LF90D Operations & Service Manual

LF90D
Operations and
Service Manual
MKT1542 Rev 3
Important Safety Information
Hazard Signal Words

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

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

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

avoided, could result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially

hazardous situation which, if not avoided, may result in property damage.
Read and understand all safety instructions carefully

before operating this machine. Failing to follow these
instructions may result in serious personal injury or
death.
• Keep clear of rotating equipment. Never wear any loose clothing which
could become tangled in the machine.
• Never rotate the drill rods without the water swivel attached to the drill
string. (Ensure the hoisting cable is attached to water swivel bail.)
• Keep guards installed and maintained in good working order.
• Always keep the work area clean.
• Avoid dangerous working environments.
• Do not operate equipment while under the influence of drugs, alcohol,
or medication.
• Keep visitors a safe distance away from the work area.
• Wear personal protective equipment such as a hard hat, safety glasses
and steel toed work boots.
• Read and understand the operations manual and labels affixed to the
machine.
• Use only Boart Longyear replacement parts. Failure to do so could
cause severe damage to the machine or the operator, and may void
your warranty.
• Use only qualified service technicians. Failure to do so could cause
severe damage to the machine or the operator, and may void your
warranty.
• Never climb on top of the machine.
• Ensure that the drill and accessories fully comply with applicable local
safety and health regulations.
• Do not exceed rated capacity of any piece of equipment.
• Never rotate the drill rods with a rod joint located behind or above the
chuck.
• Do not adjust the hydraulic system before consulting a Boart Longyear
Technician.
• Ensure that all commissioning checks and adjustments have been
thoroughly carried out before operating the machine.
• Do not change or alter the drill, its components, optional equipment or
accessories without prior approval from Boart Longyear Inc.
Unauthorized alteration may void the warranty, render the equipment
unsafe or result in decreased performance.
• Before operating any controls, be certain you know what function they
control and the ramifications of that function.
• Before operating any hoist, ensure the rope is free and clear to travel.
• When hoisting/lowering rods, make sure the hoisting cable is in complete
tension before releasing the chuck.
• For additional information on training or start up, contact your Boart
Longyear representative.
• Do not use multiple part lines on the main hoist of the LF90.
NOTE:See following page for safety decals that appear on the machine.
BOART LONGYEAR
Table of Contents
Chapter 1 General Introduction
1-2 General Information
1-3 Ordering and Returning Parts
1-4 Standard Warranty
Chapter 2 Drill Introduction

2-2 General Drill Arrangement
2-3 Tech Data
Chapter 3 Drill Components

3-2 Drill Base Module
3-3 Power Unit - Cummins 5.9L QSB
3-4 Powerview Operations
3-20 Draw Works – Sub Frame Module
3-21 Wireline Hoist Assembly Diagram
3-22 Lower Mast Section Module
3-23 Upper Mast Section Module
3-24 Hydraulic Module
3-25 Rotation Unit Module
3-26 The Control Panel
Chapter 4 Drilling Operations

4-2 Introduction
4-4 Visual Inspection of Masts
4-6 Pre-Start Checklist
4-8 Anchoring the Drill
4-13 Start Up Procedures
4-15 Mast Installation and Raising
4-18 Collaring the Hole
4-20 Rod Handling
4-22 Force on Diamond Bit
4-23 Shutdown Procedure
4-24 Lowering the Mast
BOART LONGYEAR Table of Contents cont’d
Chapter 5 Hydraulic Explanation

5-4 Valves
5-5 Pumps
5-5 Fluid Conditioners
5-5 Actuators
5-6 Cautions and Warnings
5-7 Component Explanation
5-27 Pumps
5-41 Lubrication Chart
5-43 Actuators
Chapter 7 General Maintenance and Troubleshooting

7-2 Head Slide Wear Bars
7-3 LF90 Lubrication Chart
7-4 Engine - Powerview Monitor Fault Codes
7-8 PQ Head Drive Group
7-9 PQ Head Disassembly Procedures
7-21 PQ Head Reassembly Procedures
7-57 Transmission and Head Box Lubrication
7-58 PQ Nitro Gas Chuck Planograph
7-59 PQ Nitro Gas Chuck Assembly Procedures
7-67 Installation of New Jaws
7-68 Nitrogen Gas Springs
NOTE:
All photographs and illustrations are representations only.
Actual equipment may not be exactly as shown and should be verified with
your Boart Longyear representative.
All volumes are in US gallons and litres.
Refer to Lubrication Chart for Lubricant Types and Quantities.
BOART LONGYEAR CHAPTER 1
General Introduction
1-2 General Information
1-3 Ordering and Returning Parts
1-4 Standard Warranty
© 2005 Boart Longyear Inc. Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
BOART LONGYEAR General Introduction 1-2
General Information
The purpose of this manual is to furnish the operator with detailed information
which will enable him to achieve the maximum operating performance from
his drill. It will also give information necessary to perform preventative
maintenance and make minor repairs and adjustments.
Parts Lists, with corresponding views to aid in ordering parts, are also included
Boart Longyear is backed by over 100 years of experience in the design,
manufacture and operation of core drilling equipment. Many of the accepted
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.
Ordering and Returning Parts

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

2 State exact quantity required.
3 Specify description and part number as shown in parts manual.
4 Specify method of shipment, i.e. Parcel Post, Express, Freight; and for
Overseas shipment, Air Freight, Air Parcel Post, or Ocean Freight.
All parts are priced F.O.B., our factory and separate charge will be made for
transportation and export packing.
Returning Parts
1 If you desire to return parts, whether for repairs, replacement or warranty,
a letter should first be sent to:
Boart Longyear Inc.
P.O. Box 330
North Bay, Ontario
Canada PlB 8H6
This should specify quantity and part numbers, and model and serial
number of the product, as well as the reason for requesting return.
2 DO NOT ship parts until authorization and shipping instructions are
received.
3 All parts returned must be prepaid.
Standard Warranty
It is agreed that there are no warranties expressed or implied made by
Boart Longyear except its following standard warranty and no others.
Boart Longyear Inc. warrants each new core drill and related parts sold by it
to be free from defects in material and workmanship under normal use and
service for ninety (90) days from date of first use, but not to exceed six (6)
months from date of shipment.
The obligation under this warranty is limited to the replacement or repair at
the North Bay, Ontario plant of Boart Longyear, or at a point designated by it,
of such part or parts as shall appear upon inspection at this point to have
been defective in material or workmanship at the time sold, provided that the
part or parts claimed defective are returned to the inspection point,
transportation charges prepaid.
This warranty applies only to new and unused drills and parts which, after
shipment from the Boart Longyear factory, have not been altered, changed
or repaired in any manner. This does not extend to power units, pumps and
other trade accessories not manufactured by Boart Longyear, though sold
or operated with the Company’s drills, same being subject to warranties of
the respective manufacturers thereof.
In no event shall Boart Longyear be liable for consequential damages or

liabilities caused by the failure of any drill or parts to operate properly.
This manual contains all the information pertaining to the LF90 drill for
equipment furnished on the drill.
Drill Introduction
2-2 General Drill Arrangement
2-3 Tech Data
BOART LONGYEAR Drill Introduction 2-2
General Drill Arrangement

LF90 Diamond Core Drill System
LUBE
PRESSURE
MANIFOLD
PQ
ROTATION
UNIT
CROWN BLOCK TRANSMISSION

ASSEMBLY SHIFT LEVERS
YOKED ROD
CENTRALIZER
(2)
MAST SUPPORT
LEG (2)
ALUMINIUM
ROD SLIDES (2)
STEEL
ROD SLIDE
MAST RAISING
CYLINDER (2)
ROD/CHUCK
GUARD
MECHANICAL/
HYDRAULIC
LEVELLING JACK (4)
(Actual equipment may not be exactly as shown)
Tech Data
See Appendix A
Drill Components
3-2 Drill Base Module
3-3 Power Unit - Cummins 5.9L QSB
3-4 Powerview Operations
3-20 Draw Works – Sub Frame Module
3-21 Wireline Hoist Assembly Diagram
3-22 Lower Mast Section Module
3-23 Upper Mast Section Module
3-24 Hydraulic Module
3-25 Rotation Unit Module
3-26 The Control Panel
Power Unit Instrument Control Panel
Hydraulic Control Panel
Control Panel Plan-O-Graph
BOART LONGYEAR Modular Drill Components 3-2
Drill Base Module

Included in the standard drill base module are four mechanical levelling
jack legs, operator’s stand, battery box and 50 gallon fuel tank. The base is
The towing group is designed such that all top side components can be easily positioned and slid into
for off-road use only. Ensure place during assembly of the drill.
that the towing vehicle used
An optional dual axle towing group with 4 independent torque flex axles
has the proper towing hitch
rating.
and a heavy duty, pintle type draw bar is available.
Also optional is a hydraulic levelling jack group with 4 powerful, independently
operated hydraulic levelling jacks. Each jack is equipped with a hydraulic
locking valve and mechanical lockout for a secure drill set up.
Weight: 3,096 lb (1,404.4 kg)

(with dry fuel tank, hydraulic levelling jacks and dual axle towing group
options)
Drill Base Module
Power Unit - Cummins 5.9L QSB

The standard power unit module is a liquid cooled, 6 cylinder Cummins
6BTA 5.9L which is a turbo-charged, aftercooled, diesel engine rated at
200 hp (149 kW) (intermittent) with a displacement of 360 in3 or 5.9 liters.
The engine flywheel incorporates a composite toothed adapter plate which
drives the hydraulic pumps. This power unit features a high ambient industrial
style radiator and front mounted hydraulic oil coolers. An engine protection
shuts down the engine in case of overheating, engine over speeding or loss
of oil pressure. A protective enclosure minimizes the chance for external
damage and can be locked for security.
The power unit module includes a remote instrument control panel equipped
with an engine tachometer, hour meter, oil pressure, engine temperature
and voltmeter gauges, electric throttle and emergency stop.
Information on optional power units is available on request.
Weight: 2,021 lb (916.7 kg)
00-02-0528
™ Revised 02/06
Section 78
Installation and Operations Manual

