimuth setup.
Using a long bar to assist in turning the positioner is recommended.
1. Locate the base of the Positioner so that it is sitting evenly on the

ground, using timber bearers if necessary.
2. Loosen and remove the rear cradle clamp caps and move them
clear. Ensure the feed frame clamp plates are tight.
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Chapter 4: Options
3. Start the power unit and ensure the area is clear of personnel
before operating the Positioner.
4. Slowly pull the Positioner lever up to extend the cylinder and raise
the Feed Frame, being careful not to damage any hoses.
5. To stop raising the Feed Frame, return the Positioner lever to
neutral.
6. When the required angle has been set, fit one of the supplied
support poles horizontally into the cradle clamp. Refit the two
cradle clamp caps and tighten the bolts.
7. Using the clamps provided, fasten the support pole between
the chassis recess and the horizontal support pole. Tighten the
scaffolding clamps when the required angle is achieved.
8. When the required angle has been set and checked, use an Airleg
drill to drill an anchor bolt hole into the rockface.
9. Fit a rockbolt through the mounting bracket and tighten down firmly.
The Feed Frame can now be raised from horizontal to vertical in one
operation.
Clamp plates
Tilt cylinder
counterbalance
valve
Turntable clamping plates Tilt cylinder
Figure 4–8: Feed Frame Positioner components
4.2.2 Setting up to Drill an Up Hole (0° to +90°)
Possible hazard when pinning the base — refer to site specific

procedures for pinning.
Potential for injury when packing bearers under positioner — other
personnel must keep clear when setting up the drill.
Potential for injury when tightening scaffolding clamps at height — refer
to site specific procedures regarding operators working at heights.
Possible pinch point injury when tilting the cradle to set-up drill angle.
Ensure the immediate area is clear of personnel before operating.
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Chapter 4: Options
1. Locate the base of the Positioner so that it is sitting evenly on the

ground, using timber bearers if necessary.
2. Loosen and remove the front cradle clamp caps and move them
clear. Ensure the feed frame clamp plates are tight.
3. Start the power unit and ensure the area is clear of all personnel
before operating the Positioner.
4. Slowly pull the Positioner lever up to extend the cylinder and raise
the Feed Frame, being careful not to damage any hoses.
5. To stop raising the Feed Frame, return the Positioner lever to

neutral.
6. When the required angle has been set, fit one of the supplied
support poles horizontally into the cradle clamp. Refit the two
cradle clamp caps and tighten the bolts.
7. Using the clamps provided, fasten the support pole between

the chassis recess and the horizontal support pole. Tighten the
scaffolding clamps when the required angle is achieved.
8. When the required angle has been set, use an Airleg drill to drill an
anchor bolt hole into the rockface.
9. Fit a rockbolt through the mounting bracket and tighten down firmly.
The Feed Frame can now be raised from horizontal to vertical in one
operation.
Dump lever Dump cylinder control valve
Tilt cylinder control valve

Positioner Tilt lever
Figure 4–9: Feed Frame Positioner control valves and levers
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Chapter 4: Options
4.3 Extending the Feed Frame

4.3.1 With Dump Cylinder Fitted
Ensure the area is clear of personnel before extending the feed frame.
Ensure a clear line of sight exists at all times between the operator and
the assistant.
application
1. When extending the Feed Frame forward or reverse, ensure that

there is a clear line of sight between the operator and helper at all
times. This is to reduce the likelihood of injuries.
2. Loosen the bolts on the clamp plates which are holding the Feed
Frame to the cradle, then turn on the power unit.
3. To extend the Feed Frame towards the rock face, move the dump
cylinder control lever outwards. The Feed Frame is retracted by
moving the dump cylinder control lever inwards.
4. When the desired position is achieved, tighten the bolts on the

clamping plates. Always ensure the Feed Frame is gripped by a
minimum of four bolts.
5. Switch off the power unit.
Figure 4–10: Clamping plates
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Chapter 4: Options
4.4 Removing the Skid Steer from the Positioner

Assembly
Use the correct Personal Protective Equipment and tools at all times.
Hydraulic hoses may be awkward to handle — use the correct manual
handling procedures.
Ensure all personnel are well clear of Skid Steer before moving —
maintain a clear line of sight at all times.
1. Ensure the Positioner assembly is firmly on the ground.
2. Turn off the Skid Steer, making sure the loader controls are locked.
3. Disconnect the seven hoses going to the Rotation Unit manifold

block, mark the ends for reconnection, and plug. Cap the open
ends of the manifold block.
4. Disconnect the three hoses going to the regenerative block, mark

the ends for reconnection, and plug. Cap the open ends on the
regenerative block.
Rotation ‘B’ Rotation ‘A’
Chuck B.O.D. Drain Drain
‘F’ Port Feed ‘A’ Feed ‘B’
Figure 4–11: Rotation Unit hydraulic hose connections
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Chapter 4: Options
5. Disconnect the rod holder hose, mark the ends for reconnection,
and plug. Cap the Rod Holder fitting.
Figure 4–12: Bridging plug
6. Wind the hydraulic hoses neatly around the Skid Steer assembly.
7. Pull the Red button downwards and press the bottom of the switch.
Hold the switch in the depressed position until the coupler pins
engage.
8. Return to the operator’s seat, lower the seat bar, fasten the seat
belt, and start the engine.
Figure 4–13: Positioner coupler pins
9. Tilt the positioner assembly forward to allow the assembly to slide

off the edge of the coupler.
10. Ensure nobody is behind the Skid Steer and slowly reverse away
from the Positioner.
The Skid Steer counterweight is now out of balance, so rapid
movement or uphill climbing could result in the Skid Steer
tipping up.
4.4.1.1 Reattachment
Reattaching the positioner assembly is the reverse of the above
procedure.
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Chapter 4: Options
4.5 Water Pump

4.5.1 Introduction
The Water Pump provides controlled water pressure to the drill string for
both drilling and flushing the hole.
Two Water Pumps are offered with the LM30 Modular Drill:
●● a 712 pump — it can deliver 12 US gpm (45 Lpm) at a working
pressure of 700 psi (48 bar).
●● a 520 pump — it can deliver 20 US gpm (75 lpm) at a working
pressure of 500 psi (34 bar).
Both pumps are direct coupled to a hydraulic motor, which is controlled
by a metering valve on the Control Panel.
Figure 4–14: 712 Water Pump
1–Filler Cap 3–Oil level petcock

2–Drain Plug
Figure 4–15: 535 Water Pump
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Chapter 4: Options
4.5.2 Water Pump Lubrication and Maintenance
Dispose of spent oil in an environmentally responsible manner.

operation.
4.5.2.1 712 Water Pump

1. Stop the Water Pump and let the oil settle before checking or
adding oil.
2. Clean around the Dipstick before removing it to add or check the

oil level.
Remove the Dipstick to check the oil level or use the Oil Level sight
glass.
3. It is recommended that the lubricating oil be changed after the

first 50 hours of service. Thereafter it is recommended that the
oil be changed every three months or at 500 hour intervals.
4. Drain the oil from the unit by unscrewing the plug in the end cover
of the unit.
5. Check Oil Daily. If required, fill with recommended grade.

(DO NOT overfill.)
Use only clean non detergent oil that has been stored in clean
containers.
Lubricant Type: SAE 30
Quantity: 1.5 L (51 oz.)
4.5.2.2 520 Water Pump

1. Stop the Water Pump and let the oil settle before checking or
adding oil.
2. Clean around the Filler Cap and Drain Cock before opening to add
or check oil level.
3. Use the Petcock to check the oil level.

Oil should slowly dribble out of this valve when the oil level is
correct.
4. It is recommended that the lubricating oil be changed after the

first 100 hours of service. Thereafter it is recommended that
the oil be changed every 4000 working hours or 6 monthly.
Apply water resistant grease to the three grease nipples every
3000 hours or twice a year.
5. Drain the oil from the unit by unscrewing the square headed plug
located either side of the main casting.
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Chapter 4: Options
6. Check Oil Daily. If required, fill with recommended grade.

(DO NOT overfill.)
Use only clean non detergent oil that has been stored in clean
containers.
Lubricant Type: SAE 30
Quantity: 2 L (2-1/4 US quarts)
81
Chapter 4: Options
82
Contents
5.1 Hose Connections..................................................................................... 85
5.2 Pre-Start Checks........................................................................................ 86
5.2.1 BEFORE OPERATION.................................................................... 86
5.2.2 OPERATING THE MACHINE.......................................................... 87
5.2.3 Oil Temperature Switch................................................................... 88
5.2.4 Control Panel................................................................................... 88
5.2.5 Drill Head......................................................................................... 89
5.2.6 Water Pump..................................................................................... 90
5.2.7 Positioner Assembly........................................................................ 90
5.3 Start Up....................................................................................................... 91
5.4 Purging (Flushing) and Pilot Bleeding..................................................... 91
5.4.1 Chuck Circuit................................................................................... 91
5.4.2 Rod Holder Circuit........................................................................... 92
5.4.3 Rotation (Hydraulic Motor) Circuit — Bleeding of Pilot Hoses
A and B........................................................................................... 92
5.4.4 Feed Cylinder Circuit — Bleeding of Pilot Hoses A and B.............. 93
5.4.5 Wireline Hoist Circuit — Bleeding of Pilot Hoses A and B............... 94
5.4.6 Feed Frame Dump Circuit — Bleeding of Pilot Hoses A and B....... 95
5.4.7 Positioner Tilt Circuit — Bleeding of Pilot Hoses A and B............... 95
5.4.8 Fine Feed Circuit............................................................................. 95
5.4.9 Water Pump Circuit......................................................................... 96
5.5 Function Checks........................................................................................ 97
5.5.1 Chuck/Rod Clamp........................................................................... 97
5.5.2 Rotation Direction............................................................................ 97
5.5.3 Feed Frame..................................................................................... 98
5.5.4 Drill Head — Alignment Check........................................................ 98
5.5.5 Drill Head — Thread Making/Breaking............................................ 99
5.5.6 Rod Handling................................................................................... 99
5.5.7 Water Pump................................................................................... 100
83
Table of Figures
Figure 5–1: Hose Connections — Rotation Unit ............................................... 85
Figure 5–2: Hose Connections — Main Valve Bank.......................................... 85
Figure 5–3: Oil Temperature Switch.................................................................. 88
Figure 5–4: Fill to halfway point of sight glass................................................... 89
Figure 5–5: Side View of Main Manifold Block.................................................. 93
84
5.1 Hose Connections

Rotation ‘B’ Rotation ‘A’
Chuck B.O.D. Drain Drain
‘F’ Port Feed ‘A’ Feed ‘B’

Figure 5–1: Hose Connections — Rotation Unit
Chuck
Rod Holder
Dump
Tilt
Rotation ‘B’ pilot line Rotation
Wireline ‘B’ pilot line Wireline

Feed
Feed ‘B’ pilot line
Figure 5–2: Hose Connections — Main Valve Bank
85
5.2 Pre-Start Checks
Use the correct Personal Protective Equipment at all times when handling
hydraulic oil.
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
settings of the hydraulic components are correct, and that all hoses are
properly connected and purged.
5.2.1 BEFORE OPERATION
Avoid any likelihood of accident and personal injury — DO NOT RUSH !
●● Do not operate this machine or perform maintenance work if you

have not had the appropriate training or read and fully understood the
instructions and warnings in this manual.
●● Before starting the engine make sure you know the location and
function of all the controls. Using the wrong control can cause serious
injury or death.
●● Be aware of and familiarize yourself with the safety decals on this
machine.
●● Make sure you know how to exit the machine in the event of an
emergency such as an overturn or when the main exit is unusable.
●● Avoid loose fitting clothing, jewellery, and loose personal articles.
●● Different jobs will require different protective equipment. Items such
as hard hats, protective shoes, heavy gloves, reflector type vests,
respirators, eye protection, and ear protection can be required. Know
and use the equipment that is required before you start the job.
●● Be prepared for emergencies. Always have a first aid kit and a
good fire extinguisher available. Know how to use them to address
emergencies.
●● Check that the rear access door, guards and covers are installed
correctly or closed.
●● Foreign material or grease on the steps and hand rails can cause
an accident. Keep the steps and hand rails clean, and free from oil,
grease and debris.
●● Know the rules, laws, and safety equipment necessary for
transporting this machine on a road or highway.
●● Before you operate in cold weather, familiarise yourself with the
defined cold start procedure.
●● Always face the machine and use the hand rails and steps when
getting on or off the Skid Steer. Check the seat bar for correct
operation of control interlocks.
86
●● Before starting work, walk around the machine and check for oil or
fluid leaks. Replace all broken or missing parts and do the required
lubrication and maintenance. Clean all trash and debris from the
machine.
●● Remove all loose objects from the operator’s area and from the
machine. Loose objects can jam controls and cause accidents.
●● Before you start the engine, always fasten your seat belt and pull the
seat bar down. When tramming only operate the machine from the
operator’s seat.
●● Engine exhaust fumes can cause death. If you operate this machine
in an enclosed area, make sure there is adequate ventilation to
replace the exhaust fumes with fresh air.
●● Make sure all persons are away from the machine and give a
warning before you start the engine.
●● Never get onto or off a moving machine.
●● Adapt your operating techniques to the site (e.g. conditions, slopes,
obstacles, surroundings, etc.).
5.2.2 OPERATING THE MACHINE
Know how to use the equipment before you start operation.

Ensure the power has been disconnected, and always keep a safe
working distance from power lines or cables.
●● Familiarize yourself with the machine’s capabilities and the working

space required.
●● Operations on different sites and in different weather conditions
require different protective equipment, e.g. helmet, gloves, safety
shoes, reflective jacket, mask, ear protection and eye protection.
●● Do not jump from the machine — injury can result.
●● Check all controls in a clear area to make sure the machine is
functioning correctly, and adjust all of the controls gradually for
smooth operation.
●● Do not allow other persons to ride on the machine or its attachments.
Other persons can fall or can cause an accident.
●● Dust, fog, smoke, etc., can decrease your vision and cause an
accident. Stop the machine or decrease the speed until you can see
everything around you in the work area.
●● Contact with high voltage power lines, underground cables, etc., can
cause serious injury or death from electrocution.Before you drive or
operate in an area with high voltage lines or cables, tell the power or
utility company what you are going to do.
●● Contact your local power or utility company to determine a safe
working distance from any high voltage power equipment and
become familiar with any local safety codes or regulations that apply
to the job site.
87
●● Electrical cables, gas pipes, water pipes, sewers, or other

underground objects can cause injury or death. Determine the
location of underground hazards before you operate your machine in
a new area.
●● If this machine rolls over, you can be injured or killed. You must
make a judgment if weather, road, or earth conditions will permit safe
operation on a hill, ramp, or rough ground.
●● Stay away from hazardous areas such as ditches, overhangs, etc.
Walk around the work area before you start operating and be aware
of all possible hazards.
●● Be alert and always know the location of all workers in your area.
Keep all other persons completely away from your machine. Injury or
death can result if you do not follow these instructions.
●● Always look to the rear before backing the machine.
●● Operate the machine controls from the operator’s seat only.
5.2.3 Oil Temperature Switch

1. The Oil Temperature Switch is located on the side of the suction
manifold mounted to the suction line of Hydraulic Pump, under the
CAT Skid Steer cabin. It is set to 65–70 deg. C.
2. Ensure a cooling water supply of 20–30 Lpm is available.
Figure 5–3: Oil Temperature Switch
5.2.4 Control Panel

1. Connect the hoses from the Control Panel to the Power Unit, taking
particular care to ensure that no contamination is introduced into
the system, and ctore any JIC caps and plugs in a clean location
for future use.
2. Check that all hose terminations are correct. The hose covers may
then be used to bundle these hoses together.
88
5.2.5 Drill Head
Use the correct Personal Protective Equipment at all times when handling
hydraulic oil.
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.
Figure 5–4: Fill to halfway point of sight glass
2. 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, take particular care to ensure that the front anchoring
system is free to pivot so as to allow the feed frame to be correctly
aligned without twist or distortion.
Refer to Section 4.2 for details of how to anchor the Feed Frame
Positioner.
3. Connect feed hose ‘A’ to the ‘B’ connections on the feed manifold
assembly.
Cap the feed hose ‘B’ port on the manifold assembly.
Connect the feed manifold ‘A’ port to the ‘B’ port on the manifold.
4. Connect the 3/8” hose from the ‘F’ port on the manifold block to the
‘F’ port on the feed manifold assembly.
5. Connect the rod holder hose ‘B’ port on the Rod Holder section to
the rod holder. (This is a 9/16” JIC hose end.)
89
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.
operation.
Dispose of any waste oil in an environmentally responsible manner.
a. Connect the chuck supply hose between the ‘A’ port on the Chuck
section and the Rotation Unit. (This is a 3/4” JIC hose end.)
b. Connect the rotation unit drain hose between the Drain manifold
and the Rotation Unit. (This is a 7/8“ JIC hose end.)
c. Connect the two motor hoses between the hydraulic motor ports
and the connections on the Valve section. (These hoses have 1
1/16“ JIC hose ends.)
Ensure A and B ports are correctly connected.
d. Connect the breakout device hose between the BOD connection on
the manifold block to the connection on the Rotation Unit. (This is a
7/16“ JIC hose end.)
e. Connect the motor pilot speed control hose ‘X’ between the PPX
motor connection on the Power Unit ‘X2’ port to the ‘X1’ port on the
Control Panel. (This is a 9/16” JIC hose end.)
f. Connect the motor drain hose between the Drain manifold and the
Rotation Unit. (This is a 7/8” JIC hose end.)
5.2.6 Water Pump