Please read the following information before installing. A visual inspection of this product for damage during shipping is
recommended before mounting. It is your responsibility to have a qualified person install this unit.
GENERAL INFORMATION
Display Parameters
The following are some of the engine and transmission parameters displayed
WARNING by the PowerView in English or Metric units as well as in Spanish, French,

or German (when applicable, consult engine or transmission manufacturer
for SAE J1939 supported parameters):
❖ Engine RPM
BEFORE BEGINNING INSTALLATION OF THIS MURPHY PRODUCT ❖ Engine Hours
✔ Disconnect all electrical power to the machine. ❖ Machine Hours
❖ System Voltage
✔ Make sure the machine cannot operate during installation.
❖ % Engine Load at the current RPM
✔ Follow all safety warnings of the machine manufacturer.
❖ Coolant Temperature
✔ Read and follow all installation instructions. ❖ Oil Pressure
❖ Fuel Economy
❖ Throttle Position
Description
The PowerView is a powerful new display in a line of components manufactured ❖ Engine Manifold Air Temperature
by FWMurphy as part of its J1939 MurphyLink™† Family. The J1939 ❖ Current Fuel Consumption
MurphyLink™ Family of products have been developed to meet the needs for ❖ Transmission Oil Pressure
instrumentation and control on electronically controlled engines communicating ❖ Transmission Oil Temperature
using the SAE J1939 Controller Area Network (CAN). ❖ Transmission Gear Position
The PowerView System is comprised of the PowerView and the Mlink™ ❖ Active Service Codes
PowerView Gages. The PowerView is a multifunction tool that enables equipment ❖ Stored Service Codes (when supported)
operators to view many different engine or transmission parameters and service
❖ Set Units for display (English or Metric)
codes. The system provides a window into modern electronic engines and transmis-
sions. The PowerView includes a graphical backlit LCD screen. It has excellent ❖ Engine Configuration Parameters
contrast and viewing from all angles. Back lighting can be controlled via menu or
external dimmer potentiometer. The display can show either a single parameter or a Specifications
quadrant display showing four parameters simultaneously. Diagnostic capabilities Display: 1.3 x 2.6 in. (33 x 66 mm), 64 x 128 pixels.
include fault codes with text translation for the most common fault conditions. Operating Voltage: 8 VDC minimum to 32 VDC max.
The PowerView has four buttons using self-calibrating charge transfer activation Reversed Polarity: Withstands reversed battery terminal polarity indef-
technology, which eliminates the concern for pushbutton wear and failure. In addi- initely within operating temperatures.
tion, operators can navigate the display with ease.
Operating Temperature: -40 to +85ºC (-40 to185ºF).
The enhanced alarm indication has ultra bright alarm and shutdown LEDs (amber
& red). It has a wide operating temperature range of -40 to +85º C (-40 to185º F), Display Viewing Temperature: -40 to +75ºC (-40 to 167ºF).
display viewing -40 to +75º C (-40 to 167º F), and increased environmental sealing Storage Temperature: -40 to +85ºC (-40 to185ºF).
to +/- 5 PSI (± 34kPa). It also features Deutsch DT style connectors molded into Environmental Sealing: IP68, +/- 5 PSI (+/- 34.4 kPa).
the case and fits quickly and easily into existing 2-1/16 in. (52 mm) gage opening Power Supply Operating Current: (@ 14 VDC)=
with little effort. 52 mA minimum; 268 mA maximum (LCD heater on).
Other components in the system are microprocessor-based Mlink™ CAN BUS: SAE J1939 Compliant.
PowerView Gages for displaying critical engine data broadcast by an elec- Case: Polycarbonate / Polyester.
tronic engine or transmission’s Engine Control Unit (ECU): engine RPM, oil Clamp: Polyester (PBT).
pressure, coolant temperature, system voltage, etc. and a combination audi- Connectors: 6-Pin Deutsch DTO6 Series.
ble alarm and relay unit for warning and shutdown annunciation. Up to 32
components may be linked to the PowerView using a simple daisy chain Maximum Panel Thickness: 3/8 in. (9.6 mm).
wire connection scheme using RS485. The PowerView and all connected Mounting Hole: 2.062 inch (52 mm) in diameter.
components can be powered by 12- or 24-volt systems. Auxiliary Communications: Either:
Gages: One (1) RS485 port, MODBUS RTU master.
Warranty MODBUS: One (1) RS485 port, MODBUS RTU slave, selectable
A limited warranty on materials and workmanship is given with this baud rate; 9600; 19.2K; 38.4K.
FWMurphy product. A copy of the warranty may be viewed or printed by Potentiometer (External Dimmer)Input: 1K ohm, 1/4 W
going to www.fwmurphy.com/warranty.html
Shipping Weights (all models): 1/2 lb. (225 g.)
† MurphyLinkTM is a registered trademark of FWMurphy. All other trademarks and
service marks used in this document are the property of their respective owners. Shipping Dimensions (all models): 6 x 6 x 6 in. (152 x 152 x 152 mm).
Installation 00-02-0528 page 1 of 18
GENERAL INFORMATION continued
Table of Contents Faceplate Features

General Information page # Amber Red Shutdown
Warning LED Derate LED
Description................................................. 1
Display Parameters.................................... 1
Specifications............................................. 1
Display
Key Pad Functions..................................... 2 Bezel
Mechanical Installation
Typical Mounting Dimensions................... 2
Typical Quick-connect Diagram................ 3 Menu Key Enter Key
Electrical Installation
PIN Connectors Nomenclature.................. 3 Left Arrow Key (Scroll Up) Right Arrow Key (Scroll Down)
Typical Wiring Diagrams........................... 4
Keypad Functions
Operations The keypad on the PowerView is a capacitive touch sensing system.
First Time Start Up................................... 5 There are no mechanical switches to wear or stick, and the technology
has been time proven in many applications. It operates in extreme tem-
Main Menu Navigation............................. 5 peratures, with gloves, through ice, snow, mud, grease, etc., and it allows
Selecting a Language................................. 5 complete sealing of the front of the PowerView. The ‘key is touched’
Stored Fault Codes.................................... 6 feedback is provided by flashing the screen. The keys on the keypad per-
form the following functions:
Engine Configuration Data....................... 6
Faults and Warnings............................... .7 – Menu Key - The Menu Key is touched to either
Active Fault Codes................................... 8 enter or exit the menu screens.
Shutdown Codes...................................... 8
Back Light Adjustment............................ 9 – Left Arrow - The Left Arrow Key is touched
to scroll through the screen either moving the para-
Contrast Adjustment.............................. 10 meter selection toward the left or upward.
Select Units............................................... 10
Setup 1-Up Display................................... 11 – Right Arrow - The Right Arrow Key is touched
Setup 4-Up Display.................................. 14 to scroll through the screen either moving the parameter
selection toward the right or downward.
Utilities.....................................................15
MODBUS Setup....................................... 15
– Enter Key - The Enter Key (also known as Enter
J1939 Parameters....................................17 Button) is touched to select the parameter that is high-
Glossary...................................................18 lighted on the screen.
Typical Mounting Dimensions

SIDE HOLE CUTOUT
3.489 in.
(89 mm) 1.972 in.
1.94 in. 2.062 in. (50 mm)
FRONT (50 mm) (52 mm)
diameter
2.070 in. .953 in.
(53 mm) (24 mm)
2.41 in. 0.125 in. R 0.063 in.

(61 mm) (3 mm) (1.6 mm)
0.78 in. (20 mm)
4.25 in. 3.18 in. (81 mm)
(108 mm)
MECHANICAL INSTALLATION
Typical Quick-Connect Diagram
Last PVA Gage or

PVAA Audible Alarm To optional
To Engine
external device
ECU To PVAA
A B
Audible Alarm
Terminating
To Battery Resistor PVJR
Power B
Relay N.O.
POWERVIEW A
Relay N.C.
PV100 OR Ext.
PVW-CH
Sonalert
Relay Comm.
Customer provided wire Optional PVW-A wire harness

(includes terminating resistor)
harness or CAN extension B
PVW-PH
A
harnesses or power
extension harnesses.
PVA Gage Next PVA Gage
Wire harness
External Dimmer PVW-J
Wire 24 inch.
B A B
External A
Dimmer
B+
GRND
CAN–SHLD
CAN–LO
CAN–HI
Wire harness PVW-P Wire harness PVW-J Wire harness PVW-J
ELECTRICAL INSTALLATION
PowerView Unit Back View

Deutsch DT06-6S Style Connections
Plug A Plug B
PIN 3 CAN LO PIN 4 CAN SHLD PIN 3 RS485+ PIN 4 RS485 –

– –
PIN 2 CAN HI
–
PIN 5 Dimmer A B
Potentiometer
PIN 1 V+ PIN 6 GRND PIN 1 V+ PIN 6 GRND
Recommended Connectors:
Body: Deustch DT06-6S
Wedge Lock: W6S
Terminals: 0462-201-16141
Sealing Plug: 114017
TYPICAL WIRING DIAGRAMS
IMPORTANT: To eliminate external interference: RS485(+) and RS485(-) should be twisted pair cable or twist wires together, one twist per
inch minimum. CAN–L, CAN–H and CAN Shield should be approved J1939 CAN bus cable (CAN wire for example: RADOX plug and play cable,
from Champlain cable). (RS485 wire for example: BELDEN 9841 or 3105A).
PowerView Deutsch DT06-6S Style Unit to PVA Gage

NOTE 5 RS485 (+) Data
Pin 3
Back View
NOTE 4 120 ohms
NOTE 2 RS485 (-) Data
Pin 4
Gray-CAN_SHLD Pin 4
ENGINE See
CONTROL Pin 3 NOTE 6
Green-CAN_L
MODULE 120 Ω
(SAE J1939 Yellow-CAN_H See Note Pin 2
Compliant) PVA Gage
NOTE 1
V+
Pin 1
Pin 1
Pin 6
Pin 5
Red-V+ Pin 6 GRND
Ignition Gray-Ground
Switch
Note 1: Place Resistor between Note 4: Only use 120 ohm
Blue-Back Light CAN–H and CAN–L Line near characteristic impedance cable,
NOTE 7 PowerView (included in PVW-P or ex Belden 9841.
Battery factory purchased panels).
Note 5: RS485 shield connected
Illumination Note 2: Use SAE J1939 compliant to PowerView end only.
Control*(optional) wiring or equipment.
Note 6: Place Resistor at End of
NOTE 3 Note 3: Electronic dimmer switch Line on last PVA gage. (Included
recommended with 4A, capacity for factory purchased panels.)
or heavy duty rheostat switch,
1000 ohm, 0.25 watt. Note 7: If a backlight dimmer is not
used, connect the blue backlight wire
to ground. Do not leave the blue
backlight wire unconnected.
PowerView Deutsch DT06-6S Style Unit to MODBUS Output

NOTE 5 RS485 (+) Data
Pin 3
NOTE 4 to MODBUS Output
NOTE 2 RS485 (-) Data See NOTES 6 and 8
Pin 4
Gray-CAN_SHLD Pin 4
ENGINE
CONTROL Pin 3
Green-CAN_L
MODULE 120 Ω
(SAE J1939 Yellow-CAN_H See Note Pin 2
Compliant)
NOTE 1
Note 4: Only use 120 ohm
Pin 1
characteristic impedance cable,