1. Connect the water pump hose ‘WP1’ on the manifold block to the
water pump motor ‘A’ port. (These are 3/4” JIC hose ends.)
Ensure the ‘B’ port is connected to the ‘W/P Tank’ port on the drain
block.
2. Connect the ‘WP2’ pilot hose to ‘WP’ on the manifold block and the
Control Panel. (This is a 9/16” JIC hose end.)
5.2.7 Positioner Assembly

1. Connect the two positioner tilt cylinder hoses to their respective
ports on the manifold.
2. Connect the two positioner dump cylinder hoses to their respective

connections on the manifold.
90
5.3 Start Up
Refer to section 3.3 (‘Operating the Skid Steer Rig’) for descriptions of
the required procedures for starting and stopping the Skid Steer.
5.4 Purging (Flushing) and Pilot Bleeding
Possibility of hydraulic oil under pressure — vent hoses by cracking

the fitting, slowly bleeding waste oil into a suitable container, and then
disposing of it in an environmentally responsible manner.
Use the correct Personal Protective Equipment and tools for these
operations.
Before operating the Drill, the complete purging procedure must be

performed if:
a. The Drill has been delivered by sea freight or it has been exposed
to the weather for more than one week.
b. The Drill has been idle for more than four 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.
5.4.1 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.
2. Join the two hose ends together using a 7/8“ JIC male x 3/4” JIC
male nipple. This allows the chuck oil supply to return directly to the
drain manifold thereby purging the chuck circuit.
3. Start the power unit and place the Drilling/Standby/Rod Handling

selector switch (4) into DRILLING mode.
Allow the hoses to purge for at least five minutes.
4. Return the selector switch to the STANDBY position, and stop the
power unit.
5. Reconnect the two hoses to their respective connections.
91
5.4.2 Rod Holder Circuit

1. Using a 9/16” JIC male x 7/8” JIC male nipple, disconnect the hose
from the Rod Holder and connect the hose end to the chuck drain
hose. This allows the rod holder oil supply to return directly to the
drain manifold thereby purging the rod holder circuit.
2. Ensure the Rod Holder selector switch on the Control Panel is in

the AUTOMATIC position.

selector switch (4) into DRILLING mode.
4. Return the selector switch to the STANDBY position and stop the
power unit.
5. Reconnect the rod holder hose and the chuck drain hose to their
correct fittings.
5.4.3 Rotation (Hydraulic Motor) Circuit — Bleeding of

Pilot Hoses A and B
Possibility of hydraulic oil under pressure — vent the hose by cycling the
Rotation control lever on the Control Panel.
operation.
Capture the bled oil in a suitable container and dispose of it in an
environmentally responsible manner.
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 a 1 1/16“ JIC male x 1 1/16” JIC male nipple. This
allows oil to by-pass the motor and purge the rotation circuit.
2. Start the power unit and slowly move the Rotation control lever fully
forwards. Allow the hoses to purge for at least five minutes.
3. While purging, bleed the ‘A’ pilot system by partially unscrewing

the ‘A’ pilot hose connection at the rear of the section, and allow
venting until clear oil is obtained.
Move the Rotation control lever fully rearwards and allow the hoses
to purge for at least five minutes.
4. While purging, bleed the ‘B’ pilot system by partially unscrewing
the ‘B’ pilot hose connection at the front of the section, and allow
5. Return the control lever to neutral and stop the power unit.
Reconnect the rotation unit motor hoses.
92
Rotation ‘B’ pilot hose
Wireline ‘B’ pilot hose
Feed ‘B’ pilot hose
Figure 5–5: Side View of Main Manifold Block
5.4.4 Feed Cylinder Circuit — Bleeding of Pilot Hoses

A and B
Feed control lever on the Control Panel.
operation.
Capture the bled oil in a suitable container and dispose of in an
1. Disconnect the two feed cylinder hoses from the cylinder

connections and join the two ends together.
2. Start the power unit and ensure the Rod Pulling/Rod Feeding
selector switch is in ROD PULLING mode. The Drilling/Standby/
Rod Handling selector switch must be in the ROD HANDLING
position.
Slowly move the Carriage control lever fully forwards.
3. While purging, bleed the ‘A’ pilot system by partially unscrewing the
‘A’ pilot connection at the rear of the section, and allow venting until
clear oil is obtained.
4. Return the Carriage control lever to neutral and place the Rod
Pulling/Rod Feeding selector switch into ROD FEEDING mode.
93
Move the Carriage control lever fully rearwards and allow the hoses
to purge for at least five minutes.
5. While purging, bleed the ‘B’ pilot system by partially unscrewing
the ‘B’ pilot hose connection at the front of the section, and allow
6. Return the control lever to neutral and stop the power unit.
Reconnect the feed cylinder hoses.
5.4.5 Wireline Hoist Circuit — Bleeding of Pilot Hoses

A and B
Wireline control lever on the Control Panel.
operation.
Capture the bled oil in a suitable container and dispose of in an
1. Disconnect the A and B hoses at the Wireline Hoist and join the
ends together using a nipple 3/4” JIC male x 3/4” JIC male.
2. Start the power unit and slowly move the Wireline lever fully
forwards.
3. While purging, bleed the ‘A’ pilot system by partially unscrewing the
‘A’ pilot hose connection at the rear of the section.
Allow oil to vent until clear oil is obtained.
Move the Wireline control lever fully backwards and allow the
hoses to purge for at least five minutes.
4. While purging, bleed the ‘B’ pilot system by partially unscrewing the
‘B’ pilot hose connection at the front of the section.
Allow to vent until clear oil is obtained.
5. Return the Wireline control lever to neutral and stop the power unit.
Reconnect the wireline assembly hoses.
94
5.4.6 Feed Frame Dump Circuit — Bleeding of Pilot Hoses

A and B
Possibility of hydraulic oil under pressure — vent the hose by cracking

the fitting and slowly bleeding oil in a suitable container, then disposing
of it in an environmentally responsible manner.
operation.
1. Disconnect the A and B hoses at the Dump cylinder and join the
ends together using a nipple 3/4” JIC male x 3/4” JIC male.
2. Start the power unit and slowly move the Dump cylinder control
lever fully forwards.
3. Move the Dump cylinder control lever fully backwards, and allow
the hoses to purge for at least five minutes.
4. Return the Dump cylinder control lever to neutral and stop the
power unit.
Reconnect the Dump cylinder hoses.
5.4.7 Positioner Tilt Circuit — Bleeding of Pilot Hoses

A and B
1. Disconnect the A and B hoses at the Tilt cylinder and join the ends
together using a nipple 3/4” JIC male x 3/4” JIC male.
2. Start the power unit and slowly move the Tilt cylinder control lever
fully forwards.
3. Move the Tilt cylinder control lever fully backwards, and allow the
hoses to purge for at least five minutes.
4. Return the Tilt cylinder control lever to neutral and stop the power
unit.
Reconnect the Positioner Tilt hoses.
5.4.8 Fine Feed Circuit

1. Fully close the Feed Flow control valve on the Control Panel and
wind out the Feed Pressure valve.
2. Place the Drilling/Standby/Rod Handling selector switch into

DRILLING mode and turn the Fine Feed control switch to ON.
95
Slowly wind in the Feed Pressure valve. Note the maximum

pressure obtainable on the Control Panel gauge — it should be
approx. 28 MPa.
Care is required when reading the gauges due to 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 valve 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.
5.4.9 Water Pump Circuit
Possibility of hydraulic oil under pressure — vent the hose by cracking

the fitting and slowly bleeding oil in a suitable container, then disposing
of it in an environmentally responsible manner.
operation.
1. Disconnect the A and B hoses at the water pump motor and join
the ends together using a 3/4”JIC male x 3/4” JIC male nipple.
Ensure the Drilling/Standby/Rod Handling selector switch is in the
STANDBY position and the Water Pump Speed Control Valve is
fully wound in.
2. Start the power unit and slowly wind the Water Pump Speed
Control valve fully outwards (anticlockwise) on the Control Panel.
3. While purging, bleed the WP1 pilot system by partially unscrewing
the WP1 Pilot Hose Connection at the bottom of the Control Panel,
and allow venting until clear oil is obtained.
Wind in the Speed Control valve, and stop the power unit.
4. Reconnect the water pump hoses.
96
5.5 Function Checks

5.5.1 Chuck/Rod Clamp
Possibility of hydraulic oil under pressure — slowly crack the hose fitting
and collect any waste oil in a suitable container, then dispose of it in an
operation.
1. Connect a 0–300 bar test gauge to the ‘MP’ port, a ‘Minimess’
fitting which is underneath the Water Pump section on the Control
Panel.
2. Ensure the Rod Holder switch on the Control Panel is in the

AUTOMATIC position and the Drilling/Standby/Rod Handling
selector switch is in the STANDBY position.

selector switch into the DRILLING position.
Check that the Chuck closes, the Rod Holder opens, and the test
gauge reads 140 bar.
4. Bleed the rod holder hose at the rod holder end, ensuring all
trapped air is removed.
5. Move the Drilling/Standby/Rod Handling selector switch to the

STANDBY position and confirm that the test gauge reads 25 bar.
When moving the selector from DRILLING to STANDBY the
test gauge pressure should decrease from 140 bar to 25 bar
with no more than a half second delay.
If the delay is greater than half a second, further bleeding of the
pilot lines may be required.
5.5.2 Rotation Direction
Rotating parts — ensure the immediate work area is clear before

operating.
1. With the Drilling/Standby/Rod Handling selector switch in

DRILLING mode, slowly move the Rotation control lever forwards
and ensure that the direction of rotation is in the drilling sense.
Allow the Chuck to rotate slowly for approximately five minutes.
2. 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.
97
Rotation Free Running

Unit Speed (rpm)
LM30 BQ 2000
LM30 HQ 1600
5.5.3 Feed Frame
Hoses moving forwards and rearwards, and protruding rods — keep

immediate work area clear.
1. With the Drilling/Standby/Rod Handling selector switch set to ROD

HANDLING, 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 pressure of 280 bar is achieved.

DRILLING mode, and turn the Fine Feed selector switch to ON.
4. Wind the Feed Pressure control valve inwards (clockwise) until

feed pressure of approximately 140 bar is obtained.
Adjust the carriage speed using the feed flow control valve and
ensure that the carriage movement can be stopped by closing the
feed flow control valve. (Slight movement due to spool leakage may
still occur.)
5. Whilst feeding in mid-stroke, move the Carriage control lever
rearwards and ensure that the carriage fast pull-back system
operates satisfactorily.
5.5.4 Drill Head — Alignment Check
Use the correct Personal Protective Equipment and manual handling

procedures when handling drill rods.
1. Install a straight drill rod in the Chuck with approximately 1500 mm

protruding forward of the Chuck.

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
moving the Fine Feed switch to OFF.
98
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 misalignment.
5.5.5 Drill Head — Thread Making/Breaking
Protruding rods and rotating head when thread making and breaking —
ensure immediate area is clear.
1. Place the drill rod through the Chuck and the Rod Holder then
close the Rod Holder.
2. With the Drilling/Standby/Rod Handling selector switch in ROD

HANDLING mode, stall the Chuck in the forward and reverse
directions.
In each case, ensure that the test gauge 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.
5.5.6 Rod Handling
Moving Feed Frame, rods, and hoses — ensure immediate area is clear
before starting rod handling.
If there is sufficient rod handling space in front of the Feed Frame, feed
the rods backwards and forwards in ROD HANDLING mode, noting
any delay 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. It occurs when:
a. The Carriage control lever is moved forward in ROD FEEDING

mode,
OR
b. The Carriage control lever is moved rearward in ROD PULLING
mode.
99
5.5.7 Water Pump
If the valve is wound fully out when the drill is started the discharge hose
may ‘whip’, causing possible injury — ensure the hose is firmly secured
to avoid this occurrence.
1. Ensure the water pump suction is connected to a water supply.
2. Ensure the Drilling/Standby/Rod Handling selector switch is in the

STANDBY position.
Start the power unit.
3. Slowly wind the pump speed control outwards (anticlockwise), and
check the direction of pump rotation.
Ensure the pump has primed and is pumping correctly.
4. Wind the speed control fully outwards and ensure the maximum
speed is satisfactory.
5. Set the water pump relief valve as required.
100
Contents
6.1 Introduction.............................................................................................. 103
6.2 The Main Pump........................................................................................ 103
6.3 Main Manifold Block Assembly ............................................................. 103
6.4 Feed Manifold Assembly......................................................................... 108
6.5 Setting Pressures.................................................................................... 109
6.5.1 Chuck Load Sense Relief.............................................................. 109
6.5.2 Rod Holder Load Sense Relief...................................................... 110
6.5.3 Dump Cylinder Load Sense Reliefs............................................... 110
6.5.4 Tilt Cylinder Load Sense Reliefs................................................... 110
6.5.5 Wireline Hoist Load Sense Reliefs................................................ 111
6.5.6 Rotation Load Sense Reliefs......................................................... 111
6.5.7 Feed Load Sense Reliefs.............................................................. 112
6.5.8 System Relief Valve V2................................................................. 112
6.6 Setting Flow Rates................................................................................... 113
6.6.1 Rotation Circuit.............................................................................. 113
6.6.2 Feed Circuit................................................................................... 114
6.6.3 Water Pump Circuit....................................................................... 115
6.6.4 Wireline Hoist Circuit..................................................................... 115
6.6.5 Dump Circuit.................................................................................. 116
6.6.6 Positioner Tilt Circuit...................................................................... 116
Table of Figures
Figure 6–1: Chuck and Rod Holder Solenoid Valves...................................... 104
Figure 6–2: Valves on the rear/bottom of the Manifold block.......................... 106
Figure 6–3: Chuck and Rod Holder pressure switches................................... 107
Figure 6–4: Load Sense Valves in the Main Manifold assembly..................... 109
Figure 6–5: Main Valve Bank........................................................................... 113
101
102
6.1 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 unit,
which increases the manoeuvrability of the Control Panel.
●● The high pressure system is controlled by pilot operated valves in the
manifold block 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.
6.2 The Main Pump

The Skid Steer mechanical drive group consists of a Main Pump which
is directly coupled to a Diesel engine. The pump is a swash-plate
axial piston type with a load sensing control that allows for flow control
adjustments. It produces 45 cc/rev which results in (approx.) 90 Lpm at
2000 rpm.
6.3 Main Manifold Block Assembly

The discharge from the Main Pump is delivered through the implement/
drilling block to the Main Manifold Block assembly.
This assembly consists of seven load sensing M4-12 valve sections with
an end block. The sections are all through bolted to the Manifold block
and they are also used to internally connect drain passages.
The Manifold block contains the solenoid and pilot operated valves that
direct oil from the Main Pump to the Drill Head and associated functions
when required.
The Rotation and Feed magnetic switches are bolted to Control Panel
levers on the Skid Steer rig.
The valve numbering on the hydrostatic description is to be read in

conjunction with the circuit diagram in Chapter 7.
Individual components of this main manifold assembly are as follows:
Feed Section
Controls the Fast Feed mode of the Feed cylinder and is operated by
pilot signals:
●● PPa for rapid forward movement of the Carriage
●● PPb for rapid rearward movement of the Carriage.
103
Wireline Section
Controls the speed of the Wireline Hoist and is operated by pilot signals:
●● PPa for raising the Wireline
●● PPb for lowering the Wireline.
Rotation Section
Controls the speed of the Rotation Unit and is operated by pilot signals:
●● PPa for forward rotation
●● PPb for rearward rotation.
Positioner Tilt Section

Controls the raising and lowering of the Positioner assembly.
(It is a manual operation.)
Feed Frame Dump Section

Controls the forward and reverse movement of the Feed Frame when
setting the Drill up for drilling. (It is a manual operation.)
Rod Holder Section

Contains the solenoid valve and load sense reliefs, and incorporates
electrical activation to move the spool. Hose ‘A’ is connected to the Rod
Holder and port ‘B’ is blocked.
Chuck Section
Contains the solenoid valve and load sense reliefs, and incorporates
electrical activation to move the spool. Hose ‘B’ is connected to the
Chuck and port ‘A’ is blocked.
Chuck
Solenoid Valve
Rod Holder
Solenoid Valve
Figure 6–1: Chuck and Rod Holder Solenoid Valves
Proportional Control
All Items 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
104
The pilot pressure required to start the spool movement is 8.5 bar while
22.5 bar is required to move the spool to the full flow position. In this
instance a 15.5 bar pilot signal will result in a flow of half the full flow.
Flow Limiters
Each of the above sections have a flow rate adjustment screw on the
end of the valve section. It can be used to adjust the flow through the
section, and is done when the spool is at its maximum flow position.
Load Sensing in the Sections

As the spool of these valves is shifted from the neutral position, a
connection is made between the A or B port and the load sense gallery,
with the pressure generated from this oil movement transmitted to the
load sense port via internal passages in the valve section. It is then
transmitted to the main pump controller, which senses the pressure of
the A or B port, i.e. ‘the load sense pressure’.
If more than one function is operated (e.g. Rotation and Feed), then
the highest load pressure is transmitted to the pump controller by the
selective action of the shuttle valves.
All sections are fitted with load sense relief valves and their settings limit
the maximum pressure available in the circuit.
System Relief Valve 2

This is the primary relief valve and is set to 300 bar.
It protects the Main Pump from pressure spikes.
Pilot Oil Supply Valve 4

This valve supplies the pilot oil to the circuit and is not adjustable.
It is pre-set to 35 bar.
Pilot Oil Solenoid Valve 5.1

When activated, this valve supplies pilot pressure to the B.O.D. return,
and to the Control Panel. It also supplies pressure to the ‘X’ gallery on
the M4-12 sections of the Rod Holder and Chuck sections.
Fine Feed Solenoid Valve 5.2

This valve is used during the Fine Feed operation of the Feed Cylinder
when drilling. When the valve is de-energised ‘P’ is blocked and ‘A’ is
connected to the tank ‘T’. When energised, the spool moves to connect
‘P’ to ‘A’, allowing oil to go to spool valves 8, 9, and 10, resulting in fine
feed pressure and flow.
Float Solenoid Valve 5.3

This valve is used when floating the Feed Cylinder during thread making
and thread breaking. When the solenoid is energised the spool moves
to allow oil to go to the small counterbalance valves on the feed cylinder
manifold assembly. These valves are then piloted open, connecting oil
from cylinder ports ‘A’ and ‘B’ to be joined, and the cylinder floats.
105
V10
V2
V4
V8
V9
V5.3
(Float solenoid)
V5.2
(Fine Feed solenoid)
V8
V5.1
(Pilot solenoid)
V17.2
(Shuttle Valve)
Figure 6–2: Valves on the rear/bottom of the Manifold block
Shuttle Valve 6
This shuttle valve allows the highest load pressure from the water pump
or system function to be transmitted to the main pump controller.
Pressure Reducing Valve 8

When Fine Feed solenoid valve 5.2 is energised pilot oil (at 35 bar) is
reduced down to 13 bar to move the feed section spool. This connects
Feed ‘P’ to ‘A’ and the feed flow is ready to move the cylinder.
106
Feed Pressure Directional Control Valve 9

When Fine Feed solenoid valve 5.2 is energised pilot oil spools the
normally closed DCV open. This provides feed pressure to the cylinder
when spooled across.
Directional Control Valve 10

When the pilot is operated by Fine Feed solenoid valve 5.3, the spool
connects ports 3 to 2, and allows the Feed ‘B’ return oil to go to the
Control Panel.
At the Control Panel it becomes the fine feed flow control, which
throttles oil through the valve, controlling the feed penetration rate.
In the spring return position ports 3 and 4 are connected, and return oil
is blocked.
Shuttle Valve 17.2

This valve allows either pilot signal to spool the feed valve for forward
carriage movement when fine feed is selected. It also allows oil from the
Control Panel for the fast forward feed operation.
Feed Switches
These switches, which are located on the Feed control lever, are for
forward and reverse lever movement, and give an electrical signal direct
to the PLC for synchronising rod handling functions.
Rotation Switches
These switches, which are located on the Rotation control lever, are for
forward and reverse lever movement, and give an electrical signal direct
to the PLC for synchronising rod handling functions.
Chuck Pressure
Switch (15.2)
Rod Holder Pressure
Switch (15.1)
Figure 6–3: Chuck and Rod Holder pressure switches
Rod Holder Pressure Switch 15.1

The Rod Holder pressure switch is used to provide an input signal to the
PLC as to the pressure in the Rod Holder circuit.
107
The PLC performs an interlocking function between the Rod Holder and
Chuck such that the Rod Holder will not open until the Chuck is closed
and the Chuck will not open until the Rod Holder is closed.
In situations where the rod holder should be open i.e. rod handling or
drilling, if the pressure should fall below 100 bar the drill will shutdown.
Chuck Pressure Switch 15.2

The Chuck pressure switch is used to provide an input signal to the PLC
as to the pressure in the Chuck circuit.
The PLC performs an interlocking function between the Chuck and Rod
Holder such that the Chuck will not open until the Rod Holder is closed
and the Rod Holder will not open until the Chuck is closed.
In situations where the chuck should be closed i.e. drilling, if the

pressure should fall below 50 bar the drill will shut down.
6.4 Feed Manifold Assembly

The Feed Manifold contains the components for the Float and
Regeneration circuit. The regeneration circuit redirects the outgoing oil
from the cylinder A port into the cylinder B port to give the same rod
handling speed in both directions. These components are:
Counterbalance Valve 18 and 19

These are load holding devices and are fitted as a safety interlock in the
event of a pressure loss in the feed circuit and the load running away.
Check Valve pilot operated 20

This check valve allows return oil from cylinder port A to port B as a
regenerative circuit, but prevents oil from going between A and B when
rod handling.
Check Valve spring return 21

This check valve prevents return oil from cylinder port A going to
tank and directing the oil into the B port via check valve 20. This is a
regenerative circuit.
Counterbalance Valve 17.1 and 17.2

During the thread making and thread breaking operations an oil supply
is sent via the Float directional control valve to these counterbalance
valves. They open and allow oil from cylinder A and B ports to be
connected together, thus allowing the cylinder to float.
108
6.5 Setting Pressures
operation.
Capture and dispose of any waste oil in an environmentally responsible
manner.
Chuck ‘A’ Load Sense
Chuck ‘B’ Load Sense

(behind)
Rod Holder ‘A’ Load Sense
Rod Holder ‘B’ Load Sense
(behind)
Dump ‘A’ Load Sense
Dump ‘B’ Load Sense
Tilt ‘A’ Load Sense

Tilt ‘B’ Load Sense
Rotation ‘A’ Load Sense
Rotation ‘B’ Load Sense
Wireline ‘A’ Load Sense
Wireline ‘B’ Load Sense
Feed ‘A’ Load Sense
Feed ‘B’ Load Sense
Figure 6–4: Load Sense Valves in the Main Manifold assembly
This section explains how to correctly set the individual valves in the
Main Manifold assembly, should the need arise.
6.5.1 Chuck Load Sense Relief

1. Connect a (0–100 bar) test gauge into the Chuck hose.
2. Start the power unit, ensuring all control levers are in neutral.
3. Switch the Drilling/Standby/Rod Handling selector to DRILLING.

This activates the Chuck solenoid, providing pressure to the Chuck
circuit.
4. Use a 5 mm Allen key to adjust the Chuck Load Sense Relief ‘B’
until 70 bar is achieved on the gauge.
This completes Chuck setting.
109
6.5.2 Rod Holder Load Sense Relief

1. Connect a (0–250 bar) test gauge into the Rod Holder hose.

This activates the Rod Holder solenoid, providing pressure to the
Rod Holder circuit.
4. Use a 5 mm Allen key to adjust the Rod Holder Load Sense Relief
‘B’ until 140 bar is achieved on the gauge.
For valve locations, refer to the photo at the start of this section.
This completes Rod Holder setting.
6.5.3 Dump Cylinder Load Sense Reliefs

1. Connect a (0–400 bar) test gauge into the Dump Cylinder ‘A’ hose.
3. Move the Dump control lever forward on the manifold block and
hold in position.
4. Use a 5 mm Allen key to adjust the forward load sense relief until
the gauge pressure reads 200 bar.
5. Return the Dump lever to neutral, then connect the test gauge into
the Dump Cylinder ‘B’ hose, and slowly move the Dump control
lever rearward. Hold in position.
6. Use a 5 mm Allen key to adjust the rearward load sense relief until
7. Return the Dump lever to neutral, and turn off the power unit.
This completes Dump Cylinder setting.
6.5.4 Tilt Cylinder Load Sense Reliefs

1. Connect a (0–250 bar) test gauge into the Tilt Cylinder ‘A’ hose.
3. Move the Tilt Cylinder control lever forward on the manifold block
and hold in position.
110
5. Return the Tilt Cylinder lever to neutral, then connect the test
gauge into the Tilt Cylinder ‘B’ hose, and slowly move the Tilt
Cylinder control lever rearward. Hold in position.
7. Return the Tilt Cylinder lever to neutral and turn off the power unit.
This completes Tilt Cylinder setting.
6.5.5 Wireline Hoist Load Sense Reliefs
Avoid possible machine damage. Hydraulic hose connections for the

wireline hoist MUST be correctly made so that the counterbalance valve
is metering the oil flow exiting from the hydraulic motor when the hoist is
in the cable out mode.
Failure to properly connect the hoses will cause the hoist to overspeed
when lowering the overshot into a deep hole.
1. Connect a (0–250 bar) test gauge into the Wireline ‘A’ hose.
3. Move the Wireline control lever forward on the Control Panel and
hold in position.
5. Return the Wireline lever to neutral, then connect the test gauge
into the Wireline ‘B’ hose, and slowly move the Wireline control
lever rearward. Hold in position.
7. Return the Wireline lever to neutral, and turn off the power unit.
This completes Wireline Hoist setting.
6.5.6 Rotation Load Sense Reliefs

The Rotation load sense reliefs are wound fully in to maximum.
111
6.5.7 Feed Load Sense Reliefs

1. Connect a (0–400 bar) test gauge into the Feed ‘A’ hose.
3. Move the Feed control lever forward on the Control Panel and hold
in position.
5. Return the Feed lever to neutral, then connect the test gauge
into the Feed ‘B’ hose, and slowly move the Feed control lever
rearward. Hold in position.
7. Return the Feed lever to neutral, and turn off the power unit.
This completes Feed setting.
6.5.8 System Relief Valve V2

1. Wind the pump cut-off pressure in to maximum.
2. Monitor the circuit pressure gauge on the Control Panel.
3. Disconnect the two hoses going to the Rotation Unit motor and plug
the open ends with 1 1/16” JIC plugs. Cap the motor fittings.
4. Ensure all control levers are in neutral and switch on the power
unit.
5. Move the Rotation control lever on the Control Panel forward and
lock in position.
6. Use a 5 mm Allen key to adjust the primary relief valve setting until
300 bar is achieved on the gauge.
7. Lock the locknut on the valve and reset the pump cut-off to 290 bar.
8. Return the Rotation control lever to neutral, and switch off the
power unit.
This completes setting the system relief valve V2.
112
6.6 Setting Flow Rates
operations.
Chuck
Rod Holder
Dump
Tilt
Rotation ‘B’ Pilot Line Rotation
Wireline ‘B’ Pilot Line Wireline
Feed ‘B’ Pilot Line Feed
Figure 6–5: Main Valve Bank
A hydraulic flow meter capable of measuring flow rates to a maximum of

100 Lpm is necessary to make these adjustments. The Skid Steer rpm
is to be set at 2000.
6.6.1 Rotation Circuit
Possibility of hydraulic oil under pressure — vent hose at the Control

Panel by cycling the Rotation control lever.
Ensure the Skid Steer is switched OFF before attempting these
adjustments.
1. Disconnect the two 3/4” ID hoses going to the Rotation motor at the
motor end. Cap the open connections on the motor.
2. Connect the flow meter to the Rotation motor hoses with the hose
from the Rotation Unit ‘A’ port connected to the inlet of the flow
meter.
3. Ensure the load valve on the flow meter is fully open and the
Drilling/Standby/Rod Handling selector switch on the Control Panel
is in STANDBY.
113
4. Ensure the flow adjustment screw on the end of the Rotation

section is wound fully out, then start the power unit.
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. As the Rotation circuit is fitted with 75 Lpm spools, set the required
flow to 65–70 Lpm in Forward, 20 Lpm in Reverse.
7. Return the Rotation control lever to neutral and turn off the power
unit.
6.6.2 Feed Circuit

Panel by cycling the Feed control lever.
1. Disconnect the two 3/4” ID hoses going to the feed cylinder.

Cap the open connections on the cylinder.
2. Connect the flow meter to the feed cylinder hoses, with the hose
from the Feed ‘A’ port connected to the inlet of the flow meter.
3. Ensure the load valve on the flow meter is fully open and the
Drilling/Standby/Rod Handling selector switch on the Control Panel
is in STANDBY.
4. Ensure the flow adjustment screw on the end of the Feed section is
wound fully out, then start the power unit.
5. Move the Drilling/Standby/Rod Handling selector switch to ROD

HANDLING and the Rod Pulling/Rod feeding selector switch to
ROD PULLING.
6. Slowly move the Carriage control lever on the Control Panel fully
forward and hold in position.
7. As the feed circuit is fitted with a 50 Lpm spool and the required
flow is 50 Lpm, the stops are wound fully out.
8. Return the Feed control lever to neutral and turn off the power unit:
114
6.6.3 Water Pump Circuit
Possibility of hydraulic oil under pressure — carefully disconnect the

hoses.
operations.
1. Disconnect the two hoses going to the hydraulic motor on the water
pump at the pump end. Cap the open connections.
2. Connect the flow meter to the water pump hoses, with the Water
Pump ‘A’ port connected to the inlet of the flowmeter.
3. Ensure the load valve on the flow meter is fully open, the
Drilling/Standby/Rod Handling selector lever on the Control Panel
is in ROD HANDLING, and the Water Pump speed control is
wound fully in.
4. Start the power unit and slowly wind outwards (turn anticlockwise)
the knob on the Water Pump speed control on the Control Panel.
5. The Water Pump circuit is fitted with a flow stop that only allows
15 Lpm through this circuit.
6. Wind in the water pump speed control and turn off the power unit.
6.6.4 Wireline Hoist Circuit
Avoid possible machine damage. Hydraulic hose connections for the

wireline hoist MUST be correctly made so that the counterbalance valve
is metering the oil flow exiting from the hydraulic motor when the hoist is
in the cable out mode.
Panel by cycling the Wireline control lever.
Failure to properly connect the hoses will cause the hoist to overspeed
when lowering the overshot into a deep hole.
1. Disconnect the two hoses going to the Wireline Hoist motor.

Cap the open connections.
2. Connect the flow meter to the Wireline hoses, with hose ‘A’
connected to the inlet of the flowmeter.
3. Ensure the load valve on the flow meter is fully open and all control
levers are in neutral.
4. Start the power unit and slowly move the Wireline lever forward.
115
5. Adjust the forward and reverse flows to 48–50 Lpm.
6. Return the Wireline control lever to neutral and turn off the power
unit.
6.6.5 Dump Circuit
Possibility of hydraulic oil under pressure — vent hose at the Dump Valve
section by cycling the Dump control lever.
1. Disconnect the two hoses going to the Dump Cylinder.

2. Connect the flow meter to the Dump hoses, with hose ‘A’
connected to the inlet of the flowmeter.
4. Start the power unit and slowly move the Dump Cylinder lever
forward. Allow the hoses to purge for 10 minutes.
5. Adjust the forward and reverse flows to 10 Lpm.
6. Return the Dump Cylinder control lever to neutral and turn off the
power unit.
6.6.6 Positioner Tilt Circuit
Possibility of hydraulic oil under pressure — vent hose at the Tilt Valve
section by cycling the Tilt control lever.
1. Disconnect the two hoses going to the Tilt Cylinder.

2. Connect the flow meter to the Tilt hoses, with hose ‘A’ connected to
the inlet of the flowmeter.
4. Start the power unit and slowly move the Tilt lever forward.
5. Adjust the forward and reverse flows to 10 Lpm.
6. Return the Tilt control lever to neutral and turn off the power unit.
116
The SAGE electrical schematics for

the LM30 Skid Steer CE drill rig
are filed behind this title page.
117
118
Contents
8.1 Hydraulic Oils........................................................................................... 125
8.1.1 Hydraulic Oil Hints......................................................................... 125
8.1.2 Oil Selection Chart......................................................................... 125
8.2 Hydraulic Filters....................................................................................... 126
8.2.1 Chuck Filter................................................................................... 126
8.2.2 Skid Steer Filter Elements............................................................. 126
8.2.3 Filter Hints..................................................................................... 127
8.3 BQ Rod Clamp.......................................................................................... 129
8.3.1 Rod Clamp Jaw Replacement....................................................... 130
8.3.2 Rod Clamp Guide Bushing Replacement...................................... 131
8.3.4 Rod Clamp Hydraulic Piston.......................................................... 133
8.4 HQ Mk2 Rod Holder................................................................................. 137
8.4.1 Rod Holder Jaw Replacement....................................................... 138
8.4.2 Rod Holder Guide Bush Replacement.......................................... 139
8.4.4 Rod Holder Hydraulic Piston......................................................... 142
8.5 BQ Rotation Unit and Chuck................................................................... 145
8.5.1 Chuck............................................................................................ 145
8.5.2 Rotation Unit.................................................................................. 145
8.5.5 Guide Bushing Replacement - Front............................................. 148
8.5.6 Guide Bushing Replacement - Rear.............................................. 149
8.5.7 Gear Set Replacement in Rotation Unit........................................ 150
8.5.9 Chuck Disassembly....................................................................... 153
8.5.10 Rotation Unit Disassembly.......................................................... 156
119
Chapter 8: Maintenance8
8.5.11 Rotation Unit Preassembly Checks............................................. 158

8.5.12 Rotation Unit Reassembly........................................................... 160
8.5.14 Break Out Device Operation........................................................ 165
8.5.15 Break Out Device Disassembly................................................... 166
8.6 HQ Mk2 Rotation Unit and Chuck........................................................... 173
8.6.1 Chuck............................................................................................ 173
8.6.2 Rotation Unit.................................................................................. 173
8.6.5 Guide Bush Replacement.............................................................. 176
8.6.6 Oil Seal Replacement.................................................................... 177
8.6.8 Chuck Cylinder Overhauling.......................................................... 186
8.6.9 Breakout Device Servicing............................................................ 190
8.6.10 Breakout Device Operation......................................................... 194
8.6.12 Rotation Unit Maintenance.......................................................... 197
8.7 400 Series (Direct Coupled) Feed Frame............................................... 209
8.7.1 Introduction.................................................................................... 209
8.7.2 Assembling the Feed Frame......................................................... 210
8.7.3 Feed Frame Maintenance............................................................. 210
8.7.4 Adjusting the Carriage................................................................... 212
8.7.5 Replacing the Carriage Wear Strips.............................................. 214
8.7.6 Carriage Side Plate Disassembly.................................................. 216
8.7.7 Removing the Feed Cylinder......................................................... 217
8.7.8 Removing the Cylinder Trunnions................................................. 218
8.7.9 Replacing the Feed Cylinder......................................................... 219
8.7.10 Feed Cylinder Disassembly......................................................... 220
8.7.11 Cylinder Reassembly................................................................... 223
120
8.8 The Power Unit......................................................................................... 225