Pin 6
Pin 5
Red-V+ ex Belden 9841.
Ignition Note 5: RS485 shield connected

Gray-Ground
Switch Note 1: Place Resistor between to PowerView end only.
CAN–H and CAN–L Line near
Blue-Back Light PowerView (included in PVW-P Note 6: Place Resistor at End of Line.
NOTE 7 or factory purchased panels). (Included for factory purchased panels.)
Battery
Note 2: Use SAE J1939 compliant Note 7: If a backlight dimmer is not
NOTE 3 used, connect the blue backlight wire
Illumination Control*(optional) wiring or equipment.
to ground. Do not leave the blue
Note 3: Electronic dimmer switch backlight wire unconnected.
recommended with 4A, capacity
or heavy duty rheostat switch,
For a complete listing of MODBUS Registers 1000 ohm, 0.25 watt.
Note 8: PVA gages cannot be used
with the MODBUS feature.
visit our website at www.fwmurphy.com
POWERVIEW OPERATION
PowerView Menus (First Time Start Up) 3. Touching the right arrow button will scroll down to reveal the last
1. When power is first applied to the PowerView, the "Logo" is displayed. items of “Main Menu” screen highlighting the next item down.
ADJUST BACKLIGHT
ADJUST CONTRAST
UTILITIES
2. The "Wait to Start" message will be displayed for engines with a 4. Touch the "Arrows" to scroll to the desired menu item or touch "Menu"
pre-startup sequence. Once the "Wait to Start" message is no longer dis-
to exit the Main menu and return to the engine parameter display.
played the operator may start the engine. Note: Displays only when SAE
J1939 message is supported by engine manufacturer. GO TO 1-UP DISPLAY
LANGUAGES 98% 1000 RPM
STORED CODES LOAD@RPM ENG RPM
ENGINE CONF
WAIT TO SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY 14.2 57 PSI
START SELECT UNITS BAT VOLT OIL PRES
PREHEAT
3. Once the engine has started the single engine parameter is displayed.
Selecting a Language
0 1500 3000
1. Starting at the main menu display use the "Arrows" to scroll to the
"Language" menu and once highlighted touch the "Enter" button.
1800 RPM GO TO 1-UP DISPLAY
LANGUAGES
LANGUAGES
ENG RPM COOL TEMP STORED CODES
ENGINE CONF
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
Main Menu Navigation

1. Starting at the single or four engine parameter display, touch "Menu".
2. The language choices will be displayed. Use the "Arrow" buttons to
98% 1000 RPM scroll through the selections and touch "Enter" to make a selection.
0 1500 3000 LOAD@RPM ENG RPM
1800 RPM ENGLISH ❋

14.2 57 PSI ESPAÑOL
ENG RPM COOL TEMP BAT VOLT OIL PRES
FRANÇAIS
DEUTSCH
2. The first seven items of the “Main Menu” will be displayed.

Touching the "Arrow Buttons" will scroll through the menu selection.
GO TO 1-UP DISPLAY
LANGUAGES
STORED CODES
ENGINE CONF
3. Now that you have selected the language, touch the "Menu" button to
SETUP 1-UP DISPLAY return to the main menu display.
SETUP 4-UP DISPLAY
SELECT UNITS
POWERVIEW OPERATION continued
Stored Fault Codes 5. Touch the "Menu Button" to return to the main menu.
1. Starting at the single or the four engine parameter display touch the 1 of x
"Menu button".
SPN110 FMI10
98% 1000 RPM HIGH COOLANT TEMP
1800 RPM
▼
▼
MORE HIDE
ENG RPM COOL TEMP 14.2 57 PSI

BAT VOLT OIL PRES
6. Touch the "Menu Button" to exit the Main menu and return to the
engine parameter display.
2. The main menu will pop up on the display. Use the "Arrow Buttons" to
scroll through the menu until the Stored Fault Codes is highlighted. GO TO 1-UP DISPLAY
98% 1000 RPM
STORED CODES
LOAD@RPM ENG RPM
ENGINE CONFG
GO TO 1-UP DISPLAY SETUP 1-UP DISPLAY
STORED CODES
STORED CODES SETUP 4-UP DISPLAY
SELECT UNITS 14.2 57 PSI
ENGINE CONFG ADJUST BACKLIGHT BAT VOLT OIL PRES
SETUP 1-UP DISPLAY

SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
Engine Configuration Data

1. Starting at the single or four engine parameter display touch the
"Menu Button".
3 Once the "Stored Fault Codes" menu item has been highlighted touch 98% 1000 RPM
the "Enter Button" to view the "Stored Fault Codes" (when applicable, 0 1500 3000 LOAD@RPM ENG RPM
consult engine or transmission manufacturer for SAE J1939 supported 1800 RPM
14.2 57 PSI
parameters). ENG RPM COOL TEMP BAT VOLT OIL PRES
GO TO 1-UP DISPLAY
STORED CODES
STORED CODES
ENGINE CONFG
SETUP 1-UP DISPLAY 2. The main menu will pop up on the display. Use the "Arrow Buttons"
SETUP 4-UP DISPLAY to scroll through the menu until the "Engine Configuration" is highlighted.
SELECT UNITS
ADJUST BACKLIGHT GO TO 1-UP DISPLAY
STORED CODES
ENGINE
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
4. If the word "MORE" appears above the "Arrow Buttons" there are
more stored fault codes that may be viewed. Use the "Arrow Buttons" to
scroll to the next Stored Diagnostic Code.
3. Once the "Engine Configuration" menu item has been highlighted
1 of x touch the "Enter Button" to view the engine configuration data.
SPN110 FMI10 GO TO 1-UP DISPLAY

STORED CODES
HIGH COOLANT TEMP ENGINE
ENGINE CONFG
CONFG
SETUP 1-UP DISPLAY
▼
▼
MORE HIDE
SETUP 4-UP DISPLAY
SELECT UNITS
ADJUST BACKLIGHT
4. Use the "Arrow Buttons" to scroll through the engine configuration data. or normal operation an auxiliary gage should fail, the single or four para-
meter screen will be replaced with the "MLink Gage Fault" message.
ENGINE SPEED PT 1
1000 RPM 1 of x
ENGINE OIL PRESSURE

GAGE NOT RESPONDING
▼
▼
MORE
HIDE
5. Touch the "Menu Button" to return to the main menu.

ENGINE SPEED PT 1 3. To acknowledge and "Hide" the fault and return to the single or
four parameter display, touch the "Enter Button".
1000 RPM 1 of x
ENGINE OIL PRESSURE

▼
▼
MORE
GAGE NOT RESPONDING
HIDE
GO TO 1-UP DISPLAY
STORED CODES 98% 1000 RPM 4. The display will return to the single or four parameter screen.
LOAD@RPM
ENGINE CONFG
CONFG ENG RPM
SETUP 1-UP DISPLAY

SETUP 4-UP DISPLAY
SELECT UNITS 14.2 57 PSI ! 98% 1000 RPM
OIL PRES
ADJUST BACKLIGHT BAT VOLT
1800 RPM !
14.2 57 PSI
ENG RPM COOL TEMP ! BAT VOLT OIL PRES !
! Indicates Auxiliary Gage Fault
.! Indicates Fault Warning

! Indicates Derate or Shutdown Condition Fault
Faults and Warnings 5. Touching the "Enter Button" will redisplay the hidden fault.
Touching the "Enter Button" once again will hide the fault and return the
Auxiliary Gage Fault screen to the single or four parameter display. NOTE: The fault can only
1. During normal operation the single or four parameter screen will be be cleared by correcting the cause of the fault condition.
displayed. 1 of x
98% 1000 RPM ENGINE OIL PRESSURE

GAGE NOT RESPONDING
1800 RPM
14.2 57 PSI HIDE
2. The PVA Series of auxiliary gages can be attached to the PowerView.

These auxiliary gages communicate with the Modbus master PowerView
via a daisy-chained RS-485 port. If at any time during system initialization
Active Fault Codes 5. The display will return to the single or four parameter display, but the
display will contain the "Active Fault"warning icon. Touching the "Enter
1. During normal operation the single or four parameter screen will be
Button" will redisplay the hidden fault.
displayed.
! 98% 1000 RPM
98% 1000 RPM 0 1500 3000 LOAD@RPM ENG RPM
LOAD@RPM ENG RPM
0 1500 3000
1800 RPM !
1800 RPM 14.2 57 PSI ENG RPM COOL TEMP ! 14.2
BAT VOLT
57 PSI
OIL PRES !
6. Touching the "Enter Button" once again will hide the fault and
2. When the PowerView receives a fault code from an engine control
unit the single or four parameter screen will be replaced with the "Active return the screen to the single or four parameter display.
Fault Codes" message. 1 of x WARNING
1 of x WARNING
SPN110 FMI0
SPN110 FMI0
HIGH COOLANT TEMP
HIGH COOLANT TEMP MORE HIDE
▼
▼
MORE HIDE
7. The Single or Four parameter screen will display the fault icon until
the fault condition is corrected. NOTE: Ignoring active fault codes could
3. If the word "MORE" appears above the "Arrow Buttons" there are result in severe engine damage.
more active fault codes that may be viewed.
Use the "Arrow Buttons" to scroll to the next "Active Fault Code" GO TO 1-UP DISPLAY
STORED CODES 98% 1000 RPM
LOAD@RPM ENG RPM
ENGINE CONFG
SETUP 1-UP DISPLAY
1 of x
SETUP 4-UP DISPLAY
!
SPN110 FMI0 ADJUST BACKLIGHT BAT VOLT OIL PRES !
HIGH COOLANT TEMP
▼
▼
MORE HIDE
Shutdown Codes
1. During normal operation the single or four parameter screen will be displayed.
98% 1000 RPM
4. To acknowledge and "Hide" the fault and return to the single or four
parameter display touch the "Enter Button".
1800 RPM
14.2 57 PSI
1 of x
SPN110 FMI0
HIGH COOLANT TEMP 2. When the PowerView receives a severe fault code from an engine con-
trol unit the single or four parameter screen will be replaced with the
▼
MORE HIDE "Shutdown!" message.
1 of x SHUTDOWN
SPN110 FMI0
HIGH COOLANT TEMP
MORE HIDE