8.8.1 Introduction.................................................................................... 225
8.8.2 The Main Pump............................................................................. 225
8.8.3 Heat Exchanger............................................................................. 227
8.8.4 SAE/MS Straight Thread Positionable Elbows and Tees ............. 228
8.8.5 Troubleshooting............................................................................. 229
Table of Figures
Figure 8–1: BQ Chuck Filter location............................................................... 126
Figure 8–2: BQ Rod Clamp............................................................................. 129
Figure 8–3: BQ Rod Clamp jaw replacement.................................................. 130
Figure 8–4: BQ Rod Clamp guide bushing replacement................................. 131
Figure 8–5: Hydraulic Rod Clamp Piston assembly........................................ 134
Figure 8–6: HQ Rod Holder for 400 Series Feed Frames............................... 137
Figure 8–7: HQ Rod Holder jaw replacement.................................................. 138
Figure 8–8: HQ Rod Holder guide bush replacement...................................... 139
Figure 8–9: Spring Pack replacement............................................................. 141
Figure 8–10: Loosening and Torquing Sequence............................................ 142
Figure 8–11: Rod Holder Hydraulic Piston...................................................... 143
Figure 8–12: BQ Rotation Unit and Chuck...................................................... 145
Figure 8–14: Chuck Jaw replacement and torquing sequence........................ 147
Figure 8–15: Front Guide Bush replacement................................................... 148
Figure 8–16: Rear Guide Bush replacement................................................... 149
Figure 8–17: Removing the Retaining Sleeve and Guide Bush...................... 150
Figure 8–18: Hydraulic Motor removed........................................................... 150
Figure 8–19: Rear cover removed................................................................... 151
Figure 8–20: Gear replacement on Hydraulic Motor........................................ 152
Figure 8–22: BQ cylinder assembly................................................................. 155
Figure 8–24: Rotation Unit assembly............................................................... 158
Figure 8–25: Main Housing and Rotary Shaft.................................................. 159
121

Figure 8–30: Break Out Device (cross-sectional view).................................... 166
Figure 8–31: HQ Rotation Unit and Chuck...................................................... 173
Figure 8–33: Chuck jaws removed and retightening sequence....................... 175
Figure 8–34: Front Guide Bush removed........................................................ 176
Figure 8–35: Rear Guide Bush removed......................................................... 177
Figure 8–36: Replacing the Rear Oil Seal....................................................... 178
Figure 8–37: Removing Gear Case and Hydraulic Motor ............................... 180
Figure 8–38: Removing Driven Gear, Locknut, Lockwasher, and 4 keys ....... 180
Figure 8–39: Removing Adaptor Plate, O-Ring, and Oil Seal.......................... 181
Figure 8–40: Removing Chuck Retaining Plate............................................... 183
Figure 8–41: Removing Rear Chuck Sub Plate............................................... 183
Figure 8–42: Replacing the Front Oil Seal....................................................... 184
Figure 8–43: Gear Replacement on Hydraulic Motor...................................... 185
Figure 8–44: Removing the Chuck Jaws......................................................... 186
Figure 8–45: Removing the Chuck Cylinders.................................................. 188
Figure 8–46: HQ Chuck assembly — exploded view...................................... 188
Figure 8–47: Torquing Sequence.................................................................... 189
Figure 8–48: Breakout Device oil seals........................................................... 190
Figure 8–50: Removing Gear Housing and O-Ring......................................... 198
Figure 8–51: Exploded view of main housing components............................. 198
Figure 8–52: Main Housing oil groove............................................................. 199
Figure 8–55: Chuck Retaining Plate and Spindle ‘O’-rings.............................. 202
Figure 8–57: 400 Series Feed Frame.............................................................. 209
Figure 8–58: Fit and tighten the four M12 bolts............................................... 210
Figure 8–59: Direct Coupled Feed Frame — working position........................ 210
122
Figure 8–60: Feed Frame service and maintenance points............................ 211

Figure 8–61: Loosen in two places on each side............................................. 212
Figure 8–62: Feed Cylinder hex. nut............................................................... 212
Figure 8–63: Adjusting the Carriage slides...................................................... 213
Figure 8–64: Carriage Assembly..................................................................... 214
Figure 8–65: Tighten nine M10 bolts to 44 Nm (30 lbft) torque....................... 215
Figure 8–66: Carriage Side Plate disassembly................................................ 216
Figure 8–67: Feed cylinder removal................................................................ 217
Figure 8–68: Removing the Cylinder Trunnions.............................................. 218
Figure 8–69: Feed cylinder disassembly......................................................... 220
Figure 8–70: Piston rod assembly................................................................... 222
Figure 8–71: Rod end gland and End cap gland............................................. 223
Figure 8–72: The LM30 Skid Steer Power Unit............................................... 225
Figure 8–73: Main Pump pressure setting....................................................... 226
Figure 8–74: Heat Exchanger location and hose connections........................ 227
Figure 8–75: Elbow fitting components............................................................ 228
Figure 8–76: Elbow installation........................................................................ 228
Figure 8–77: Elbow tightening......................................................................... 229
123
124
Chapter 8: Maintenance – Hydraulic Oils
8.1 Hydraulic Oils

8.1.1 Hydraulic Oil Hints
Always wear the correct Personal Protection Equipment and tools when
handling hydraulic fluid.
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.
Regularly check all hoses, fittings, drain plugs etc. for indications of oil
leakage. Correct as required.
Keep hydraulic oil clean. Use oil from unopened 20 litre containers and
dispose of any half-filled drums.
8.1.2 Oil Selection Chart
CAT® HYDOTM Advanced 10 is used extensively in the Skid Steer hydraulic

system.
If a different oil is required contact your local Boart Longyear
representative or the local CATERPILLAR office and request details of a
suitable replacement.
If this recommendation is not followed it may void the CAT equipment
warranty.
OIL TANK CAPACITIES and LUBRICANT TYPES

TANK CAPACITY LUBRICANT TYPE
CAT246C SKID STEER
HYDRAULIC SYSTEM 57 L (15 US gallon) CAT HYDO Advanced 10
HYDRAULIC TANK 42 L (11 US gallon)
BQ ROTATION UNIT 1.0 L (1/4 US gallon) MOBILGEAR SHC 320
(or equivalent)
HQ Mk2 ROTATION 0.6 L (1/7 US gallon) MOBILGEAR SHC 320
UNIT (or equivalent)
712 WATER PUMP 1.8 L (61 Fluid Ounces) SAE 30W
125
Chapter 8: Maintenance – Hydraulic Filters
8.2 Hydraulic Filters
Always wear correct Personal Protective Equipment and use the correct
tools when replacing filter elements.
8.2.1 Chuck Filter

10 micron beta-rated filter with clogging indicator mounted on Rotation
Unit.
Longyear Part Number: 56156
Vendor Part Number: HYDAC 060D010BNHC
Figure 8–1: BQ Chuck Filter location
8.2.2 Skid Steer Filter Elements
Element Action
a. Fuel System Filter and Water Separator Element

Boart Longyear Part No.: 3070387 Replace every 500 hours
b. Engine Oil Filter
c. Air Cleaner Element (Primary Filter)
Boart Longyear Part No.: 3070382 Check daily
(Secondary Filter)
Boart Longyear Part No.: 3070383 Check daily
d. Hydraulic Filter
126
e. Filter Assembly Breather Hydraulic

f. Hydraulic Oil Replace every 2000 hours
Refer to the CAT Skid Steer Operators Manual for a detailed

description of the Engine Maintenance System.
8.2.3 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 at 500 hr

intervals, whichever occurs first. All elements are of non-washable type
and must be discarded and replaced with new ones each time the filters
are serviced.
8.2.3.1 Filter Indicators

Hydraulic filters are often fitted with indicators to show when the filters
become blocked:
●● some filters progressively change colour
●● others include “pop-up” buttons (or other visual indicators).
In the first instance, filters with colour change indicator will usually
display a predominant green band when the element is new, which
slowly turns to red as the filter starts to block. The element must be
replaced when the colour of the band turns completely red.
In the second instance, filters with pop-up indicators will initially appear
normal, but when the filter becomes blocked a pop-up/visual indicator is
immediately apparent. The element must be replaced when the indicator
has “popped”.
127
128
Chapter 8: Maintenance – BQ Rod Clamp
8.3 BQ Rod Clamp
DO NOT reuse worn rod holder components when carrying out repairs
and general service work.
DO NOT use an LM drill with missing or badly worn rod holder guide
bushes that allow the drill rods to rotate against the inner slide.
DO NOT attempt to weld or repair worn or cracked sections on the inner
slide — replace the damaged item with a new part.
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. It
has two jaws which are held in the gripping position by a spring pack.
Hydraulic pressure is required to open the jaws, and both jaws retract
radially away from the rod to a position where both jaws are protected
from contact with the rod by means of two guide bushings.
The Outer Sleeve of the Rod Clamp is reversible for extended life. An
assembly tool is available which enables the spring pack to be easily
serviced.
The Rod Clamp will allow the passage of all reamer shell sizes up to
and including BQ.
8.3.3.1 Rod Clamp Specifications

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)
Figure 8–2: BQ Rod Clamp
129
8.3.1 Rod Clamp Jaw Replacement
Beware of potential hazard when removing the inner slide due to an

unbalanced load (29 Kg).
Use correct lifting equipment and Personal Protective Equipment for this
application.
Beware of pinch point hazards when removing the inner slide assembly.
1. Remove the two spring clips and withdraw the pins.
2. Remove the inner slide assembly from the outer face clamp. Wear
strips may fall out if they are not held as the inner slide assembly is
being withdrawn.
3. Slide rod clamp jaws out of wear strip opening.
Figure 8–3: BQ Rod Clamp jaw replacement
8.3.1.1 Reassembly
Use the correct Personal Protective Equipment when handling and using
cleaning fluids.
Use the correct lifting equipment for this operation, and beware of pinch
point hazards when reassembling..
130
4. Inspect assembly and ensure the tee bolt is tight.
5. Clean and lightly grease all sliding surfaces.
6. Slide in new jaws so the slot engages the tee bolts.
7. Smear grease on wear strips, hold in position and slide inner slide
assembly into the outer sleeve.
The Outer Sleeve is reversible for extended use.
8.3.2 Rod Clamp Guide Bushing Replacement
application.
The front and rear guide bushings can be replaced on the Rod Clamp
without removing the assembly from the Feed Frame.
1. Remove the four socket capscrews from the guide bushing clamp
using a 6 mm Allen key.
2. Remove the guide bushing clamp, then the guide bushing.
Figure 8–4: BQ Rod Clamp guide bushing replacement
8.3.2.1 Reassembly
3. Insert guide bushing into the recess with the longer sleeve side
facing outward.
4. Place guide bushing clamp in position and retain with the four
socket capscrews.
131
8.3.3 Spring Pack Replacement
Beware of potential hazard due to oil under pressure — bleed off slowly.
Potential hazard when removing inner slide due to unbalanced load
(29 Kg) — use correct lifting equipment.
1. Disconnect the hydraulic hose to the Rod Clamp at the JIC fitting.
Use caps to cover ends.
2. Remove the spring pins from the retaining pins and withdraw them.
3. Slide the Rod Clamp inner slide assembly from the outer Clamp
housing.
4. Insert the Spring Pack assembly tool into the guide sleeve and
tighten firmly. Alternatively, a hydraulic press can be used in place
of the Spring Pack assembly tool to retain spring tension.
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.
Beware of potential pinch point hazard when removing inner slide

assembly and springs — spring pack under load.
application.
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 plate, and plug.
8. Slide all of the components from the guide sleeve.

Clean and inspect them for wear and damage.
9. Check rear of the cylinder for signs of oil leakage or damage to the
circlip. Refer to the Rod Clamp Hydraulic Piston section if leaks are
found.
If one or more of the disc springs are broken, all of the springs
must be replaced.
132
8.3.3.1 Reassembly
Potential hazard — spring pack under load.

Beware of potential pinch point hazards when refitting springs, and
between the inner and outer slide assembly.
application.
10. Stand the guide sleeve upright with the disc spring actuating plate
in position at the bottom.
11. Cover the disc springs individually with liberal amounts of

Molybdenum Disulphide grease.
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.
13. Insert the Spring Pack assembly tool into guide sleeve and tighten
until 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 assemble, ensuring that the two jaw wear strips are correctly
positioned.
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.
8.3.4 Rod Clamp Hydraulic Piston
Circlip may come off pliers when compressed — cover when removing.
Use the correct Personal Protective Equipment when cleaning.
Use the correct tools for this operation.
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.
133
3. Withdraw the Piston in the same direction as the circlip.
4. Using a suitable tool, remove the piston rod seal and rod wiper
located in the cylinder housing and the piston seal located in the
Piston.
5. Clean all parts and replace any worn or damaged items.
8.3.4.1 Reassembly
Potential hazard — spring pack under load.

Circlip may come off pliers when compressed — cover when fitting.
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, and check that all seals are correctly seated and that
none are damaged.
10. Lubricate the piston rod and the cylinder bore with clean hydraulic
fluid and then gently feed the Piston into the cylinder.
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.
Figure 8–5: Hydraulic Rod Clamp Piston assembly
134
8.3.5 Rod Holder Troubleshooting
Refer to Input/Output test charts in Chapter 10 for the required lights that
should be ON.
Whenever troubleshooting the Rod Holder, always remember that the

operation requires hydraulic pressure to open the Rod Holder and
spring tension to close it.
1. If the Rod Holder will not grip the rods properly, check for:
○○ Worn jaw bodies and/or worn Tungsten Carbide jaw inserts.
○○ Broken spring(s) in spring pack.
○○ Inner slide assembly seized into outer housing.
○○ Worn drill rods.
○○ Incorrect number of springs in spring pack.
○○ Spring orientation incorrect in spring pack.
2. If Rod Holder fails to open, check for:

○○ Air in Rod Holder hose.
○○ Rod Holder solenoid valve not energised.
○○ Rod Holder solenoid valve or cable/connector faulty.
○○ Low hydraulic pressure in rod holder circuit.
Pressure should be 140 bar when the Rod Holder solenoid is
energised.
135
136
Chapter 8: Maintenance – HQ Mk2 Rod Holder
8.4 HQ Mk2 Rod Holder
DO NOT reuse worn rod holder components when carrying out repairs
and general service work.
DO NOT use an LM drill with missing or badly worn rod holder guide
bushes that will allow the drill rods to rotate against the inner slide
DO NOT attempt to weld or repair worn or cracked sections on the inner
slide. Replace the damaged item with a new part.
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, both jaws move radially away from the drill rod to a
position where the jaws are protected from touching the drill rod by the
guide bushings.
It is therefore important that the guide bushes are always in good

condition to maintain optimum rod holder jaw life. Continuing to use the
drill with worn bushes will cause premature wear of the gripper points in
the jaws, and result in the rod holder slipping when rod handling.
Weight: Rod Holder 50 Kg (without brackets)
Retaining ring
on spring cap
Wiper to prevent Increased thickness Outer sleeve
contamination ingress of side plates
Larger diameter
piston
Figure 8–6: HQ Rod Holder for 400 Series Feed Frames
The Rod Holder can be readily serviced in the field and this is made
easier 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 be taken when servicing this component.
137
8.4.1 Rod Holder Jaw Replacement
Beware of potential hazard when removing inner slide due to unbalanced

load (50 Kg).
Use the correct Personal Protective Equipment for this application.
Beware of Pinch Points when removing inner slide assembly.
1. Remove the two R clips and withdraw the pins.
2. Remove the inner slide assembly from the rod holder bracket
using appropriate lifting device. Hold the wear strips in place as the
inner slide assembly is withdrawn to prevent them dropping out of
position.
3. Slide the two jaws out of the recess in the inner slide.
The jaws can only be removed from one side only, depending on
the orientation of the tee slot in the back of the jaw.
Figure 8–7: HQ Rod Holder jaw replacement
8.4.1.1 Reassembly
Beware of Pinch Points when reassembling.
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.
138
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.
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 the chuck, then refit the two pins and R clips.
6. Using a grease gun, apply clean EP grease to both the top and
bottom grease nipples.
8.4.2 Rod Holder Guide Bush Replacement
Use the correct tools and Personal Protective Equipment for this
application.
Both guide bushes can be replaced without needing to remove the inner
slide assembly from the rod holder.
1. Use a 6 mm Allen key to remove the four socket head capscrews

from the guide bush retaining clamp, then remove the clamp from
its location.
2. Remove the first guide bush from its location, then the remaining
guide bush in the same way.
8.4.2.1 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.
Figure 8–8: HQ Rod Holder guide bush replacement

139
8.4.3 Spring Pack Replacement
Beware of potential hazard when removing the disc spring housing —

springs under load.
Beware of potential hazard due to oil under pressure. Bleed off slowly.
Beware of potential hazard when removing inner slide due to unbalanced
load (50 Kg).
Beware of potential Pinch Hazard when removing springs and the inner
slide assembly. If one or more of the disc springs are broken, all 30 of the
springs should be replaced.
Use the correct tools and Personal Protective Equipment and tools for
this application.
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 springs in the rod holder have fatigued excessively
and must be replaced. The rod holder contains 30 springs and it is
recommended that all springs are replaced at the same time to prevent
recurrent failure.
1. Disconnect the hydraulic hose going to the rod holder. Plug the end
of the hose and cap the open fitting on the rod holder connection.
2. Remove an R clip from each of the pins and remove the two pins
from the rod holder.
3. Carefully withdraw the inner slide assembly from the rod holder
bracket and relocate it to a work bench where it can be worked on.
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 retaining flange.
The bolts should be removed in the sequence as shown in the
Loosening and Torquing Sequence diagram on the next page.
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.
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.
140
Figure 8–9: Spring Pack replacement
8.4.3.1 Reassembly
Potential Hazard — spring pack under load.

Beware of potential pinch hazard when refitting springs, and between the
inner and outer slide assembly.
application.
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.
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 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.
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.
141
During reassembly, beware of pinch hazard between inner and

outer slide assembly.
9. Fit the two retaining pins through the holes in the bracket and
secure with the R clips.
10. Using a grease gun, apply clean EP grease to both the top and
bottom grease nipples.
Figure 8–10: Loosening and Torquing Sequence
8.4.4 Rod Holder Hydraulic Piston
Circlip may come off pliers when compressed. Cover when removing.
operation, especially when cleaning.
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.
3. Remove the piston by pushing on it from the jaw end.
4. Using a small lever, prise the two seal out of location in the
cylinder. Likewise remove the seal from the outside of the piston.
5. Clean and inspect all parts. Replace any worn or damaged items.
142
Figure 8–11: Rod Holder Hydraulic Piston
8.4.4.1 Reassembly
When following this reassembly procedure, ensure that the hands and
face are kept well clear.
Oil under pressure. Open bleed screw slowly.
Circlip may come off pliers when compressed. Cover when fitting.
1. Dip all new seals in clean hydraulic oil prior to installation.
2. Fit the rod wiper into the cylinder housing with the lip facing the jaw
end. 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.
7. Reassemble the spring pack to the cylinder assembly following the

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 the rod holder cylinder.
143
8.4.5 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 the rods properly Check for:
●● 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.
144
Chapter 8: Maintenance – BQ Rotation Unit and Chuck
8.5 BQ Rotation Unit and Chuck

8.5.1 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.
8.5.1.1 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)
8.5.2 Rotation Unit
Figure 8–12: BQ Rotation Unit and Chuck
The Rotation Unit is fitted with a variable displacement hydraulic motor

that drives a hollow spindle via a helical reduction gear set. The gears
are contained in a separate gear case and are lubricated by an 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.
145
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)
8.5.3 Gearbox Lubrication and Maintenance

Drain waste oil into a suitable container and dispose of it in an
1. Stop motor before checking or adding oil.
2. Clean around the oil filler before removing to add oil.
3. It is recommended that the lubricating oil be changed after the first

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.
1–Oil fill/breather 2–Oil level sight glass 3–Drain plug
Figure 8–13: Gearbox Service locations
4. Drain oil while the unit is still warm, examining for contamination or
metal particles.
146
5. Fill with the recommended lubricant.

Use only clean oil that has been stored in clean containers.
6. Do not overfill. This will result in overheating and possible

malfunction of the unit.
For information about the correct oil type and tank capacity
refer to the Oil Selection Chart at the beginning of this chapter.
8.5.4 Chuck Jaw Replacement
operation.
Note: The guide bush and guide bush retaining plate do not need to be
removed unless different sized jaws are being fitted.
1. Remove the three hex. head bolts (M8 x 1.25 x 25 mm long) from
the chuck hood using a 13 mm spanner and remove the hood.
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.
Figure 8–14: Chuck Jaw replacement and torquing sequence
147
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.
5. Tighten all bolts to 22 Nm (16 ft lb) torque.
8.5.5 Guide Bushing Replacement - Front
operation.
1. Remove the three socket head setscrews on the guide bushing

retaining plate using a 6 mm Allen key and remove.
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.
Figure 8–15: Front Guide Bush replacement
148
8.5.6 Guide Bushing Replacement - Rear
operation.
1. Remove the four socket head capscrews on the guide bush

retaining plate using a 6 mm Allen key and remove.
2. Remove the guide bushing.
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 four socket head capscrews.
Tapered sleeve
Guide bush
Bush retaining plate
Figure 8–16: Rear Guide Bush replacement
149
8.5.7 Gear Set Replacement in Rotation Unit

Possible crush hazard when removing the motor — use correct lifting
equipment.
operation.
1. Drain the oil from the gear case.
2. Using a 6 mm Allen key, remove the three socket head setscrews

that retain the guide bushing retaining sleeve. Remove the sleeve
assembly.
Retaining sleeve
Guide bush assembly
Figure 8–17: Removing the Retaining Sleeve and Guide Bush
3. Loosen the hose fittings on the motor manifold and undo the hoses
completely at the Rotation Unit.
Figure 8–18: Hydraulic Motor removed
150
4. Using a 19 mm spanner, remove the four bolts that hold the

hydraulic motor to the gear case and remove the motor and gear
attached to the shaft.
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.
Figure 8–19: Rear cover removed
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 that fit into the shaft.
Ensure the oil seal that fits onto the gear is not worn or damaged.
Ensure the ‘O’ ring under the gear is not damaged.
Replace components if necessary.
Reassembly
Possible crush hazard when refitting the motor — use correct lifting
equipment.
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.
151
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.
8. Refit the guide bushing retaining sleeve and tighten the three
socket head setscrews.
9. Refill the gear case with the recommended gear oil.

8.5.8 Gear Replacement on Hydraulic Motor
operation.
1. Using a 19 mm spanner, remove the bolt, washer, and safety

washer off the motor shaft .
2. The Gear can be withdrawn by hand off the motor shaft spline.
Reassembly
1. Press the drive gear onto motor shaft spline by hand.
2. Fit retaining washer, safety washer, and bolt. Use Locktite 242
(or similar) and tighten to 77 Nm (57 lb).
Figure 8–20: Gear replacement on Hydraulic Motor
152
8.5.9 Chuck Disassembly
operation.
Possible crush hazard when removing Chuck from Rotation Unit — use
the correct lifting equipment.
Take care to retain the three ‘O’ rings on the rear of the chuck plate.
1. Undo the three hex. head bolts which fasten the chuck hood to the
Chuck and remove the hood.
2. Undo the remaining nine hex. head bolts in the front retaining
plate and 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 are located between each chuck cylinder. The Chuck is
now free to be removed from the Rotation Unit.
5. Each of the three cylinder assemblies are held to the rear subplate
by four socket head capscrews.
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.
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
Figure 8–21: BQ Chuck assembly
153
8.5.9.1 Cylinder Disassembly
Compression hazard from cir-clip — cover when removing.

Compression hazard from chuck springs — slowly release press.
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 release the press.
4. The piston, return springs and end cap are now able to be removed
from the cylinder body. The piston may be removed by holding the
cylinder body with piston end facing down and tap the back of the
cylinder body with a soft hammer.
8.5.9.2 Cylinder Reassembly
Compression hazard from cir-clip — cover when fitting.

Compression hazard from chuck springs.
Ensure that the cir-clip is fitted with the tangs located under the high side
of the cylinder body.
operation.
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 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.
154
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 the end cap down until a new cir-clip can be placed in the
groove. Release the press.
Figure 8–22: BQ cylinder assembly
8.5.9.3 Chuck Reassembly
Possible crush hazard when refitting Chuck to Rotation Unit — use the
correct lifting equipment.
operation.
1. Fit a new ‘O’ ring into the chuck subplate ‘O’ ring groove of each
cylinder body and hold in place with grease.
Fit the three chuck cylinders individually into position. Replace 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.
5. Fit the nine socket head capscrews and tighten them uniformly.
Torque to 45 Nm (33 ft lb).
6. Check that the chuck jaws slide freely in the chuck jaw recesses.
155
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
Figure 8–23: BQ Chuck assembly
8.5.10 Rotation Unit Disassembly
Beware of potential hazard when removing the Rotation Unit due to its
weight — use the correct lifting equipment.
Before disassembly clean all external surfaces of the Rotation Unit.
Potential crush hazard when removing the Motor and Chuck from
Rotation Unit due to their weight — use the correct lifting equipment.
When handling the rotary seal components and the main spindle use
extreme care so as not to damage the sealing surfaces.
operation, especially when handling cleaning fluids.
1. Clean the hose fittings where they join to the Rotation Unit fittings.
2. Disconnect rotation ports A and B hoses and fit the correct plugs
and caps to hoses and fittings.
3. Disconnect the BOD, drain and chuck lines and fit the correct plugs
and caps to the hoses and fittings.
156
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 from the carriage.
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 unit body at the rotation unit end.
11. Undo the four hex. head bolts retaining the hydraulic motor to the
gear case end cover and remove the hydraulic motor.
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 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 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.
157
20. Remove the front end oil seal cir-clip. The front end oil seal and
bearing can now be pressed out of the housing.
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 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.
Rear gear cover
Gear housing
Adapter plate
Main housing Rotation Unit

driven gear
Keys
Intermediate seal
Figure 8–24: Rotation Unit assembly
8.5.11 Rotation Unit Preassembly Checks
operation.
Compression Hazard from cir-clip — cover when refitting.
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.
158
Ensure that this groove has no sharp edges which may damage the
‘O’ ring during assembly.
Rotary shaft
Main housing
Figure 8–25: Main Housing and Rotary Shaft
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 seal is free to move laterally in the main housing.
Figure 8–26: Main Housing rotary seal and cir-clip
159
8.5.12 Rotation Unit Reassembly
operation, especially when working with compressed air.
Possible falling hazard due to gearbox weight and shape.
Compression hazard from cir-clip — cover when refitting.
IMPORTANT: Be careful that the ‘O’ rings do not get pinched on the cir-
clip groove.
Possible crush hazard when refitting the motor, when refitting the Chuck
to the Rotation Unit, and when refitting the Rotation Unit to the Carriage
— use the correct lifting equipment.
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.
2. Dip the ‘O’ rings and back-up washers in clean hydraulic oil and fit
them to the rotary seal as shown in the diagram.
Figure 8–27: Rotary Seal ‘O’-rings and back-up washers
3. Stand the Rotation Unit main body on its front bearing end.
4. Smear the inside bore of the main housing with hydraulic fluid then
carefully push the rotary seal assembly into place.
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.
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.
160
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).
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.
17. Press the rear oil seal into the end cover.
18. Apply sealant to the mating faces and attach the end cover to the
rear 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 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 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.
161
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.
30. Fit the nine socket head capscrews and tighten them uniformly.
Torque to 45 Nm (33 ft lb).
Check 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 the recommended gear oil.
35. Refit the Rotation Unit to the Drill.
8.5.13 Rotation Unit Rotary Seal Test

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.
162
8.5.13.1 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 (approx. 20 litre capacity) graduated in one
litre increments.
●● a magnetic thermometer to 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.)
●● a stop watch (or wrist watch) to time the one minute testing cycle.
8.5.13.2 Important Note For Rotary Seal
Potential crush hazard between the Chuck and the Carriage when head
rotating slowly — keep hands clear at all times.
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.
3. Allow the oil to circulate for at least five 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.
8.5.13.3 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.
Ensure that the hydraulic reservoir is filled with an oil grade suitable for
the operating ambient temperature.
IMPORTANT: Refer to the Oil Selection Chart at the start of this

chapter.
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.)
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8.5.13.4 Testing Method
1. Ensure that the Control Panel valves are in the following position
and start the Skid Steer.
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 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. Switch the Drilling/Standby/Rod Handling selector to DRILLING.

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.
164
This completes the Rotation Unit Rotary Seal test.
Figure 8–28: Rotary seal testing
8.5.14 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.
6 5
3
1
1–Rack engaging connection 5–Rotation speed poppet

2–Rack pressure connection 6–Sequence valve
3–Chuck pressure connection 7–Inspection plug
4–Rack return (pilot) connection
Figure 8–29: BOD Nomenclature
165
8.5.15 Break Out Device Disassembly
1. Follow steps 1 through 7 in the ‘Gear Set Replacement’ section

starting on page 8-40 to remove the rear cover.
2. Loosen and remove the two hex. head plugs located at the ends of
the 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 sliding surfaces of the pistons.
Figure 8–30: Break Out Device (cross-sectional view)
IMPORTANT: Ensure the main and return piston are correctly

installed.
166
The rack gear must be installed with tooth orientation in line with
the driven gear and a large, flat surface against the return cylinder.
Also ensure the ‘Tee’ fitting connected to the main piston has a
0.8 mm orifice.
Reassembly
Reassembly of the break out device is performed in a reversal of its

disassembly.
It is recommended that new ‘O’ rings and seals are used in all locations
and that a liberal amount of clean hydraulic oil is used to lubricate the
‘O’ rings and also on all sliding surfaces.
8.5.16 Setting Sequence Valve Pressure
Hose may ‘kick’ when sequence valve opens — hold hose firmly and
point open end into a bucket.
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 open ‘T’ fitting.
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 will increase the pressure on the circuit pressure
gauge. Oil will flow from the hose when the sequence valve ‘F’
opens. Adjust to the setting as specified in the table below.
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.
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.
167
8.5.16.1 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.
8.5.16.2 Break Out Device Specification Table

Rotation Unit Type
Component HQ55/75 H/T HQ45/55/75 BQ45
Main Piston Length (mm) 123 129 113

Return Piston (mm) 117 117 113
Sequence Valve Setting (bar) 220–230
Reverse Rotation Pressure (bar) * 130–150
Orifice Tee Piece (mm) 0.8
Orifice Poppet Size (mm) 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.
168
8.5.17 Rotation Unit Troubleshooting
Use the correct Personal Protective Equipment at all times.

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. 1 Adjust pressure in the chuck circuit if necessary.
Should read 70 bar whilst drilling. 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 capacity 1 Break joint with stillson — do not overtorque joints
of drill. on make up of threads.
2 Rod joints tightening up down the hole due to 2 Break joint with stillson — take steps to condition
vibration. the hole or alter drilling parameters to reduce
vibration.
3. Break Out Device not functioning correctly. 3. Perform checks shown on previous page.
Hydraulic Fault
1 Refer to Pressure Checking Table in Chapter 9. 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 assembly. 2 Disassemble the cylinder assembly and if one 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 a 4 Replace the chuck filter element.
clogged chuck filter.
169
Symptom Action
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.
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 excessively 2 Replace the driven gear.
worn.
3 O-ring on front face of driven gear missing or 3 Fit a new O-ring to driven gear and hold it in
damaged. position with a smear of grease when reinstalling
gear on the shaft.
4 Hydraulic motor leaking oil through front shaft seal. 4 Remove and repair the motor.
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 be Condition hole to reduce torque and vibration, or
indicated by a circuit pressure of 240–250 bar as slow drilling speed, if necessary.
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 circuit outwards using a 3 mm Allen key.
pressure of less than 240 bar as the RPM starts The adjustment is very sensitive.
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 the
incorrectly set for operating conditions. speed control valve.
170
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 of inwards using a 3 mm Allen key.
285 bar as the Chuck stalls. The adjustment is very sensitive.
There will be no steady decrease in RPM, rather Test the drilling function and note the circuit
the Chuck will go from max. RPM to stall. pressure at which the RPM starts to fall as the drill
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 when
indicated by difficulty in maintaining full drilling under load. This should be no more than five
circuit pressure when the oil is warm. 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.
171
172
Chapter 8: Maintenance – HQ Mk2 Rotation Unit and Chuck
8.6 HQ Mk2 Rotation Unit and Chuck

8.6.1 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.
8.6.2 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 an 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.
Weight: Rotation Unit and Chuck: 235 Kg
Figure 8–31: HQ Rotation Unit and Chuck
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.
173
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.
8.6.3 Gearbox Lubrication and Maintenance
●● Stop motor before checking or adding oil.

●● Clean around the oil filler before removing to add oil.
●● It is recommended that the lubricating oil be changed after the first
100 hours of service.
●● Thereafter, 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.
●● Fill with the recommended lubricant.
●● Use only clean oil which has been stored in clean containers.
●● Do not overfill. This will result in overheating and possible
malfunction of the unit.
1–Oil fill/breather 2–Oil level sight glass 3–Drain plug.

Figure 8–32: Gearbox Service locations
174
8.6.4 Chuck Jaw Replacement
8.6.4.1 Chuck Jaw Removal

Note: The guide bush and guide bush retaining plate do not need to be
removed unless different size jaws are being fitted. See below.
1. Remove the 12 socket head cap-screws (M10 x 1.5 x 55 lg) from

the front of the chuck using an 8 mm Allen key and remove the
front retaining plate.
2. Slide the 3 chuck jaws from their recesses in the Chuck.
Reassembly
operation.
IMPORTANT: If the chucks and jaws are incorrectly fitted, resultant

damage will occur to both parts in operation.
1. Clean and lightly grease all moving surfaces.
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 capscrews to a torque of 90 Nm (66 ft lb).
Figure 8–33: Chuck jaws removed and retightening sequence
175
8.6.5 Guide Bush Replacement
8.6.5.1 Front Guide Bush
operation.
1. Remove the 4 socket head capscrews (M8 x 1.25 x 25 lg) on the

guide bush retaining plate using a 6 mm Allen key and remove.
2. Remove the guide bush.
Figure 8–34: Front Guide Bush removed
8.6.5.2 Rear Guide Bush
operation.
1. Remove the four M8 socket head capscrews in the guide bush

retaining plate and then remove the plate.
2. Prise the guide bush retaining sleeve from the spindle which should
also release the guide bush.
3. Remove the guide bush from the retaining sleeve.
4. If changing to a different size guide bush, also remove the tapered

sleeve which is located in the inside end of the spindle.
176
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.
Note: A tapered sleeve is not used when bushings for HQ size rods are
installed.
Figure 8–35: 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.
8.6.6 Oil Seal Replacement
8.6.6.1 Rear Oil Seal Replacement
operation, especially when handling lubricants and removing the guide
bush.
177
1. Drain the oil from the gearbox by removing the most convenient
drain plug. If the rotation unit is horizontal this will be the bottom
plug.