3. To acknowledge and "Hide" the fault and return to the single or 2. The main menu will pop up on the display. Use the "Arrow Buttons"
four parameter display touch the "Enter Button". to scroll through the menu until the "Adjust Backlight" is highlighted.
1 of x SHUTDOWN GO TO 1-UP DISPLAY
STORED CODES
SPN110 FM10 ENGINE CONFG
HIGH COOLANT TEMP SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
MORE HIDE SELECT UNITS
ADJUST BACKLIGHT
ADJUST BACKLIGHT
4. The display will return to the single or four parameter display, but
the display will contain the "Shut Down" icon. Touching the "Enter 3. Once the "Adjust Backlight" menu item has been highlighted touch
Button" will redisplay the hidden fault. the "Enter Button" to activate the "Adjust Backlight" function.
GO TO 1-UP DISPLAY
! 98% 1000 RPM
0 1500 3000 LOAD & RPM ENG RPM
STORED CODES
ENGINE CONFG
1800 RPM ! SETUP 1-UP DISPLAY
14.2 57 PSI SETUP 4-UP DISPLAY
ENG RPM COOL TEMP! BAT VOLT OIL PRES
SELECT UNITS
ADJUST BACKLIGHT
5. Touching the "Enter Button" once again will hide the fault and return
the screen to the single or four parameter display.
1 of x SHUTDOWN 4. Use the "Arrow Buttons" to select the desired backlight intensity.
SPN110 FM10 ADJUST BACKLIGHT
HIGH COOLANT TEMP
MORE HIDE
6. The Single or Four parameter screen will display the fault icon until
the fault condition is corrected. NOTE: Ignoring active fault codes could
result in severe engine damage. 5. Touch the "Menu Button" to return to the main menu.
! 98% ADJUST BACKLIGHT

LOAD & RPM
1000 RPM
0 1500 3000 ENG RPM
1800 RPM !
14.2 57 PSI
ENG RPM COOL TEMP ! BAT VOLT OIL PRES
!
Back Light Adjustment

1. Starting at the single or four engine parameter display touch the 6. Touch the "Menu Button" to exit the Main menu and return to the
"Menu Button".
GO TO 1-UP DISPLAY
98% 1000 RPM ENGINE CONFG LOAD@RPM ENG RPM
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
1800 RPM SELECT UNITS 14.2 57 PSI
14.2 57 PSI ADJUST BACKLIGHT BAT VOLT OIL PRES
Contrast Adjustment Select Units

1. Starting at the single or four engine parameter display, touch the 1. Starting at the single or four engine parameter display touch the
"Menu Button". "Menu Button".
98% 1000 RPM 98% 1000 RPM

LOAD@RPM
0 1500 3000 ENG RPM
1800 RPM 1800 RPM

14.2 57 PSI 14.2 57 PSI
2. The main menu will pop up on the display. Use the arrow buttons to
2. The main menu will pop up on the display. Use the "Arrow Buttons"
scroll through the menu until the "Select Units" is highlighted.
to scroll through the menu until "Adjust Contrast" is highlighted.
GO TO 1-UP DISPLAY
GO TO 1-UP DISPLAY STORED CODES
STORED CODES ENGINE CONFG
ENGINE CONFG SETUP 1-UP DISPLAY
SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY
SETUP 4-UP DISPLAY SELECT
SELECTUNITSD
UNITS
SELECT UNITS ADJUST BACKLIGHT
ADJUST BACKLIGHT
3. Once the "Select Units" menu item has been highlighted touch the
3. Once the "Adjust Contrast" menu item has been highlighted touch "Enter Button" to access the "Select Units" function.
the "Enter Button" to activate the "Adjust Contrast" function. GO TO 1-UP DISPLAY
STORED CODES
STORED CODES ENGINE CONFG
ENGINE CONFG SETUP 1-UP DISPLAY
SETUP 1-UP DISPLAY SETUP 4-UP DISPLAY
SETUP 4-UP DISPLAY SELECT
SELECTUNITSD
UNITS
SELECT UNITS ADJUST BACKLIGHT
ADJUST BACKLIGHT
ADJUST CONTRAST
4. Use the arrows to highlight the desired units. "English" for Imperial
units i.e. PSI, ºF or Metric kPa, Metric Bar for IS units i.e. kPa, Bar, ºC.
4. Use the "Arrow Buttons" to select the desired contrast intensity.
ENGLISH
ADJUST CONTRAST METRIC KPA
METRIC BAR
5. Touching the "Menu Button" will take you back through the menus. 5. Touch the "Enter Button" to select the highlighted units.
ENGLISH
METRIC KPA
METRIC BAR

6. Touch the "Menu Button" to return to the "Main Menu". 4. Three options are available for modification of the 1-Up display.
a). Use Defaults – This option contains a set of engine parameters:
ENGLISH ❉ Engine Hours, Engine RPM, System Voltage, Battery Voltage, %
METRIC KPA
METRIC BAR
Engine Load at Current RPM, Coolant Temperature, Oil Pressure.
b). Custom Setup – This option allows for the modification of what
parameter, the number of parameters, and the order in which the
parameters are being displayed.
c). Automatic Scan – Selecting the scan function will cause the
1-Up Display to scroll through the selected set of parameters
one at a time, momentarily pausing at each.
5. Use Defaults - To select "Use Defaults" use the arrow buttons to
scroll to and highlight "Use Defaults" in the menu display.
engine parameter display. USE DEFAULTS
USE DEFAULTS
CUSTOM SETUP
GO TO 1-UP DISPLAY
98% AUTOMATIC SCAN OFF
STORED CODES
LOAD@RPM
1000 RPM
ENG RPM
ENGINE CONFG
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
BAT VOLT OIL PRES
ADJUST BACKLIGHT
6. Touch the "Enter Button" to activate the "Use Defaults" function.

USE
USEDEFAULTS
DEFAULTS
Setup 1-Up Display CUSTOM SETUP
AUTOMATIC SCAN OFF
1. Starting at the single engine parameter display, touch the "Menu Button".
98% 1000 RPM
LOAD@RPM ENG RPM
0 1500 3000
1800 RPM 14.2 57 PSI

7. A message indicating the “Single Engine” parameter display parame-

ters are reset to the factory defaults will be displayed, then the display
2. The main menu will pop up on the display. Use the "Arrow Buttons" to
will return to the “Custom Setup” menu.
scroll through the menu until the "Setup 1-up Display" is highlighted.
GO TO 1-UP DISPLAY
STORED CODES RESTORED TO
ENGINE CONFG DEFAULTS
SETUP1-UP
SETUP 1-UPDISPLAY
DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITSD
ADJUST BACKLIGHT
3. Once the "Setup 1-up Display" menu item has been highlighted
touch the "Enter Button" to access the "Setup 1-up Display" function.
GO TO 1-UP DISPLAY
STORED CODES
ENGINE CONFG
SETUP1-UP
SETUP 1-UPDISPLAY
DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITSD
ADJUST BACKLIGHT

8. Custom Setup - To perform a custom setup of the 1-Up Display, use 13. Touch the "Enter button" to select the highlighted parameter for inc
the arrow buttons to scroll to and highlight "Custom Setup" on the display. sion in the Single Engine Parameter Display.
USE DEFAULTS
ENGINE SPEED
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF PERCENT LOAD AT CURRENT RPM 2
ENGINE OIL PRESSURE 1
ENGINE COOLANT TEMP 3
9. Touching the "Enter Button" will display a list of engine parameters.

14. Continue to scroll and select additional parameters for the custo
USE DEFAULTS 1-Up Display. Touch the "Menu button" at any time to return to the
CUSTOM
CUSTOMSETUP
SETUP
AUTOMATIC SCAN OFF
"Custom Setup" menu.
15. Automatic Scan - Selecting the scan function will cause th

Up Display to scroll through the selected set of parameters one at a t
Use the "Arrow Buttons" to scroll to the "Automatic Scan" function
USE DEFAULTS
CUSTOM SETUP
10. Use the "Arrow Buttons" to scroll to and highlight a selected para- AUTOMATIC
AUTOMATICSCAN OFF
SCAN OFF
meter (parameter with a # symbol to right of it).
USE DEFAULTS
ENGINE SPEED 1
PERCENT LOAD AT CURRENT RPM 3
ENGINE OIL PRESSURE 2 This number indicates
the order of display for
ENGINE COOLANT TEMPERATURE
the parameters and
that the parameter is
selected for display.
16. Touching the "Enter Button" toggles the "Automatic Scan" functio
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
AUTOMATICSCAN OFF
SCAN ON
11. Touch the "Enter Button" to deselect the selected parameter remov-
ing it from the list of parameters being displayed on the 1-up display.
USE DEFAULTS
ENGINE SPEED 1
ENGINE COOLANT TEMPERATURE
17. Touching the "Enter Button" again toggles the "Automatic Scan
function off.
USE DEFAULTS
CUSTOM SETUP
AUTOMATIC
AUTOMATICSCAN OFF
SCAN OFF
12. Use the "Arrow Buttons" to scroll and highlight the desired parameter
that has not been selected for display.
ENGINE SPEED
ENGINE OIL PRESSURE 1 Note that the numbers
now indicate the new
ENGINE COOLANT TEMP
order of display for
the parameters.
18. Once the "Use Defaults", "Custom Setup" and "Automatic Scan" func- 4. Touch the "Enter Button" to activate the "Use Defaults" function.
ns have been set touch the "Menu Button" to return to the main menu. This action will reset the unit to the factory default.
USE DEFAULTS USE
USE DEFAULTS
DEFAULTS
CUSTOM SETUP CUSTOM SETUP
AUTOMATIC
AUTOMATICSCAN OFF
SCAN ON
5. The "Use Defaults"screen will be displayed during the reseting peri-

19. Touch the "Menu Button" to exit the Main menu and return to the od then will automatically return to the "Setup 4-Up Display" menu.
gine parameter display.
GO TO 1-UP DISPLAY
STORED CODES RESTORED TO
ENGINE CONFG 0 1500 3000
SETUP 1-UP DISPLAY DEFAULTS
SETUP 4-UP DISPLAY
SELECT UNITS
1800 RPM
ADJUST BACKLIGHT ENG RPM COOL TEMP
6. Select the "4-Up Custom Setup" from the "4-Up Setup" menu.
Setup 4-Up Display USE DEFAULTS
1 From the single or four engine parameter display touch the "Menu Button". CUSTOM
CUSTOM SETUP
SETUP
98% 1000 RPM

LOAD@RPM
0 1500 3000 ENG RPM
1800 RPM 57 PSI

14.2
2 The main menu will pop up on the display. Use the "Arrow Buttons" to 7. The quadrent with the backlit parameter value is the current selected
roll through the menu until the "Setup 4-Up Display" is highlighted. parameter. Use the "Arrow Buttons" to highlight the parameter value in
the quadrant you wish to place a new parameter.
GO TO 1-UP DISPLAY
STORED CODES 125°F 1000 RPM
ENGINE CONFG COOL TEMP ENG RPM
SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
14.2
14.2 57 PSI
SELECT UNITS
ADJUST BACKLIGHT BAT VOLT OIL PRESP
3 Once the "Setup 4-Up Display" menu item has been highlighted
8. Touch the "Enter Button" and a list of parameters will appear.
uch the "Enter Button" to activate the "Setup 4-Up Display" menu.
GO TO 1-UP DISPLAY 125°F 1000 RPM