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.
Figure 8–36: Replacing the Rear Oil Seal
Reassembly
operation, especially when handling lubricants.
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.
3. Apply silicone gasket cement to the flange on the seal housing and
its mating face on the gearbox.
178
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 the sleeve. Place this assembly into the end of the rotation unit
spindle.
9. Refill the gearbox the recommended gear oil.

8.6.6.2 Intermediate Oil Seal
operation.
Oil under pressure — undo slowly, and dispose of spent oil in an
Possible crush injury when removing motor — use the correct lifting
equipment.
drain plug.

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:
○○ lower breakout device connection
○○ upper breakout device connection
○○ chuck drain on top of gearbox
○○ chuck filter.
179
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 to one side.
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. 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. Use gear puller p/n 59484 withdraw the gear from the shaft.
Do not lose the four keys which fit into the shaft.
Figure 8–37: Removing Gear Case and Hydraulic Motor
Figure 8–38: Removing Driven Gear, Locknut, Lockwasher,

and 4 keys
180
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.
Figure 8–39: Removing Adaptor Plate, O-Ring, and Oil Seal
Reassembly
operation.
Lift motor into place using the correct lifting equipment.
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 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.
181
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. Refit the four M10 hexagon head bolts and tighten
securely.
13. Reconnect the hydraulic hoses to their correct position on the

rotation unit.
15. If necessary, fit a new tapered sleeve into the end of the spindle.
spindle.
18. Refill the gearbox using the recommended gear oil.

19. If applicable, reassemble the tacho proximity sensor into location
on the rotation unit.
182
8.6.6.3 Front Oil Seal Replacement
Potential crush injury between chuck and carriage when removing chuck
— use correct lifting equipment.
Circlip under compression — cover when removing.
1. Remove the twelve socket head capscrews on the chuck front

retaining plate. Remove the plate together with the guide bushing.
Figure 8–40: Removing Chuck Retaining Plate
2. Slide out the three chuck jaws, then slide off the chuck hood.
3. Remove the six M12 socket head capscrews that attach the rear
chuck sub plate to the spindle retaining plate and carefully remove
the chuck.
Figure 8–41: Removing Rear Chuck Sub Plate
183
4. Undo and remove the twelve M10 socket head capscrews holding
the retaining plate to the spindle and remove the plate.
5. Remove the circlip from its groove in the rotation unit housing.
6. The front oil seal is now free to be levered out of its location in the
housing.
Reassembly
Compression hazard from circlip — cover until seated in its groove.

Potential crush hazard between chuck and carriage — use correct lifting
equipment when reassembling chuck onto rotation unit.
1. Before fitting a new front oil seal ensure that the oil seal spacer is in
location in the housing against the front bearing.
Figure 8–42: Replacing the Front Oil Seal
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.
5. Carefully inspect the condition of the O-ring and backup ring

located in the bore of the spindle retaining plate. If necessary
renew these items.
184
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 capscrews are fitted.
10. Fit the six M12 socket head capscrews and tighten these uniformly
to 160Nm (118 ft/lb).
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).
8.6.7 Gear Replacement on Hydraulic Motor
Figure 8–43: 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.
185
Reassembly
1. Press drive gear onto motor shaft by hand, with the machined area
on the gear for the special retaining washer facing out.
2. Fit retaining washer, safety washer and bolt. Use ‘Loctite 242’ (or
similar) and tighten to 77 Nm (57 lb).
8.6.8 Chuck Cylinder Overhauling
8.6.8.1 Chuck Removal and Disassembly
Potential crush hazard when removing chuck from rotation unit — use
correct lifting equipment for this operation.
Take care to retain the three small O-rings on the rear of the chuck plate.
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, then slide off the chuck hood.
3. 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.
The three cylinder assemblies are held to the rear sub plate by four
socket head capscrews each.
4. Undo the screws and remove the cylinder assemblies.
5. Locate and retain in a safe place the three small O-rings from the
front face of the rear sub-plate.
Figure 8–44: Removing the Chuck Jaws
186
8.6.8.2 Chuck Cylinder Disassembly
Use correct Personal Protective Equipment and tooling for this operation.
Note: The piston may be removed by holding the cylinder body with piston end
facing down and tap the back of the cylinder body with a soft hammer.
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 release the press.
4. The piston, return springs and end cap are now able to be removed
from the cylinder body.
8.6.8.3 Inspection and Replacement of Parts
Compression hazard from cir-clip— cover when removing.
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 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
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
Compression hazard from cir-clip — cover when fitting.
187
1. Position the piston evenly into the cylinder bore and, using a
suitable mandril, press the piston into the cylinder bore.
2. Apply liberal amounts of Molybdenum Disulphide grease to the

return springs and position them around the piston.
3. Replace the end cap into the cylinder assembly.
4. Place the assembly under a press.

Using a suitable mandril, press the end cap down until a new
cir-clip can be placed in the groove, then release the press.
It is important that the cir-clip is installed so that the tangs are
located under the high side of the cylinder body.
Figure 8–45: Removing the Chuck Cylinders
Figure 8–46: HQ Chuck assembly — exploded view
188
8.6.8.4 Chuck Reassembly
Potential crush hazard between chuck and carriage when refitting — use
correct Personal Protective and lifting equipment.
IMPORTANT: Ensure that the tee-slots in the back of the jaws are properly
aligned with the tee bolts in the chuck cylinders.
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 to dislodge the O-rings, position the Chuck into
the plate attached to the main shaft.
Fit the six socket head capscrews and torque to 160 Nm (118 ft lb).
3. Slide the chuck hood into place. A smear of grease inside the
chuck hood will help it to pass over the O-rings.
4. Grease the sides of the three chuck jaws and slide into position in
the chuck.
5. Refit the front retaining plate and torque the twelve socket head
capscrews to 90 Nm (66 ft lb).
Figure 8–47: Torquing Sequence
189
8.6.9 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 service work that requires removal of the rear cover is when the
rack gear needs inspection and replacement.
8.6.9.1 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.
Figure 8–48: Breakout Device oil seals
190
Inspection and reassembly
1. Carefully inspect both the cylinder bore and the piston for signs of
wear 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.
8.6.9.2 Breakout Device Return Cylinder removal and repair
1. Disconnect the hydraulic hose where it connects to the fitting on the

bottom of the cylinder and plug the open end of the hose.

rotation unit.
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.
cylinder. Remove the O-ring from the outside of the cylinder near
the thread.
191
Inspection and re-assembly
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.

into the gearbox.
9. Refit the hydraulic fitting and then the hydraulic hose.
8.6.9.3 Cylinder Rack Engaging removal and repair
1. Disconnect the hydraulic hose where it connects to the fitting on the

end of the cylinder and plug the open end of the hose.

rotation unit.
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.
cylinder. Remove the O-ring from the outside of the cylinder near
the thread.
192
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.

into the gearbox.
8. Refit the hydraulic fitting and then the hydraulic hose.
8.6.9.4 Rack Gear removal and repair
Possible crush injury when removing motor due to its weight — use
correct lifting equipment.
To gain service access to the rack gear it is necessary to first remove

the rear cover from the gearbox.
drain plug.

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
○○ lower breakout device connection
○○ upper breakout device connection
○○ chuck drain on top of gearbox
○○ chuck filter.
193
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 to one side.
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 piston are correctly installed. Rack gear must
be installed with tooth orientation in line with the driven gear and a large, flat
surface against the return cylinder. Also ensure the ‘Tee’ fitting connected to
the main piston is fitted with a 0.8 mm orifice.
1. Carefully examine the condition of the rack and if it shows signs of

significant wear it should be replaced.
The rack is reversible so if one side shows excessive wear it can
be turned around and the other side used as the working face.
2. Reassemble the rack and rack carrier into the rotation unit.
3. Refit the return springs and the socket head shoulder bolts,
tightening these securely.
4. Reassemble the remainder of the components in the same order as

they were removed.
8.6.10 Breakout Device Operation

The Breakout 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.
194
6 5
3
1
1–Rack engaging connection 5–Rotation speed poppet

2–Rack pressure connection 6–Sequence valve
3–Chuck pressure connection 7–Inspection plug
4–Rack return (pilot) connection
Figure 8–49: BOD Nomenclature
8.6.11 Setting Sequence Valve Pressure
Hose may ‘kick’ when sequence valve opens — hold firmly and point into
bucket.
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 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. Oil will flow from the hose when the
sequence valve ‘F’ opens.
Adjust to the setting as specified in the table overleaf.
5. The correct setting of the valve is a commencement of oil flow
from the hose. Adjusting valve clockwise will increase its cracking
pressure.
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.
195
8. If the pressure exceeds 180 bar, check components listed in the

BOD malfunction checks (see below).
8.6.11.1 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.
8.6.11.2 Break Out Device Specification Table

Rotation Unit Type
Component HQ55/75 H/T HQ45/55/75 BQ45
Main Piston Length (mm) 123 129 113

Return Piston (mm) 117 117 113
Sequence Valve Setting (bar) 220–230
Reverse Rotation Pressure (bar) * 130–150
Orifice Tee Piece (mm) 0.8
Orifice Poppet Size (mm) 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.
196
8.6.12 Rotation Unit Maintenance
8.6.12.1 Rotation Unit Disassembly
1. Follow steps 1 through to 12 in the ‘Intermediate Oil Seal

Replacement’ section starting on page 175.
2. Follow steps 1 through to 7 in the ‘Front Oil Seal Replacement’

section on page 179.
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.
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 supplied 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.
197
Figure 8–50: Removing Gear Housing and O-Ring
Figure 8–51: Exploded view of main housing components
8.6.12.2 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.
198
Figure 8–52: Main Housing oil groove
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.
Figure 8–53: Main Housing rotary seal and cir-clip
Reassembly
Possible falling hazard due to gearbox weight and shape.
DO NOT press into final position whilst supporting the outside of the
main housing as damage may occur.
Possible crush hazard when refitting the motor, and between the Chuck
and the Carriage — use correct lifting equipment.
IMPORTANT: Ensure the oil inlet port on the main housing is in the
correct position in relation to the rear gear housing.
IMPORTANT: Be careful that the O-rings do not get pinched on the cir-clip
groove.
199
1. Clean all the components carefully and use compressed air to blow
out the two oil passages in the shaft and the oil passage in the
main housing.
2. Dip the O-rings and back-up washers in hydraulic oil and fit them to
the rotary seal as shown in the diagram below.
Figure 8–54: Rotary Seal ‘O’-rings and back-up washers
3. Stand the Rotation Unit main body on its front bearing end.
4. Smear the inside bore of the main housing with hydraulic fluid then
carefully 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 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 in its correct position.
9. Slide the O-ring over the rear bearing until it fits against the
shoulder of the main housing.
10. Fit the rear housing onto the rear bearing and tighten up the six
socket head bolts evenly around the diameter. Torque to 90 Nm
(60 ft lb).
11. Fit the oil seal spacer and 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.
Installation is made easier if Boart Longyear tool p/n 602025
is used.
12. Insert the cir-clip in its groove correctly.
13. Press the intermediate oil seal into the intermediate oil seal adaptor
so that the oil seal opening faces toward the rear bearing.
200
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 the correct manner and
press the driven gear into final position with a maximum press force
of 10 ton.
17. Tighten the locknut very firmly with the taper facing out. A small
amount of grease should be placed between the locknut and driven
gear to lubricate the surfaces. Make sure the driven gear is in the
correct final position. It is critical that no gaps remain between the
bearings, spindle shoulder, gear 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.
If necessary, fit a new tapered sleeve into the end of the spindle.
spindle.
24. Apply gasket sealant to the hydraulic motor mounting face and the
mating surface on the gearbox housing then assemble the motor
into location. Refit the four M10 hexagon head bolts and tighten
securely.
25. Reconnect the hydraulic hoses to their correct position on the

rotation unit.
26. 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.
27. 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.
28. 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.
201
O-Ring
Back-up Ring Back-up Ring
Chuck Retaining Plate
O-Ring Spindle
Figure 8–55: Chuck Retaining Plate and Spindle ‘O’-rings
29. Fit the twelve M10 socket head capscrews and torque them
uniformly to 90 Nm (60 ft lb).
30. Reassemble the chuck to the rotation unit. Refer to the chuck
reassembly section on page 185.
31. Refill the gearbox with the recommended gear oil.

32. If applicable, reassemble the tacho proximity sensor into location
on the rotation unit.
8.6.13 Rotation Unit Rotary Seal Test

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.
8.6.13.1 Requirements
The Drill must be set up on-site or in a workshop as for normal
operation.
202
The only extra items required for this test are:

●● a graduated container (approx. 20 litre capacity) graduated in one
litre increments.
●● a magnetic thermometer to 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.)
●● a stop watch (or wrist watch) to time the one minute testing cycle.
8.6.13.2 Important Note For Rotary Seal
Potential crush hazard between the Chuck and the Carriage when head
rotating slowly — keep hands clear at all times.
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.
3. Allow the oil to circulate for at least five 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.
8.6.13.3 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.
Ensure that the hydraulic reservoir is filled with an oil grade suitable for
the operating ambient temperature.
IMPORTANT: Refer to the Oil Selection Chart earlier in this chapter.

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.)
203
8.6.13.4 Testing Method
1. Ensure that the Control Panel valves are in the following position
and start the Skid Steer.
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 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. Switch the Drilling/Standby/Rod Handling selector to DRILLING.

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.
204
This completes the Rotation Unit Rotary Seal test.
Figure 8–56: Rotary seal testing
205
8.6.14 Rotation Unit Troubleshooting

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. 1 Adjust pressure in the chuck circuit if necessary.
Should read 70 bar whilst drilling. 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 capacity 1 Break joint with stillson — do not overtorque joints
of drill. on make up of threads.
2 Rod joints tightening up down the hole due to 2 Break joint with stillson — take steps to condition
vibration. the hole or alter drilling parameters to reduce
vibration.
3. Break Out Device not functioning correctly. 3. Perform checks shown on previous page.
Hydraulic Fault
1 Refer to Pressure Checking Table in Chapter 9. 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 assembly. 2 Disassemble the cylinder assembly and if one 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 a 4 Replace the chuck filter element.
clogged chuck filter.
206
Symptom Action
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.
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 excessively 2 Replace the driven gear.
worn.
3 O-ring on front face of driven gear missing or 3 Fit a new O-ring to driven gear and hold it in
damaged. position with a smear of grease when reinstalling
gear on the shaft.
4 Hydraulic motor leaking oil through front shaft seal. 4 Remove and repair the motor.
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 be Condition hole to reduce torque and vibration, or
indicated by a circuit pressure of 240–250 bar as slow drilling speed, if necessary.
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 circuit outwards using a 3 mm Allen key.
pressure of less than 240 bar as the RPM starts The adjustment is very sensitive.
to fall. Test the drilling function and note the circuit
pressure at which the RPM starts to fall as the drill
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 the
incorrectly set for operating conditions. speed control valve.
207
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 of inwards using a 3 mm Allen key.
285 bar as the Chuck stalls. The adjustment is very sensitive.
There will be no steady decrease in RPM, rather Test the drilling function and note the circuit
the Chuck will go from max. RPM to stall. pressure at which the RPM starts to fall as the drill
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 when
indicated by difficulty in maintaining full drilling under load. This should be no more than five
circuit pressure when the oil is warm. 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.
208
Chapter 8: Maintenance – 400 Series (Direct Coupled) Feed Frame
8.7 400 Series (Direct Coupled) Feed Frame

8.7.1 Introduction
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, e.g. to carry out routine inspections of various
load bearing components such as feed cylinder, and carriage trunnions.
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)
Figure 8–57: 400 Series Feed Frame
209
8.7.2 Assembling the Feed Frame
Use the correct manual handling procedures at all times.

operation.
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 that the four M12 bolts are firmly tightened.
Ensure the feed cylinder cover is fitted to avoid injury to personnel from
the moving cylinder.
Figure 8–58: Fit and tighten the four M12 bolts
Figure 8–59: Direct Coupled Feed Frame — working position
8.7.3 Feed Frame Maintenance
8.7.3.1 Recommended Service Intervals:
operation.
Note: It is important that Feed Frame maintenance is done on a regular basis

to ensure a long service life of all components.
Daily:
1. Grease carriage slides at the commencement of each shift —

grease nipples on each side.
210
2. Grease rod clamp outer housing — grease nipples in top and

bottom faces.
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.
8. Check oil level in rotation unit gearbox and add oil if necessary.
9. Check adjustment of carriage slides and adjust if necessary.