STORED CODES COOL TEMP ENG RPM
ENGINE CONFG
SETUP 1-UP DISPLAY 14.2
14.2 57 PSI
SETUP
SETUP 4-UP
4-UP DISPLAY
DISPLAY BAT VOLT OIL PRESP
SELECT UNITS
ADJUST BACKLIGHT

9. The parameter that is highlighted is the selected parameter for the 15. Touch the "Menu Button" to exit the Main menu and return to the
screen. Use the "Arrow Buttons" to highlight the new parameter to be engine parameter display.
placed in the quadrent selected in the previous screen. GO TO 1-UP DISPLAY
ENGINE SPEED 3 The number to the right of the ENGINE CONFG COOL TEMP ENG RPM
ENGINE HOURS parameter indicates the quadrant SETUP 1-UP DISPLAY

in which it is displayed. SETUP 4-UP DISPLAY
DISPLAY
ENGINE COOLANT TEMPERATURE 1 SELECT UNITS 143°F 57 PSI
BATTERY POTENTIAL 1. = Upper Left Quadrent ADJUST BACKLIGHT OIL TEMP OIL PRES
ENGINE OIL TEMPERATURE

TEMPERATURE 2 2. = Lower Left Quadrent
ENGINE OIL PRESSURE 4 3. = Upper Right Quadrent
4.= Lower Right Quadrent
10. Touch the "Enter Button" to change the selected parameter in the Utilities (Information and troubleshooting)
quadrant to the new parameter. 1. Starting at the single or four engine parameter display, touch the “Menu button”.
ENGINE SPEED 3
ENGINE HOURS 125% 1000 RPM
0 1500 3000 COOL TEMP ENG RPM
ENGINE COOLANT TEMPERATURE 1
BATTERY POTENTIAL 2 1800 RPM
TEMPERATURE 143°F 57 PSI
ENG RPM COOL TEMP OIL TEMP OIL PRES
2. The main menu will be displayed. Use the “Arrow buttons” to scroll
11. Use the "Menu Button" to return to the “4-UP Custom Setup” screen. through the menu until the “Utilities” is highlighted.
ENGINE SPEED 3 STORED CODES

ENGINE HOURS ENGINE CONFG
SETUP 1-UP DISPLAY
ENGINE COOLANT TEMPERATURE 1
SETUP 4-UP DISPLAY
BATTERY POTENTIAL SELECT UNITS
TEMPERATURE 2 2 Note the number to the right of
ADJUST BACKLIGHT
ENGINE OIL PRESSURE 4 the selected parameter indicating
UTILITIES
that the parameter is now
assigned to that display location.
12. The parameter in the selected quadrent has changed to the parame- 3. Once the “Utilities” menu item has been highlighted, touch the
ter selected in the previous screen. “Enter Button” to activate the “Utilities” functions.
STORED CODES
125°F ØRPM
1000 RPM ENGINE CONFG
COOL TEMP ENG RPM SETUP 1-UP DISPLAY
SETUP 4-UP DISPLAY
SELECT UNITS
143°F 57 PSI ADJUST BACKLIGHT
OIL TEMP OIL PRESP UTILITIES
4. Touch "Select" to enter the “Gage Data” display. When “Gage Data” is
13. Repeat the parameter selection process until all spaces are filled. selected the PowerView will communicate with the analog gages at a fixed
14. Touch the "Menu Button" to return to the main menu. rate of 38.4 k Baud, 8 data bits, no parity check, 1 stop bits, half duplex.
125°F ØRPM GAGE DATA

1000 RPM
REMOVE ALL GAGES
COOL TEMP ENG RPM
SOFTWARE VERSION
MODBUS SETUP
143°F 57 PSI FAULT CONVERSION
OIL TEMP OIL PRESP DEMO MODE ON
SAE J1939 MurphyLink System Implementation of J1939 Parameters

Source: SAEJ1939-71 Surface Vehicle Recommended Practice
Description PGN Parameter Display Value
Elec Eng Cont #2 - EEC2 61443 Accelerator Pedal Position THROTTLE

Percent Load at Current RPM LOAD@RPM
Elec Eng Cont #1 - EEC1 61444 Actual engine % torque ENG TORQ
Engine Speed ENG RPM
Engine hours, Revolutions 65253 Total Engine Hours ENG HRS
Fuel Consumption 65257 Trip Fuel TRIP FUEL
Total Fuel Used FUEL USED
Engine Temperature 65262 Engine Coolant Temp COOL TEMP
Fuel Temperature FUEL TEMP
Engine Oil Temperature OIL TEMP
Engine Intercooler Temperature INTC TEMP
Engine Fluid Level/Pressure 65263 Fuel Delivery Pressure FUEL PRES
Engine Oil Level OIL LVL
Engine Oil Pressure OIL PRES
Coolant Pressure COOL PRES
Coolant Level COOL LVL
Fuel Economy 65266 Fuel Rate FUEL RATE
Instantaneous Fuel Economy FUEL ECON
Average Fuel Economy AVG ECON
Ambient Conditions 65269 Barometric Pressure BARO PRES
Air Inlet Temperature AIR IN TP
Inlet/Exhaust Conditions 65270 Boost Pressure BST PRES
Intake Manifold Temp MANI TEMP
Air Filter Differential Pressure AIR DIF PR
Exhaust Gas Temperature EXH TEMP
Engine Fluid Level/Pressure #2 65243 Injector Metering Rail 1 Pres INJ PRES1
Injector Metering Rail 2 Pres INJ PRES2
Fan Drive-FD 65213 Estimated Percent Fan Speed FAN SPD
65226 DM1 - Active Diagnostic SRVCCODE
Diagnostic Messages 65227 DM2 - Previously Act Diag Codes STORCODE
65228 DM3 - Diagnostic Clear
Machine Hours (PowerView Calculated) N/A Machine Hours MACH HRS
Engine Conf. 65251 Engine Configuration ENG CONF
Hydraulic Pressure Governor Info-HPG 61448 Hydraulic Oil Pressure HYD PRES
Electronic Transmission Controller #1 61442 Output Shaft Speed OUT SFT SP
Electronic Transmission Controller #1 61442 Input Shaft Speed IN SFT SPD
Electronic Transmission Controller #1 61442 Torque Converter Lockup Engaged TORQ LOCK
Electronic Transmission Controller #2 61445 Selected Gear SLECT GEAR
61445 Current Gear CURNT GEAR
Transmission Fluids 65272 Transmission Oil Pressure TRAN PRES
Transmission Oil Temperature TRAN TEMP
Transmission Control 1-TC1 256 Requested Gear REQ GEAR
Auxiliary Pressures & Temperatures 65164 Auxiliary Temperature AUX TEMP
Auxiliary Pressure AUX PRES
Auxiliary Input/Output Status 65241 Auxiliary I/O #1 AUX 10 1
Cruise Control /Vehicle Speed 65265 Wheel Based Vehicle Speed VEH SPD
Alternator Voltage ALT VOLT
Vehicle Electrical Power 65271 Electrical Potential (Voltage) SYS VOLT
Battery Pot. Voltage (Switched) BAT VOLT
Vehicle Distance 65248 Trip Distance TRIP DIST
Total Vehicle Distance VEH DIST
Vehicle Fluids-VF 65128 Hydraulic Oil Temperature HYD TEMP
Dash Display-DD 65276 Fuel Level FUEL LEVEL
Rudder 127245 Rudder Angle RUD ANG
Speed 128259 Water Referenced H20 REF.SP
Small Craft Status, Port Trim 130576 Port Trim Tab P TRIM TAB
Small Craft Status, Starboard Trim 130576 Starboard Trim Tab S TRIM TAB
Support Allison DTCs Retarded Temperature Above Normal RETARDED OIL TEMPERATURE ABOVE NORMAL
(SPN=120, FMI=15)
Transmission Oil Temperature Above TRANSMISSION OIL TEMPERATURE ABOVE NORMAL
Normal (SPN=177, FMI=15)
Unknown General Transmission Fault GENERAL TRANSMISSION FAULT UNKNOWN
(SPN=2003, FMI=31)
GLOSSARY (Troubleshooting information)
CANBUS FAILURE
PowerView has not received any CAN messages for at least 30 seconds.
NO DATA
PowerView has not received the particular message being displayed for
at least 5 seconds.
NOT SUPPORTED
PowerView has received a message from the ECU stating the displayed
message is not supperted.
DATA ERROR
PowerView has received an error message from the ECU for the dis-
played message.
EMPTY
No parameter selected for this 4-UP quadrant.
WAIT TO START PREHEATING

This is a message from the engine indicating it is in a preheating cycle.
Wait until this message clears before starting the engine.
TIMEOUT ECU NOT RESPONDING

The ECU did not respond to the PowerView request.
NO GAGE DATA
The PowerView has no record of connected gages to the RS485 bus.
Display Not Visible

Press and hold the “Menu” button for approximately 3 seconds.
MURPHY, the Murphy logo, and POWERVIEW™ are registered and/or common law trademarks of Murphy Industries,
www.fwmurphy.com Inc. This document, including textual matter and illustrations, is copyright protected by Murphy Industries, Inc., with
all rights reserved. (c) 2006 Murphy Industries, Inc. Other third party product or trade names referenced herein are
918.317.4100 Email: sales@fwmurphy.com the property of their respective owners and are used for identification purposes only.
Draw Works – Sub Frame Module

Contained in this module are the dual acting mast raising cylinders ,wireline
hoist, mainline hoist, and mast swivel mounting blocks.
The wireline hoist is powered by a fixed displacement Geroler motor which
incorporates counter balance valves to prevent hoist overrun.
The mainline hoist is also powered by a fixed displacement axial piston with
a counter balance valve to prevent hoist overrun. In addition, the mainline
hoist features a spring applied, hydraulically released brake and an internal
Sprag bearing mechanism which ensures the mainline hoist drum must be
hydraulically powered to unlock the drum (i.e. the load cannot drive the drum
ahead of the hydraulic motor).
Weight: 1,156 lb (524.4 kg)

(complete with mast raising cylinders less mainline and wireline cable)
Wireline Hoist Assembly Diagram
Hydraulic Motor Wireline Guard
Wireline Drum
Side Plate (RHS)
Side Plate (LHS)
Retaining / Bearing Guard

Disassemble Tool
Bearing Shaft
Support Bearing
NOTE: Refer to the Parts Manual for complete component breakdown
Lower Mast Section Module

The lower mast section module pivots in the draw works sub frame to allow
the desired drilling angles to be achieved. It also houses the feed cylinder
which has the rod end directly connected to the base of the mast.
The feed cylinder body is directly attached to the drill head carriage which
slides on the upper face of the lower mast section.
The two mast support legs are retained on the lower mast section. Also,
located on this mast section is the operator’s rod guide actuating lever for
positioning the cable operated yoked rod centralizer plates which are located
on both the middle and upper mast sections.
The bottom casing positioner base is removable and features a hollow spigot
which retains the casing adapter collar and/or casing guide bushing.
A HW sized hydraulic rod clamp is fitted to the casing positioner.
The lower mast is equipped with a telescopic rod guard to protect the operator.
(not shown in the photo).
The weldment to attach the mast raising cylinders is also fitted to the top of
the lower mast section.
Weight: TBA lb (TBA kg)

(complete with bulk head hoses and rod clamp)
Lower Mast Section Module
Upper Mast Section Module

When the operator chooses to work with 10 ft (3 m) rod joints, the upper
mast section module is directly connected to the lower mast section. Rod
pulls of 10 ft (3 m) above the drill head can be accomplished using this
combination. As with the middle mast section, the upper mast section also
has an aluminium rod slide and a yoked rod guide.
The upper mast section carries the crown block assembly which contains a
single 30" (762 mm) diameter, light weight, nylatron sheave for the mainline
cable and two smaller steel sheaves for the wireline cable.
Weight: 530 lb (240 kg)

(complete with crown block)
Upper Mast Section Module
Hydraulic Module
This module contains 3 triple stacked hydraulic pumps, control valves, a
60 gallon aluminium reservoir mounted above the pumps to provide a flooded
suction, hydraulic hoses, function controls, filters and gauges.
The reservoir is constructed from aluminium to prevent internal corrosion
and features 100 mesh suction strainers on each pump inlet. These are
fitted with 3 psi (20 kPa) vacuum bypass valves which will allow full oil flow
access to the pumps in case the strainers become blocked or when starting
up in sub zero temperatures (32°F – 0°C).
The hydraulic module also contains the drill control panel ,gauges and engine
instrument control panel.
Weight: 1,410 lb (639.6 kg)
Rotation Unit Module

The PQ rotation unit module is powered by a variable displacement, bent
axis, hydraulic motor. This is connected through an adapter box and splined
coupling to a 4-speed mechanical transmission (4 forward speeds). The final
drive of the rotation unit is through heavy duty, straight cut gears which rotates
the main spindle.
Boart Longyear’s patented PQ gas spring chuck is used to transmit the rotary
power of the drill head to the rod string. The chuck opens to allow oversize
reaming shells and bits to pass through the spindle. The bolt on chuck design
allows for reverse rotation to break rod joints. The chuck has seven jaws
which are applied through nitrogen gas springs for a superior axial holding
force.
Weight: 1,452 lb (659 kg)
The Control Panel
For clarity the control panel is broken down into two parts, the power unit
instrument control panel (part of the power unit module) and the hydraulic
control panel.
Power Unit Instrument Control Panel

1 Ignition Switch
Two position, on /off toggle switch.
Lift up to energize the ignition circuit. Push down to denergize the
ignition circuit and shut down the power unit.
2 Protection Bypass Switch

Two position, on/off toggle switch.
Lift up the switch to bypass the engine protection system while starting
the power unit. Hold this switch on for approx. 60 seconds after the
engine starts to allow the engine oil pressure to rise to its operating
pressure.
3 Engine Start Switch

Lift up to engage the starter and release when the engine starts.
4 Lamp Test Light Switch

Lift up the switch to test the engine protection warning bulbs. The oil
pressure, coolant temperature, engine overspeed and emergency stop
warning bulbs should illuminate.
If one of the lights do not illuminate the bulb is burnt. Release the
switch after testing the bulbs. If the engine shuts down due to a oil
pressure, coolant temperature, engine overspeed or emergency stop
fault, the relevant bulb will illuminate to warn the operator of the problem.
Test the warning bulbs prior to each engine start up.
4
3
2
1
5 Engine Pre-heat Switch

In cold ambient temperatures, lift this switch up to preheat the intake
manifold prior to cranking the engine to start. Hold the switch up for
approximately 30 seconds prior to starting.
NOTE: 6 Emergency Stop Switch
After activating the emergency Two position, on/off push button switch.
switch, it must be reset by lifting it Depress this switch to stop the engine in a emergency.
up to the top position before the
engine can be restarted. 7 Engine Speed Switch (Throttle)
The engine speed switch controls the rpm of the diesel engine. Hold
toggle switch up to bring engine up to desired high idle rpm or down to
bring engine to low idle speed.
5 6
8 Oil Pressure Fault Light

Illuminates to indicate a fault with the engine oil pressure, i.e. oil
pressure too low. The engine protection system will shut down the
engine to prevent damage.
9 Coolant Temperature Fault Light

Illuminates to indicate a fault with the engine coolant temperature, i.e.
engine coolant temperature too high. The engine protection system
will shut down the engine to prevent damage.
10 Overspeed Fault Light

Illuminates to indicate a fault with the engine speed, i.e. engine speed
too high. The engine protection system will shut down the engine to
prevent damage
11 Emergency Stop Fault Light

Illuminates to indicate that the emergency stop has been activated.
The engine will not start until the stop button is lifted up to reset.
8
9 10
11
12 Oil Pressure Gauge

Allows the operator to monitor the engine oil pressure.
13 Water Temperature Gauge

Allows the operator to monitor the engine coolant temperature.
14 Voltmeter
Allows the operator to monitor the battery condition and charging
system.
15 Hour Meter
Allows the operator to monitor the engine hours for service intervals.
16 Tachometer
Allows the operator to monitor the engine RPM .
13
12
16
14
15
Hydraulic Control Panel

NOTE: 17 Rotation Directional Control Lever
To prevent damage to the chuck This controls the forward or reverse rotation of the chuck.
never rotate the drill head with the Move the lever “upward” for forward rotation and “downward” for reverse
chuck in the open position. rotation. The lever incorporates a mechanical lockout to prevent the
operator from shifting from forward rotation directly into reverse. This
valve section is detented in the forward and reverse directions. The
control lever has a mechanical lockout device to prevent accidental
operation.
18 Fast Feed Directional Control Lever

This lever controls the “up” and “down” traverse of the drill head.
It is not used when fine feeding during drilling operations (i.e. it remains
in the neutral position). Upward movement of the lever raises the drill
head, downward movement of the lever will lower the drill head. This
valve section is spring centred.
NOTE:
19 Mainline Hoist Control Lever
Movement of this lever in the “upward” direction will spool the hoisting
When hoisting and lowering rods,
cable onto the mainline hoist drum (raising the drill string), while moving
make sure the hoisting cable is in
the lever “downward”, will unspool cable off the mainline hoist drum
complete tension before releasing
the chuck.
(lowering the drill string). This valve section is spring centred.
20
19
18
17
NOTE: 20 Wireline Hoist Control Lever

In order to prevent damage to the “Upward” movement of this lever spools cable onto the wireline hoist
hydraulic motor, completely stop drum (raising the overshot), while moving the lever “downward”,
the rotating drum before changing unspools cable off the wireline hoist drum (lowering the overshot).
direction. The control lever has a mechanical lockout device to prevent accidental
operation.
21 Feed Pressure Gauge

This gauge registers the system pressure of the circuit.
22 Bit Weight Gauge

This gauge reads the bleed off pressure in the hydraulic feed cylinder.
As weight on the bit is increased, the value of the needle will fall (i.e. it
registers the bleed off pressure in the feed cylinder). See chart for
details.
23 Rod Torque Gauge

This gauge registers the system pressure of the main valve bank
functions, i.e. Rotation, Fast Feed, Mainline Hoist, Wireline Hoist
The maximum pressure in the following two circuits is limited by the
individual port relief cartridges in the main valve bank.
i.e. Fast Feed — 2500 psi (17.2 MPa)
Wireline Hoist — 2500 psi (17.2 MPa)
Both the rotation and mainline hoist circuits will register up to full system
pressure which is set at 4500 psi (31 MPa).
When in drilling mode, this gauge will register the amount of resistance
required to rotate the drill string (i.e. Rod Torque).
Alternatively, this gauge will register the pressure required to induce
movement in the remaining main valve bank functions when these are
in use.
i.e. Fast Feed — up to 2500 psi (17.2 MPa)
Mainline Hoist — up to 4500 psi (31 MPa)
Wireline Hoist — up to 2500 psi (17.2 MPa)
24 Secondary Circuit Pressure Gauge

This gauge indicates the hydraulic system pressure of the water pump
circuit. It serves as a torque gauge for the hydraulic driven water pump.
25
24
23
22
21
25 Auxiliary Circuit Pressure Gauge

This gauge indicates the system pressure of the auxiliary circuit. The
auxiliary circuit has the following functions:
• Chuck Open/Close
• Rotation Speed Control
• Rod Clamp Open /Close
• Mast Raising/Lowering
• Mudmixer Motor Rotation
• Rod Making/Breaking
• Fine Feed Control
The maximum pressure in the following two circuits is limited by
individual pressure control valves:
Boart Longyear PQ Chuck 1400 to 1450 psi
Rotation Speed Control 25 to 400 psi (0.2 to 2.8 MPa)
Both the feed and auxiliary control will be up to full system pressure,
which is set at 2000 psi (13.7 MPa). This gauge reads secondary pump
compensator setting which is set at 2000 psi (13.7 MPa). This is
explained in greater detail in the Hydraulic Explanation.
26 Chuck Open/Close Valve

This two position detented selector valve will “open” or “close” the chuck.
Never rotate the drill head with Moving the lever forward closes the chuck, rearward movement of the
the chuck in the open position. lever opens the chuck. There is a mechanical lockout device on this
lever to prevent accidental operation.
27 Hydraulic Rod Clamp Valve

This two position detented selector valve will “open” or “close” the rod
Never close the rod clamp while clamp. Moving the lever forward closes the rod clamp, rearward
the rods are rotating. movement of the lever opens the rod clamp. There is a mechanical
lockout device on this lever to prevent accidental operation.
28 Mast Raising/Lowering Valve

This three position spring return selector valve controls the speed and
Do not operate this valve until direction of travel of the dual mast raising cylinders when raising and
you are familiar with the mast lowering the mast. Moving the lever forward raises the mast and
raising and lowering rearward movement of the lever lowers the mast. The mast raising
procedures. cylinders are located in the draw works module.
29 Hydraulic Mud Mixer Valve

This two position detented selector valve activates the mud mixer.
Forward movement of the lever will switch the mud mixer circuit off,
while rearward movement of the lever initiates the circuit.
30 Rod Making/Breaking Valve

This three position spring return selector valve activates the head float
Never activate this lever while down while making rods joints and up while breaking rod joints. Moving
in the drilling mode. the lever forward causes the head to float downwards and rearward
movement of the lever causes the head to float upwards.
31 Feed Control Selector Valve