See the following pages for further detail.
10. Check the rod holder and rotation unit guide bushings for wear and
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
Figure 8–60: Feed Frame service and maintenance points
211
8.7.4 Adjusting the Carriage
Use the correct manual handling procedures, Personal Protective

Equipment, and tools for this operation.
Possible crush hazard — Do not get hands caught between the Chuck
and the carriage top plate.
IMPORTANT: The correct procedure must be followed when adjusting the

Carriage.
1. Move the drill head carriage fully forward against the rod clamp and
leave the Power Pack running.
2. Undo the four locknuts on the carriage slide adjusting bolts and
leave loose.
Figure 8–61: 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.
Figure 8–62: Feed Cylinder hex. nut
212
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 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 be rotated by hand whilst performing this adjustment.
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.
Figure 8–63: Adjusting the Carriage slides
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 is smooth in either direction and that the drill rod passes
evenly through the rod clamp.
10. Open the Chuck and remove the drill rod. Add lithium based grease
to the four grease nipples on the carriage slides.
213
8.7.5 Replacing the Carriage Wear Strips

Equipment, and tools for this operation, especially when handling and
using cleaning fluids.
Carriage side plate may fall — use correct lifting equipment.
IMPORTANT: Complete work to one carriage side before beginning the

other.
1. Move the drill head carriage to a suitable working position on the

Feed Frame and switch off the Skid Steer.
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 plate as the bolts are removed.
3. Clean the removed carriage side plate assembly with degreasing

fluid (or similar) and check for any other worn or damaged
components.
4. Remove the two plastic wear strips from the adjusting block by
levering out with a screwdriver.
Figure 8–64: Carriage Assembly
214
Reassembly

Equipment, and tools for this operation, especially when handling and
using cleaning fluids.
Carriage side plate assembly may fall — use the correct lifting equipment.
1. Clean the inner area where wear strips locate in the adjusting
block, prior to fitting the new wear strips.
2. Install the new wear strips and insert new trim clips (four per side)
to hold 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 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.
Figure 8–65: Tighten nine M10 bolts to 44 Nm (30 lbft) torque
215
8.7.6 Carriage Side Plate Disassembly
operation.
Adjusting block may fall — remove when at ground level or on bench.
Compression hazard — circlip may come off pliers. Cover when
removing.
1. Perform steps 1 to 4 in the previous section, ‘Replacing the

Carriage Wear Strips’.
2. Remove the two circlips located on the ends of the adjusting block
spigot.
3. The adjusting block should now be free to be removed from the

side plate.
4. Loosen the two hex. locknuts and unscrew the two adjusting
screws from the side plate.
Reassembly
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
Figure 8–66: Carriage Side Plate disassembly
216
8.7.7 Removing the Feed Cylinder
Use the correct Personal Protective Equipment, lifting equipment, manual

handling procedures, and tools for this operation.
Ensure the Feed Frame is positioned horizontally to allow for the safe
removal of the feed cylinder.
Beware of Hydraulic Oil under pressure — vent hose by cycling the Feed
lever on the Control Panel.
Rotation Unit is difficult to initially pivot — use assistance.
1. Switch on the LM30 Skid Steer and move the drill head carriage
forward until it is at the end of the cylinder stroke.
2. Remove the rear cylinder cover from the Feed Frame by removing
the M12 bolts.
3. Loosen and remove the hex. nut that fastens the feed cylinder
piston rod to the feed frame chassis. Remove the flatwasher and
store the nut and washer for reassembly.
4. Disconnect the hydraulic hoses going to the feed cylinder

connections on the counterbalance valve and plug the hose ends.
5. Undo the Rotation Unit latch bolts and swing them free. Swing the
Rotation Unit over to one side.
6. Remove the twelve M12 bolts holding the cylinder trunnions to the
carriage top plate and store for reassembly.
7. The feed cylinder should now be free to be withdrawn through the

back of the feed frame.
Figure 8–67: Feed cylinder removal
217
8.7.8 Removing the Cylinder Trunnions
operation, especially when handling and using cleaning fluids.
Change out trunnions before failure — keep clear of moving parts.
1. Perform the steps described in the previous section to remove the

Feed Cylinder.
2. Carefully remove the cylinder mounting brackets from the trunnions

by sliding off the spigot.
3. Using a 6 mm Allen key, remove the eight M8 socket head

capscrews holding the trunnions to the cylinder assembly.
4. Remove the trunnions from the cylinder and clean all components
thoroughly.
Socket head
capscrews Cylinder
assembly
Bush
Cylinder
trunnion
Cylinder mounting
bracket
Figure 8–68: Removing the Cylinder Trunnions
Reassembly
218
1. If necessary, replace the cylinder mounting bracket bushes by

pressing out the old bush and replacing with a new one.
2. Clean all components and apply a quality lubricant to all surfaces.
3. Using new M8 socket head capscrews, fit the trunnion to the

cylinder assembly and torque to 45 Nm (33 ftlb).
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.
8.7.9 Replacing the Feed Cylinder
Use the correct Personal Protective Equipment, lifting equipment, manual

handling procedures, and tools for this operation.
Possible pinch point hazard between cylinder rod and opening in front of
chassis — keep hands well clear.
Hoses moving forwards and rearwards — keep immediate area clear.
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.
2. Lift the feed cylinder from underneath and align the twelve holes in
the cylinder trunnion brackets with the carriage top plate holes.
Fit the twelve M12 bolts and torque to 77 Nm (57 lb/ft). Use Loctite
stud lock on threads.
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.
6. Fit the front washer and Nyloc nut to the piston rod and tighten
them finger tight.
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 211 for
details.
219
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 cylinder.
This completes replacement of the feed cylinder.
8.7.10 Feed Cylinder Disassembly
Collect spent oil in a suitable container and dispose of in an

operation.
Cylinder may topple over due to its weight — get assistance if required.
1. Carefully tilt the removed cylinder up on its ends and drain any
remaining oil through the port openings.
2. Using a suitably sized ‘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 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 the threaded end of the piston rod and rotating it
counterclockwise while 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.
Piston rod
End cap gland Rod end gland
Figure 8–69: Feed cylinder disassembly
220
8.7.10.1 Piston and Piston Rod Disassembly and Inspection

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, then 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.
8.7.10.2 Piston and Piston Rod Reassembly
operation, including when using the drill and handling oils.
11. Place the piston rod in the vice and secure firmly using soft jaws to
prevent damage to the rod.
12. Apply a generous amount of hydraulic oil to the area of the rod
where the piston and cushioning collar slide.
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.
221
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
Figure 8–70: Piston rod assembly
8.7.10.3 Rod End Gland
Use the correct tools when removing and refitting seals.

20. Remove the two ‘O’ rings from the outside diameter of the gland.
21. Remove both the rod seals and rod wiper from the bore of the
gland and check the gland for any damage.
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.
8.7.10.4 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.
222
Rod wiper
Rod seals
O’ ring
‘O’ ring and
and BU ring
BU ring
O’‘ ring
‘O’ ring and
and BU ring
BU ring
Rod end gland End cap gland
Figure 8–71: Rod end gland and End cap gland
8.7.11 Cylinder Reassembly
1. Clean the bore of the cylinder thoroughly with cleaning fluid,

ensuring no old oil or contamination is left behind.
2. Inspect the bore of the cylinder for any scoring.

If it is O.K., apply a coating of clean hydraulic oil.
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.
Tighten the gland firmly against the shoulder of the cylinder using
the ‘C’ spanner.
The cylinder is now ready for replacement into the Feed Frame.
223
224
Chapter 8: Maintenance – The Power Unit
8.8 The Power Unit

8.8.1 Introduction
The LM30 Power Unit contains the necessary components to power the
drill rig via a diesel-driven hydraulic pump.
Other facilities within the compact power unit include a sealed hydraulic
reservoir, hydraulic logic, and integrated facilities for performance
diagnosis.
All LM30 power units are factory cycle tested and adjusted for optimum
hydraulic performance, and hose connections are made to clearly
labelled bulkhead fittings on the end of each unit.
Figure 8–72: The LM30 Skid Steer Power Unit
8.8.2 The Main Pump
8.8.2.1 Main Pump Condition Test
Ensure the drill is turned OFF before attempting these adjustments.
It may be necessary to condition test the main pump for of any of the
following reasons:
●● Poor drilling performance whilst drilling under maximum load,
●● Metal particles present in the pressure and return hydraulic filters.
Refer to the CAT Operations and Service Manual for a detailed
description of Skid Steer pump removal, troubleshooting, and
testing.
225
8.8.2.2 Main Pump Pressure Setting
Rotation lever on the Control Panel.
Ensure the drill is turned OFF before these adjustments are attempted.
operation.
1. Ensure the Control Panel valves are in the following positions and
switch on the power unit.
a. The Rotation control lever and the Carriage control lever must be in
the neutral position.
b. The water pump speed control (if fitted) must be wound fully in
(clockwise) to the zero speed position.
c. The Drilling/Standby/Rod Handling selector switch (4) must be in
the STANDBY position.
d. The Rod Pulling/Rod Feeding selector switch can be in either
position.
e. Connect a test gauge to the pilot system pressure tapping port on
the bottom of the Control Panel.
Pressure Control Adjustment (Pump max. pressure)
Standby Load Sensing High Flow Pump

Adjustment Pressure Tap Compensator Valve
Figure 8–73: Main Pump pressure setting
2. Monitor the pilot pressure gauge and adjust the main pump stand-
by pressure (if necessary) to 25 bar by adjusting the lower main
pump adjustment screw. Turn off the power unit.
3. Disconnect the two rotation hoses from the Rotation Unit and cap.
Ensure the two hose ends are plugged and turn on the power unit.
4. Slowly move the Rotation control lever fully forward and lock into
position to pressurise the main pump.
5. Screw in the upper adjustment screw until the test gauge reads 285
bar.
226
6. Return the Rotation control lever to neutral and switch off the drill.
7. Reconnect the two hoses to the Rotation Unit.
8.8.3 Heat Exchanger
operation.
IMPORTANT: Ensure that new gaskets are fitted each time the end caps
are removed and replaced.
Either connection
may be used
Figure 8–74: Heat Exchanger location and hose connections
Cooling of the hydraulic oil is provided by a two-pass, water to oil

heat exchanger. Either connection may be used for the inlet water
connection. With an inlet water temperature of +20 degrees C and a
flow of 20 to 30 Lpm, the hydraulic oil temperature would normally be
between 40 and 60 degrees 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 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
to drain the heat exchanger or fit sacrificial anodes in areas where very
corrosive water is used.
227
8.8.4 SAE/MS Straight Thread Positionable Elbows and

Tees
8.8.4.1 Installation Instructions
operation.
Wrench Elbow body

pa
Front ferrule
Rear ferrule
Nut
Locknut
‘O’ ring
Figure 8–75: Elbow fitting components
1. Lubricate the O-ring with a lubricant compatible with the system

fluid, the 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.
Screw in
Figure 8–76: Elbow installation
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.
228
Hold
Tighten Position
Figure 8–77: Elbow tightening
4. Hold the wrench pad with a back-up wrench and tighten the locknut
until the washer is against the face of the boss.
8.8.5 Troubleshooting

Symptom Action
1 Automatic Engine Shutdown parameters
exceeded
(indicated by a solid light on the Control Panel Refer to pages 49–57 of the Skid Steer Operators
Fault indicator light) Manual for settings and descriptions.
2 Skid Steer is Shutting Down on Low Fuel Alarm
(indicated by a solid light on the Control Panel Check the level on the fuel gauge (a gauge indicates
Fault indicator light) the tank level), and fill if necessary.
3 Skid Steer is Shutting Down on High
Temperature Alarm in the Drill Circuit
(indicated by a solid light on the Control Panel Allow the Drill to cool down and locate the source of
Fault indicator light) the heat.
Check that adequate water flow is available through
the heat exchanger and the high temperature probe is
not faulty.
4 Skid Steer is Shutting Down on Low Oil Level
Alarm
(indicated by a solid light on the Control Panel Add more oil of the correct grade to the hydraulic tank,
Fault indicator light) then locate and correct source of the leak.
Ensure the oil level switch (located in the oil tank
behind the seat) is not faulty.
229
Symptom Action
5 Feed Magnet Switch Fault
(indicated by solid lights on the Control Panel Move the Carriage lever forward and reverse, checking
Fault indicator light) the status of PLC inputs I:1/02 and I:1/03.
If both are ON at the same time then there is a fault.
Check feed magnet switches.
Check the cable for damaged/broken wires.
6 Chuck Pressure Switch Fault
(indicated by a solid light on the Control Panel Switch to DRILLING mode and check I:1/05 is ON.
Fault indicator light) If not ON , check the pressure switch.
7 Rod Holder Pressure Switch Fault
(indicated by a solid light on the Control Panel Switch to DRILLING mode and check I:1/04 is ON.
Fault indicator light) If not ON, check the pressure switch.
8 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 should not vent until the
circuit pressure gauge reads 285 bar.
Stall the carriage at each end of its stroke and
check again if the engine stalls.
If it does then adjust the Feed reliefs as detailed in
the pressure setting notes.
9 Diesel Engine stalls when Rod Making or
Breaking
1 Relief Valve venting. 1 The main relief valve in the manifold block should
not vent until the circuit gauge reads 310 bar.
Stall the Chuck in the forward and reverse
directions, ensure the circuit gauge reads 285 bar
and check if the engine stalls.
If it does then adjust the main relief valve in the
manifold block as detailed in the pressure setting
notes.
NOTE: When checking the PLC inputs refer to ‘Electrical Control System drawings’ in Section 10.
These descriptions can also be read in conjunction with the Input/Output test chart.
230
Contents
9.1 Explanation of the Checking System..................................................... 233
9.2 Function Test Chart ............................................................................... 234
9.2.1 (Blank) Function Test Chart........................................................... 235
9.3 Hydraulic Circuit Diagrams..................................................................... 236
Table of Figures
Figure 9–1: Troubleshooting the Hydraulic System......................................... 233
Figure 9–2: Hydraulic Component Symbols used
in Circuit Diagrams............................................................................................. 236
231
232
9.1 Explanation of the Checking System

The task of troubleshooting the hydraulic system can be done using the
circuit pressure gauge (on the left hand side of the Control Panel), or by
using an external test gauge. This external connection is:
●● located beneath the Water Pump section on the Control Panel,
●● a ‘Minimess’ type fitting, and
●● measured in bar.
Whilst drilling it is recommended that the circuit pressure gauge remain

connected to the ‘MP’ port so that the torque generated by the head can
be continuously monitored at the Control Panel.
Circuit pressure
gauge
‘Minimess’
test port
(under)
Figure 9–1: Troubleshooting the Hydraulic System
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 and plugged with the
correct fittings.
●● All exposed components and assemblies must be covered and
protected.
●● All oil entering the hydraulic system must be filtered.
●● Oils of different brands and grades should not be mixed.
●● At all times use the correct grade of oil to suit the operating
conditions.
233
234
LM30 Function Test Chart Pressure Readings (Bar)
Notes
R od R od 9.2
function 11.
Control Rotation F eed Wireline R od H andl i ng F i n e C h u ck R od F eed B.O.D./ System
F eed/ H ol der C h u ck
Operation lever lever Lever Selector Feed Status Holder Pressure Pilot Pressure
R od P ul l Status
1 R od H andl i ng Neutral Neutral Neutral R od H andl i ng Either Off Closed Closed 70 0 0 35 100
2 Standby Neutral Neutral Neutral Standby Either Off Open C l o se d 0 0 0 35 35
3 Drilling Neutral Neutral Neutral Drilling Either Off C l o se d Open 70 140 0 35 160

Drilling with
4 Rotation and Forward Neutral Neutral Drilling Either On C l o se d Open 70 140 0–200 35 160–250
F i ne F eed
R od P ul l i ng R od
Ensure water pump is turned OFF for all tests except

5 Neutral Forward Neutral R od H andl i ng Off Open Closed 0 0 0 35 285
The ROD HOLDER selector must be set to Automatic.

(Forward Stroke) P ul l i ng
6 Neutral Rearward Neutral R od H andl i ng Off Closed Open 70 140 0 35 285
(Reverse Stroke) P ul l i ng
R od F eedi ng R od
Function Test Chart
7 Neutral Forward Neutral R od H andl i ng Off Closed Open 70 140 0 35 285

(Forward Stroke) F eedi ng
R od F eedi ng R od
8 Neutral Rearward Neutral R od H andl i ng Off Open Closed 0 0 0 35 285
(Reverse Stroke) F eedi ng
Threadmaking
9 Forward Neutral Neutral R od H andl i ng Either Off C l o se d C l o se d 70 0 0 35 285
(Head Stalled)
Threadbreaking Rearwar-
10 Neutral Neutral R od H andl i ng Either Off Closed Closed 70 0 0 35 285
(Head Stalled) d
11 Water Pump Neutral Neutral Neutral Standby Either Off Open Closed 0 0 0 35 35–75
Wireline
‘MP’ port beneath the Water Pump section.

12 Neutral Neutral Forward Standby Either Off Open C l o se d 0 0 0 35 35–175
(Forward, Stall)
Wireline Rearwar-
13 Neutral Neutral Standby Either Off Open Closed 0 0 0 35 35–175
(Reverse, Stall) d
connecting a test gauge to their respective hose ends.