The detented three position feed selector controls movement of the
drill head when in fine feed (drilling) mode. The center position blocks
the fine feed circuit and allows the direction of the drill head to be
controlled by the fast feed lever.
Moving the lever forward will convert the system to fine feed in the
downward direction (drilling mode). Rearward movement of this lever
will convert the system to fine feed in the upward direction (back
reaming, getting weight off the bit).
31
30
29
27
26
28
33
34
➚
32
32 Chuck Adjustment Control

This valve controls the pressure required to open and close the
hydraulic chuck. Once set, this should not be altered during normal
operation.
33 Rotation Speed Control

This rotary control alters the minimum displacement setting of the
rotation motor and thus varies the rpm and torque output of the drill
head. Clockwise rotation will increase rpm to maximum, while
counterclockwise rotation decreases the rpm. This control can be used
to “fine tune” the rpm of the drill string after the operator has selected
the gear he intends to operate in.
34 Mainline Brake Release Control

This two position, detented, 90° rotary valve controls the oil flow to
Do not release the mainline release or apply the mainline winch brake. Rotate the lever in the
winch brake unless in fine feed
clockwise direction to apply the brake to hold the rod weight with the
drilling mode or rods are
hoisting cable . Rotate the lever counterclockwise to release the brake
securely held in the chuck or
when in drilling mode.
rod clamp.
35 Rod Clamp Adjustment Control

This valve controls the pressure required to open and close the
hydraulic rod clamp. Once set, this should not be altered during normal
operation.
36 Mast Raising Adjustment Control

This valve controls the oil pressure to mast raising cylinders to raise or
lower the mast. Once set, this should not be altered during normal
operation.
37 Mud Mixer Sequence Valve (not shown)

This valve ensures that the fine feed circuit receives priority from the
auxiliary pump. The adjustable cartridge is located on the rear side of
the auxiliary manifold. Once set, this should not be altered during normal
operation.
38 Mud Mixer Speed Control

This valve controls the rotation speed of the mud mixer or cathead
motor. Clockwise rotation of the valve knob will decrease rpm, while
counterclockwise rotation will increase rpm to maximum.
39 Rod Breaking Float Control (not shown)

This valve controls the float up pressure of the head when breaking
rods. It requires readjustment whenever there is a change in the drilling
angle or the rod size being used. Adjustment is located on rear side of
auxiliary manifold.
NOTE: 40 Rod Making Float Control
The valve that controls the float up This valve controls the float down pressure of the head when making
pressure of the head while making rods. It requires readjustment whenever there is a change in the drilling
rods is located on the opposite angle or the rod size being used.
side of this valve. It also requires
readjustment whenever there is a 41 Rod Making/Breaking Pilot Operated Check Valves
change in the drilling angle or the One check valve is positioned on each side of the manifold. The
rod size being used. purpose of these check valves is to ensure that the head does not
move when the rod making float control valve is in the neutral position.
42 Rod Making Torque Limiter Valve

The purpose of this valve is to limit the rotation torque available for
pretorquing rod joints while making up rod joints. The adjustment screw
is turned clockwise to increase the rod make up torque.
43 Feed Rate Control Valve

This valve controls the feed rate or penetration of the drill string. Turn
clockwise to slow the penetration rate or counterclockwise to increase
the penetration rate.
44 Feed Pressure Reducing Control

This valve controls the desired sensitivity of Feed Rate Control (item
42) as required when rod weight contributes to the force on bit.
43
40
41 44
38
36
35
45 Water Pump Control (not shown)

Located just below the auxiliary valve bank is the water pump control
valve. Turn it counterclockwise to start or increase the rotation speed
of the fluid pump. Complete clockwise rotation of this control will cease
operation of the fluid pump.
46 Optional Levelling Jack Control Valve (not shown)

If the drill is equipped with the optional hydraulic levelling jack group,
Never operate the levelling this valve is located inside the control console. To access the valve
jacks when the mast is erected. open the small door in front of the control console.
To operate the levelling jacks, first open the diverter ball valve located
above the levelling jack control valve bank to divert oil from the auxiliary
manifold to power the levelling jacks.
Lifting the control lever causes the levelling jack selected to extend,
lifting the drill. Pushing down on the control lever causes the levelling
jack selected to retract, lowering the drill.
Refer to the control decal for levelling jack selection and direction of
operation. Once the drill is levelled return the diverter ball valve to the
closed position to prevent accidental operation.
Water Coolant
Temperature Temperature
Gauge Oil Pressure Fault Light
Rod
Fault Light
Torque
Overspeed Feed
Voltmeter Gauge
Fault Light Pressure
Tachometer Gauge Auxiliary Circuit
Emergency Pressure
Stop Gauge
Oil Pressure Fault Light Secondary
Gauge Pressure Gauge
Bit Weight Gauge

Hour Meter
Lamp Test
Light Switch Wireline Hoist
Control Lever
Engine Mainline Hoist

Start Switch Control Lever
Ignition Switch Fast Feed

Directional
Rotation Control Lever
Protection
Directional
Bypass Switch
Control Lever
Emergency
Stop Switch Feed Control
Selector Valve
Engine Hydraulic
Pre-heat Switch Rod
Mud Mixer
Making/Breaking
Valve
Valve
Rod Making
Torque Limiter Valve Feed Rate Control Valve
Feed Pressure
➚
Hydraulic Rod
Engine Speed Reducing Control
Clamp Valve
Switch (Throttle) Rod Making
Float Control
Mast
Rod Making/Breaking
Chuck Raising/Lowering
Check Valve
Open/Close Valve
Valve Mud Mixer
Mainline Brake Speed Control
Release Control Mast Raising
Adjustment Control
Chuck Rod Clamp
Rotation Speed Control
Adjustment Adjustment
Control Control
Drilling Operations
4-2 Introduction
Safeguards
Routine checks should include
4-4 Visual Inspection of Masts

4-6 Pre-Start Checklist
4-8 Anchoring the Drill
4-13 Start Up Procedures
4-15 Mast Installation and Raising
4-18 Collaring the Hole
Casing Guide Bushing
Casing Adapter Collar
4-20 Rod Handling

Inserting the Core Barrel
Rod Making Procedure
Rod Breaking Procedure
Stacking Drill Rods
Opening the Head
Yoked Rod Centralizer
4-22 Force on Diamond Bit

4-23 Shutdown Procedure
4-24 Lowering the Mast
BOART LONGYEAR Drilling Operations 4-2
Introduction
The following are recommended guidelines and practices to help
prolong the life of your newly obtained Boart Longyear mast.
Enclosed is a checklist for a visual inspection which should be done
every 1000 hrs of operation. (Inspections may have to be done more
often when operating in extreme environmental conditions.) Make
copies of the checklist for each inspection. The checklist should be
signed and filed for future reference.
Safeguards:
Operator shall be familiar with the equipment and its proper care. If
adjustments or repairs are necessary, or if any damage is known, the
operator shall report the details promptly to an appointed person and shall
notify the next operator upon changing shifts.
In the mast erecting and lowering operations, ensure that the drill is securely
anchored first. A slow practical operating speed should be used during this
function at all times.
There is no way of judging the remaining strength of a rusty cable, therefore,
rusty cable lines must be replaced immediately. Areas adjacent to end
connections should be examined closely for any evidence of corrosion.
Design modifications or welding to the mast weldments is prohibited. These
modifications could result in weakening of the mast members and therefore,
possibly causing a structural failure later.
Routine checks should include:

• Inspection of welds in erecting mechanism for cracks and other signs of
deformity.
• Inspection of wire rope, including operating lines, raising lines, and guy
lines, for kinks, broken wires, or other damage. Make certain that guy
lines are not fouled.
• Check unit for level and correct placement before erecting operation.
• Check lubrication of crown sheaves.
• During drilling operations, it is advisable to make scheduled inspections
of all bolted connections to ensure that they are tight. 48 hours after the
initial erection of the mast, check the bolts for correct torque.
• Ensure that the Load Rating and Warning decals are installed on the
mast and are in good shape.
• Steel becomes brittle when operating in low temperature conditions.
EXTREME CAUTION must be exercised when operating at or below -
25°C (-13°F) as the mast may no longer hold the rated load. Frequent
visual inspection of mast members and welds is even more critical at
these temperatures, see page 8.
• Ensure support legs are located on a solid footing and tied back to a
solid anchoring point.
Never exceed the Rated Hook

Load, which is indicated on the
Load Rating decal. When
calculating hook load, always
include load handling devices YY - MM - DD
(travelling blocks, etc.)
354129-B
Visual Inspection of Masts

The following is a checklist for a visual inspection of the mast. Ensure that the inspection is
performed by an individual with knowledge of all mast operational procedures during erection or
relocation of mast. Each section has a pass or fail choice. If there is a problem, it should be noted
and corrected immediately. Make copies of this checklist and file this check list for future reference.
1 Crown Assembly:
Condition:
Sheaves Warped OK
Grooves Worn OK
Spacers or Seals Bad OK
Grease Fitting Missing OK
Crown Frame Bent Flanges Bent Webs OK
Cracked Welds OK
Comments: Rusty Needs Repair
Needs Painting Other:
2 Vertical Members:
A. Front Leg, Driller’s Side
Condition:
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
Safety Pins Missing OK
B. Front Leg, Off Driller’s Side
Condition:
Bow Slight Bad OK
C. Rear Leg, Off Driller’s Side
Condition:
Bow Slight Bad OK
D. Rear Leg, Driller’s Side (Not applicable for “T” style mast)
Condition:
Bow Slight Bad OK
Comments: Needs Repair Other:
3 Bracing
Condition: Slight Damage Badly Damaged OK
Needs Repair
4 Adjustable Support Legs and Feet
Condition: Damaged Cracked Welds OK
Worn Pins/Hole Needs Repair
Corroded
5 Working Platform
Condition:
Racking Platform
Frame: Damaged Cracked Welds OK
Pin Connections Worn OK
Safety Pins Missing Worn OK
Fingers Damaged Needs Repair OK
Working Platform Damaged Cracked Welds OK
Handrails Damaged Needs Repair OK
6 Guyline Anchorage
Condition:
Guyline Damaged Needs Adjusting Needs Replacing OK
Cable Clamps Loose Needs Repairing OK
Turnbuckles Damaged Needs Replacing OK
Anchor and Deadman Replace OK
7 Bolt Connections
All bolted connections are to be inspected, tightened, and missing parts replaced or
visibly marked as missing or damaged and in need of repair.
All connections found to be satisfactory as checked and loose bolts tightened OK
All connections visually inspected and spot checked for tightness and no further OK
bolt tightening or repairs necessary.
8 Substructures for Mast
Damages: Minor Major OK
Corrosion: Minor Major OK
Condition:
Connections Worn Cracked Welds OK
9 Mast Raising and Angling Cylinders:
Condition: Oil Leaks Hose/Tubing Damage
10 Summary of Inspection
Appearance: Good Fair Poor
Repairs Needed: None Minor Major
Number of Missing Parts:
11 List of work to be completed:
Signature : Date:
Ref No.:
Pre-Start Checklist
1 Check diesel engine oil level.
2 Check all fluid levels. Refer to Lubrication Chart for lubricant types and
quantities.
If any of the above require attention, be sure to thoroughly clean the

area surrounding the filler locations before adding liquids. Use only
clean, uncontaminated containers for filling, not ones that have been
used to hold foreign fluids.
For more detailed diesel engine servicing requirements, refer to the
diesel engine operations and maintenance manual.
For more detailed hydraulic servicing requirements, refer to the
Lubrication Chart for recommended service intervals.
3 Visually check the drill for any loose or unserviceable components, leaks,
faulty equipment, etc., and repair these before operating the machine.
If the mast has not been raised,
ensure the drill is properly
supported by the four levelling
jacks in a level orientation.
Before raising the mast, ensure

there are no overhead power
lines, trees or structures which
could foul the tower during
raising, drilling or lowering.
Make certain there are no loose

objects on the mast which may
fall off during the raising of the
tower or when operating the
drill.
Anchoring the Drill