Positioner
14 Neutral Neutral Neutral Standby Either Off Open C l o se d 0 0 0 35 35–200
(Raise)
Positioner
15 Neutral Neutral Neutral Standby Either Off Open C l o se d 0 0 0 35 35–200
(Lower)
Feed Frame
The CHUCK, ROD HOLDER, B.O.D./PILOT pressures are monitored by

16 Neutral Neutral Neutral Standby Either Off Open Closed 0 0 0 35 35–200
Dump (Forward)
Feed Frame
17 Neutral Neutral Neutral Standby Either Off Open Closed 0 0 0 35 35–200
Dump (Reverse)
The MAIN CIRCUIT PRESSURE is monitored by connecting a test gauge into the
Notes
Ensure water pump is turned OFF for all tests except function 11. The CHUCK, ROD HOLDER, B.O.D./ PILOT pressures are monitored by
connecting a test gauge into their respective hose ends.
LM30 Function Test Chart Pressure Readings (Bar)
Notes
R od R od
function 11.
Control Rotation F eed Wireline R od H andl i ng F i n e C h u ck R od F eed B.O.D./ System
F eed/ H ol der C h u ck
Operation l e ve r lever L e ve r Selector Feed Status Holder Pressure Pilot Pressure
R od P ul l Status
1 R od H andl i ng Neutral Neutral Neutral R od H andl i ng Either Off Closed Closed

9.2.1
2 Standby Neutral Neutral Neutral Standby Either Off Open Closed

3 Drilling Neutral Neutral Neutral Drilling Either Off C l o se d Open
Drilling with
4 Rotation and Forw ard Neutral Neutral Drilling Either On C l o se d Open
F i ne F eed
Ensure water pump is turned OFF for all tests except

5 Neutral Forward Neutral R od H andl i ng Off Open Closed
The ROD HOLDER selector must be set to Automatic.

(Forward Stroke) P ul l i ng
6 Neutral Rearward Neutral R od H andl i ng Off Closed Open
(Reverse Stroke) P ul l i ng
R od F eedi ng R od
7 Neutral Forward Neutral R od H andl i ng Off C l o se d Open
(Forward Stroke) F eedi ng
R od F eedi ng R od
8 Neutral Rearward Neutral R od H andl i ng Off Open Closed
(Reverse Stroke) F eedi ng
Threadmaking
9 Forward Neutral Neutral R od H andl i ng Either Off Closed Closed
(Head Stalled)
(Blank) Function Test Chart
Threadbreaking Rearwar-
10 Neutral Neutral R od H andl i ng Either Off Closed C l o se d
(Head Stalled) d
11 Water Pump Neutral Neutral Neutral Standby Either Off Open Closed
Wireline
‘MP’ port beneath the Water Pump section.

12 Neutral Neutral Forward Standby Either Off Open Closed
(Forward, Stall)
Wireline Rearwar-
13 Neutral Neutral Standby Either Off Open Closed
(Reverse, Stall) d
connecting a test gauge to their respective hose ends.

Positioner
14 Neutral Neutral Neutral Standby Either Off Open Closed
(Raise)
Positioner
15 Neutral Neutral Neutral Standby Either Off Open C l o se d
(Lower)
Feed Frame
The CHUCK, ROD HOLDER, B.O.D./PILOT pressures are monitored by

Dump (Forward)
Feed Frame
Dump (Reverse)
The MAIN CIRCUIT PRESSURE is monitored by connecting a test gauge into the
235
Notes
Ensure water pump is turned OFF for all tests except function 11. The CHUCK, ROD HOLDER, B.O.D./ PILOT pressures are monitored by
9.3 Hydraulic Circuit Diagrams

The hydraulic schematics that are filed at the back of this folder are
provided to help you troubleshoot the hydraulic system should the need
arise.
Note that design pressures appear on the diagrams, and actual

pressures may vary slightly from those shown.
HINT: Always check pilot pressures first.
Figure 9–2: Hydraulic Component Symbols used

in Circuit Diagrams
236
Contents
10.1 Introduction............................................................................................ 239
10.2 LM30 CAT246C Skid Steer Test Chart ................................................ 240
10.2.1 Fault Finding Test Example......................................................... 241
10.2.2 Standby Test 1 — STANDBY AUTO........................................................242
10.2.3 Standby Test 2 — STANDBY + ISOLATE...............................................242
10.2.4 Drill Mode Test 3 — DRILL MODE...........................................................243
10.2.5 Drill Mode Test 4 — DRILL MODE + ROTATION + FINE FEED..........243
10.2.6 Rod Handling Test 5 — ROD HANDLING + ROD PULLING.................244
— ROD HANDLING + ROD PULLING + REVERSE CARRIAGE.............244
— ROD HANDLING + ROD PULLING + FORWARD CARRIAGE...........245
— ROD HANDLING + ROD PULLING + THREAD BREAKING...............246
10.2.10 Rod Handling Test 9 — ROD HANDLING + ROD FEEDING..............246
— ROD HANDLING + ROD FEEDING + FORWARD CARRIAGE........247
— ROD HANDLING + ROD FEEDING + REVERSE CARRIAGE..........248
— ROD HANDLING + ROD FEEDING + THREAD MAKING.................248
10.3 PLC Input/Output Descriptions............................................................ 249
10.4 Testing Procedure — Pressure Switches and Solenoid Valves........ 250
10.4.1 Testing a Pressure Switch........................................................... 250
10.4.2 Testing a Solenoid Valve............................................................. 251
Table of Figures
Figure 10–1: PLC and Expansion Module....................................................... 239
Figure 10–2: Electrical troubleshooting — control settings.............................. 240
237
238
10.1 Introduction
Provided in this section are the PLC Input / Output test charts and the
Electrical Control system schematics.
By combining these together and setting the controls for each function,
the input and output status lights can be recorded, and then compared
to the design readings.
The expansion module and PLC are both used on the test chart
and must be carefully read when troubleshooting.
PLC
Expansion Module inputs
Expansion Module outputs
Figure 10–1: PLC and Expansion Module
239
10.2 LM30 CAT246C Skid Steer Test Chart

This set of instructions has been made for easier fault finding on the
LM30 CAT246C Skid Steer Drill Rig. Please follow carefully.
All rods should be removed from the rig prior to doing the testing.
The test runs through each of the drill functions and checks the input/
output status of the PLC.
The desired input/outputs have been included as a reference point to

enable the faults to be fixed quickly.
Use the photos of the control panel for reference to ensure the correct
operations are occurring during the test. An example has also been
included on the next page to assist.
1 2 3 4
Figure 10–2: Electrical troubleshooting — control settings
1. Water control OFF (full clockwise)
2. Torque control OFF (full anti-clockwise)
3. Fine Feed OFF (full clockwise)
4. Feed Pressure OFF (full anti-clockwise)
For each of the following tests ensure the pressure and flow control
valves at the front of the control panel have been set in the above
positions.
240
10.2.1 Fault Finding Test Example

Symptom — Loss power to main pilot solenoid when placed into
drill mode and no funtions work. The chuck closes and the rod holder
opens, but power is lost to the mains solenoid valve and rig goes into
fail safe mode.
Begin with Test #1 and continue until a problem occurs.
With assistance from another person, place the controls in the positions
shown and fill out the input/out put table as per below.
The Test #3 chart is shown below.
NOTE – Do not be alarmed if the machine shuts down.
The machine will do what it is being told to do by the PLC. If the

machine is shutting down, it is a good sign that the PLC is in good
working condition and a device in the field, such as a pressure switch, is
the problem area.
1 Expansion Module • Main PLC
DESIRED
Input • 1 2 • • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13
ACTUAL
Input • 1 2 • • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13
The differences in the Desired and Actual charts above indicate the
problem area (e.g. #4 input on expansion module and #14 output
on expansion module).
The above test chart would indicate that the rod holder pressure OK
switch is not working for some reason. If the machine does not receive
input #4, then the PLC thinks that the Rod Holder is closed. The
machine will then go into fail safe mode by activating output 14 which
controls the main solenoid.
The problem could be in the following areas:
●● Low pressure to the Rod Holder.

Need to check the pressure in the Rod Holder hydraulic circuit and
DCV controlling the oil flow. Check that the Rod Holder solenoid is
receiving 24v to operate.
●● Faulty rod holder pressure OK switch.
Need to check that the switch is changing state when the pressure is
going on and off. Need to check the cable returning to the PLC.
241
10.2.2 Standby Test 1 — STANDBY AUTO
Ensure all switches and levers are in the positions as indicated in photo.
Fill in the input/output chart below by comparing to the PLC unit.
DESIRED
Input 0 1 2 • • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
10.2.3 Standby Test 2 — STANDBY + ISOLATE
During this test, the Rod Holder will open after pushing the button.
DESIRED
Input 0 1 2 • 4 • 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
242
10.2.4 Drill Mode Test 3 — DRILL MODE
During this test, the chuck should close and the rod holder should open.
DESIRED
Input • 1 2 • • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
10.2.5 Drill Mode Test 4 — DRILL MODE + ROTATION + FINE FEED
For this test, the unit is in drill mode and rotation lever locked into the
fully forward position and the fine feed switch turned on.
DESIRED
Input • 1 2 • • 5 • 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
243
10.2.6 Rod Handling Test 5 — ROD HANDLING + ROD PULLING
In this test, the rig is switched to Rod Handling and in Rod Pulling mode.
No lever movement.
DESIRED
Input 0 • • 3 • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

— ROD HANDLING + ROD PULLING + REVERSE CARRIAGE
This is a repeat of test 5, but with the feed lever pulled in the reverse
direction. The chuck should close, the rod holder should open and the
carriage move rearward.
244
DESIRED
Input 0 • • 3 • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

— ROD HANDLING + ROD PULLING + FORWARD CARRIAGE
Fill in the input/output chart below by comparing to the PLC unit
This is a repeat of test 5, but with the feed lever moved in the forward
direction. The chuck should open, the rod holder should remain closed
and the carriage move forward.
DESIRED
Input 0 • • 3 • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
245

— ROD HANDLING + ROD PULLING + THREAD BREAKING
Set the rig in Rod Handling and Rod Pulling mode. Simulate breaking
threads by moving the Rotation lever in the reverse direction.
DESIRED
Input 0 • • 3 • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
10.2.10 Rod Handling Test 9 — ROD HANDLING + ROD FEEDING
In this test, the rig is switched to Rod Handling and in Rod Feeding
mode. No lever movement.
246
DESIRED
Input 0 • 2 • • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

— ROD HANDLING + ROD FEEDING + FORWARD CARRIAGE
This is a repeat of test 9, but with the Feed lever moved in the forward
direction. The chuck should close, the rod holder should open and the
carriage move forward.
DESIRED
Input 0 • 2 • • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
247

— ROD HANDLING + ROD FEEDING + REVERSE CARRIAGE
This test is a repeat of test 9, but with the Feed lever moved in the
reverse direction. The chuck should open, the rod holder should remain
closed and the carriage move rearward.
DESIRED
Input 0 • 2 • • 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

— ROD HANDLING + ROD FEEDING + THREAD MAKING
Set the rig in Rod Handling and Rod Feeding mode. Simulate making
threads by moving the Rotation lever in the forward direction.
248
DESIRED
Input 0 • 2 • • 5 • 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
ACTUAL
Input 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Output 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
10.3 PLC Input/Output Descriptions

The following tables list PLC input descriptions and wire numbers.
Inputs (Fixed Controller)

Input Description
0 Drill selected I:0/00
1 Rod Handle I:0/01
2 Rod Pull I:0/02
3 Rod Feed I:0/03
4 Auto Rod Handle I:0/04
5 Isolate OPEN I:0/05
6 Fine Feed ON I:0/06
8 Gripper Pushbutton I:0/08
Inputs (Expansion Module 1)

Input Description
0 Rotation Forward Magnetic Switch I:1/00
1 Rotation Reverse Magnetic Switch I:1/01
2 Feed Forward Magnetic Switch I:1/02
3 Feed Reverse Magnetic Switch I:1/03
4 Rod Holder Pressure Switch I:1/04
5 Chuck Pressure Swithch I:1/05
6 Spare
7 Emergency Stop Healthy Safeguard I:1/07
8 Spare
9 Skid Steer Hydraulic Oil I:1/09
Temperature OK
10 Skid Steer Hydraulic Oil Level Low I:1/10
11 Skid Steer Armrest Up I:1/11
Handbrake Engaged
12 Spare
13 Skid Steer Engine Oil Pressure I:1/13
Engaged On
14 Spare
15 Front Guard Closed I:1/15
Magnetic Safety Switch
249
The following tables list PLC output descriptions and wire numbers.
Outputs (Fixed Controller)
Output Description
0 Control Panel Feed Fault LED O:0/00
1 Control Panel Chuck Fault LED O:0/01
2 Rod Holder Fault LED O:0/02
3 Control Panel Hydraulic Oil Low O:0/03
LED
4 Control Panel Hydraulic Oil O:0/04
Temperature High LED
5 Control Panel Engine Fault LED O:0/05
Outputs (Expansion Module 2)
Output Description
0 Fine Feed Enable Relay K1527 O:2/00
1 Float Enable Relay K1528 O:2/01
2 Rod Holder Enable Relay K1529 O:2/02
3 Chuck Enable Relay K1530 O:2/03
4 Pilot Isolation Enable Relay K1531 O:2/04
5 Spare
6 Spare
7 Spare
8 Control Panel Rod Drop LED O:2/08
9 Engine Shut Down Relay K1536 O:2/09
10 Spare Relay K1537 O:2/10
11 Warning Beeper Relay K1538 O:2/11
12 Warning Light Relay K1539 O:2/12
13 Spare Relay K1540 O:2/13
14 Main Pilot Isolation Stop Valve O:2/14
Enable Relay K1541
15 Spare
10.4 Testing Procedure — Pressure Switches and

Solenoid Valves
10.4.1 Testing a Pressure Switch
1. Remove the plug top from the switch
2. Switch the Multi-meter to read Resistance(Ohms)
3. Place the red cable connection into the voltage (ohm) port and the
black cable into the common port on the multi-meter.
250
4. Connect the red probe to pin 1 and the black probe to pin 3 of the
pressure switch.
5. The multi-meter display should read ‘0’ L as the pressure switch is

normally open.
6. Apply pressure to activate the switch and when it closes the circuit
is complete, giving a reading on the display.
7. Remove the pressure that activates the switch and when it opens
the circuit is broken and the display will read zero.
8. This indicates the pressure switch is working correctly.

Replace the plug top.
10.4.2 Testing a Solenoid Valve

1. Check that the PLC output status LED for the function being tested
is illuminated.
2. Remove the cap from the solenoid valve to access the terminals.
3. Put the Multimeter Red (positive) probe onto pin 1, and the Black
(negative) probe onto pin 2.
4. The multimeter should read zero volts.
5. Activate the solenoid switch to energise the valve, and the

Multimeter should now read 24 volts.
6. If the reading changes (as outlined above) the solenoid is working

correctly.
If it does not change the solenoid should be replaced and the wiring
checked from the PLC to the solenoid.
7. On the end of the solenoid switch is a manual override button that
can be pressed when the cap is removed.
Press this button to check whether the problem is hydraulic or
electrical.
251
252
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GLOBAL DRILLING PRODUCTS

Copyright © 2014 Boart Longyear. All rights reserved.

LM30 SKID STEER

1.12 Fire Fighting ............................................................................................ 30

Chapter 2: General Information

Chapter 3: Drill Introduction and Operation

Chapter 5: Drill Commissioning

5.4.4 Feed Cylinder Circuit — Bleeding of Pilot Hoses A and B.............. 93

Chapter 6: Hydrostatic Explanation

6.6.5 Dump Circuit.................................................................................. 116

Chapter 7: Electrical Schematics

8.5.9 Chuck Disassembly....................................................................... 153

8.7.10 Feed Cylinder Disassembly......................................................... 220

Chapter 9: Troubleshooting the Hydraulic System

Chapter 10: Troubleshooting the Electrical System

10.2.13 Rod Handling Test 12

Chapter 2: General Information

Chapter 3: Drill Introduction and Operation

Figure 3–7: Rotation Motor Speed Control........................................................ 58

Chapter 5: Drill Commissioning

Chapter 6: Hydrostatic Explanation

Chapter 7: Electrical Schematics

Figure 8–31: HQ Rotation Unit and Chuck...................................................... 173

Chapter 9: Troubleshooting the Hydraulic System

Chapter 10: Troubleshooting the Electrical System

THIS PAGE INTENTIONALLY LEFT BLANK

1.12 Fire Fighting ............................................................................................ 30

1.1 Reference Note for Users Manual

THE AVAILABLE MANUAL CONSISTS OF TWO PARTS.

Parts 1 and 2 of this manual must be stored in a protected place on the

BOART LONGYEAR is constantly striving to improve its products

1.2 Important Safety Information

FURTHERMORE, ANY ADDITIONAL NATIONAL REGULATIONS

IF THE DRILL RIG IS APPLIED BEYOND THE FEDERAL

1.2.1 Hazard Signal Indicators

This is the safety alert symbol. It is used to alert you to potential

Warning and Caution indicators are located throughout the manual

Indicates an imminently hazardous situation which, if not avoided, could

Indicates a potentially hazardous situation which, if not avoided, could

Indicates a potentially hazardous situation which, if not avoided, MAY

These notices are given to prevent personal injury, death and/or

Notes: are indicated to draw attention to detailed instructions. These

1.3 Safety Warnings and Guidelines

The customer is also responsible to take the necessary safety

Safety is the most important element of any procedure. Preparation is

Follow the general safety practices listed below to reduce exposure to

1.3.1 Before operating the drill rig

●● ISOLATE all energy sources before servicing any equipment.

1.3.2 Whilst operating the drill rig

1.3.3 After operating the drill rig

1.3.4 General “Housekeeping”

●● keep the work area clean and avoid dangerous working

1.3.5 Cautions and Warnings

EXTEND/RETRACT — Component extends and

HOT SURFACE — Surface adjacent to this

PRESSURE VESSEL — This component

MANUAL — Indicates to refer to this manual

HEARING PROTECTION — Must be worn HARD HAT — Must be worn

LOADED SPRINGS — Warning that springs

1.4 General Safety Instructions

4. Replacement of Worn Parts

Figure 1–1: 3 metre Danger Zone

In case of danger the operator must give warning signals,and these

If persons do not leave the dangerous zone, despite having been