The LF90 is a highly mobile, lightweight diamond core drill. Because of
these attributes, it is essential that the drill is securely anchored to the
Do not operate the LF90 without formation being drilled. This can be achieved in a variety of ways which will
the drill being levelled and be discussed below.
securely anchored.
Unconsolidated Overburden
The most expeditious means of securing the LF90 in unconsolidated
formations is to use twin anchor logs cemented and buried in the ground
with chain or wire rope attached to them, protruding to the surface. The
chain or wire rope can then be passed through the lifting eyes on the four
corners of the drill base and the entire machine “cinches” down onto
supporting timbers.
1 Dig two trenches 10 ft (3 m) long and 3 ft (1 m) wide in front of and behind
the drill. These trenches should be a minimum of 3 ft (1 m) deep.
2 Into each trench place a log (minimum 10" (25 cm) diameter, preferably
hardwood in good condition) or alternately, 3 old 10 ft (3 m) HQ drill rods.
Ensure that log or rod bundle Securely fasten enough 3/8" (1 cm) diameter chain or 5/8" (16 mm) wire
(3 rods) placement at the rear rope to each end of the log or drill rod bundle so there will be 5 ft (1.5 m)
of the drill will not interfere with
protruding from the surface after the trenches have been filled.
any proposed drill hole angles.
3 Place a covering of rocks and boulders over the logs or drill rod bundles
and lay the free end of the chain or cable over the top of the trench,
removing any slack.
Run chain or wire rope

No Drill Hole through two lifting lugs
Interference and attach as per #5.
Log or
Rod Bundle
DRAW
WORKS
Winch or
Turnbuckle
DRILL BASE
Trenches POSITION
ENGINE
Log or
Rod Bundle
3/8” (1 cm) Dia. Chain or

5/8” (16 mm) Dia. Wire Rope
4 Cement the log or rod bundles into position with enough grout mixture to
cover the layer of rocks and boulders. Backfill and compact the soil into
the trenches and restore the site to a level condition. Allow 12 hours for
the cement to cure.
5 Position some 10" X 10" (25 cm X 25 cm) timbers longitudinally under
where the drill base levelling jacks will be positioned.
6 Place the drill on the timbers and run additional 3/8" (1 cm) chains through
the two front and two rear lifting lugs on the drill base. Attach each chain
to one free end of the chain or wire rope protruding from the trenches
(which is attached to the cemented log or rod bundle) and tension the drill
down with a come-along style winch, turnbuckles, etc.
The chain or wire rope must be adequately pretensioned so that it is
immediately effective in transferring load. This tensioning can be verified
by applying a load to the midspan of the cable and measure the deflection
perpendicular to the cable. For a 17" (432 mm) rope, a deflection of 1/4"
(6 mm) under a 150 lb (68 kg) force will indicate that the required preload
of 1000 lbf (454 kg) is present.
Apply a 150 lb (68 kg) force and

adjust the tension until a deflection
of 1/4” (6 mm) is observed.
17” (432 mm) Rope
45°
7 Ensure the drill is level in both directions and the mechanical levelling
jacks have been securely clamped into the drill base. If the drill is equipped
with hydraulic levelling jacks ensure that the mechanical lockout devices
are in place.
3/8” (1 cm) Dia. Winch or

Chain or 5/8” Turnbuckle
(16 mm) Dia.
Wire Rope
Leveling Jacks
Timbers
Backfill and Compact Trenches
Min. 3 ft
Rocks and Boulders
(1 m) Deep
Hardwood Logs or HQ Drill Rods
End View of Engine
Alternate Anchoring Methods

8 If the drill site is particularly hard and difficult to dig, an alternative pattern
of anchoring the drill can be used. This involves burying three hardwood
logs (minimum diameter of 10" (25 cm), and in good condition/not rotting)
just below the earth’s surface, cross ways at 90° to the final positioning of
the drill.
A 10' (3 m) HQ drill rod with attached chain should be positioned beneath
and at 90° to the buried logs, with the chain end of the rod at the mast end
of the drill. The anchor chain should be tensioned back to the base at an
angle to prevent the drill pushing itself off line when high bit loads are
applied on angle holes.
Ensure the drill is level in both directions and the levelling jacks
have been securely clamped into the drill base.
Top View
Drill Base
Compact Soil Fill Position
on Timbers
HQ Drill
Rod
Chain or Timbers
Wire Rope
Hardwood Logs
Mast End
Side View
Draw Works Unit
3/8” (1 cm) Dia. Drill Base

Chain or 5/8”
(16 mm) Dia. Timbers
Wire Rope
Compact Soil Fill

Hard Surface
HQ Drill Rod Hardwood Logs
Anchoring with Compacted Back Fill
9 Another pattern of anchoring when the site is difficult to dig is uses

concrete in a shallow trench. Use four (4) pieces of 2' (0,6 m) minimum
length scrap HQ drill rod, each with 3/8" (1 cm) diameter chain or 5/8"
(16 mm) wire rope attached . The chain or wire rope should be long enough
so that 5' (1,5 m) protrudes after the trench has been filled.
Place one piece of rod and chain or wire rope in each of the four (4) outer
corners of the trench, beyond the levelling jacks. Fill the trench with
concrete, covering the pieces of rod and chain or wire rope to surface
level, and keeping the protruding chain or wire rope ends free.
The collar area for drilling vertical holes should be kept clear of concrete.
Allow 12 hours for the concrete to cure. Next, position two (2) 10" x 10"
(25 cm x 25 cm) timbers longitudinally under where the drill base levelling
jacks will be positioned. Place the drill on the timbers. Use additional 3/8"
(1 cm) diameter chain or 5/8" wire rope around each of the outer four (4)
corners of the drill base. Attach each chain or wire rope to the free end of
the chain or wire rope protruding from the concrete and tension the drill
down with a come-along style winch, turnbuckle, etc.
Chain or wire rope must be adequately pretensioned so that it is
immediately effective in transferring load. This tensioning can be verified
by applying a load to the midspan of the cable and measure the deflection
perpendicular to the cable. For a 17" (432 mm) rope, a deflection of 1/4"
(6 mm) under a 150 lb (68 kg) force will indicate that the required preload
of 1000 lbf (454 kg) is present.
Apply a 150 lb (68 kg) force and

adjust the tension until a deflection
of 1/4” (6 mm) is observed.
17” (432 mm) Rope
45°
Top View
Anchor Chain
or Cable
Concrete Pad
Hole
Collar Tie-Downs
(4) Cable Timbers
or Chain
Drill Base
Mast End
Side View
Draw Works Unit
3/8” (1 cm) Dia. Drill Base

Chain or 5/8” Tie-Downs
(16 mm) Dia. (4) Cable
Wire Rope or Chain
Timbers
Concrete Pad
Hard Surface
HQ Drill Rods
Anchoring on a Concrete Pad
Ensure the drill is level in both directions and the mechanical

levelling jacks have been securely clamped into the drill base. If
the drill is equipped with hydraulic levelling jacks ensure that the
mechanical lock out devices are in place.
Ensure the location of any obstacles at the rear of the drill will not be in
the way of all proposed drill hole angles.
10 Alternatively, if the drill site is heavily forested, the LF90 can be anchored
to the base of sturdy, healthy trees in the immediate area. Once again,
the machine should be anchored so that the drill will not push itself off the
hole when high bit loads are encountered.
11 Burning Casing In
Experienced operators may find that burning a piece of casing into the
ground may be the fastest means of anchoring the drill.
12 Drill and Insert Rockbolts if on bedrock.
Start Up Procedures
1 Proceed to start the drill as follows, only after the pre start check has
been completed.
2 Ensure the control panel levers and gear box selector are in the following
position:
Before operating controls, know
• Chuck Lever (10) — Forward (Closed)
how each control functions.
• Mainline Brake Lever (18) — Fully Clockwise (Applied)
• Rod Clamp Lever (11) — Forward (Closed)
• Mast Raising Lever (12) — Center Position (Neutral)
• Mud Mixer lever (13) — Forward (Off)
• Rod Making/Breaking Lever (14)
— Center Position (Neutral)
• Feed Selector (15) — Center Position (Neutral)
• Head Rotation Lever (1) — Center Position (Neutral)
• Fast Feed Lever (2) — Center Position (Neutral)
• Mainline Hoist Lever (3) — Center Position (Neutral)
• Wireline Hoist Lever (4) — Center Position (Neutral)
• Rotation Speed (17) — Fully counterclockwise (Slow)
• Feed Rate (26) — Fully clockwise (Off)
• Water Pump Control (28) — Fully clockwise (Off)
• Drill Head Gear Selector — (Neutral)
• Feed Pressure Reducing Control (27)
— Fully clockwise (Max)
• Mainline Winch Brake Release Valve
— Fully clockwise (Applied)
3 Lift up the ignition switch to energise the circuit.
4 Push down the engine speed switch , then release to ensure the engine
speed is set to a low idle prior to starting.
5 Lift the lamp test switch to check the bulbs in the engine protection warning
lamps.
6 For a cold ambient engine start, lift the engine preheat switch for
60 seconds to preheat the engine intake manifold.
7 Lift the protection bypass switch to bypass the protection circuit. Hold up
this switch up for approx. 60 seconds after engine startup to allow the oil
pressure to rise to its normal operating level.
8 Lift the engine start switch to engage the engine starter, and release it
once the engine starts.
Do not continue to crank the engine if it doesn’t start after 30 seconds.
Excessive cranking can damage the electrical starter solenoid or
motor.
Before operating controls, know all of the functions.
Investigate why the engine will not start (i.e. fuel or electrical
problems) before cranking excessively.
9 Allow the diesel engine to warm up for two minutes before gradually
increasing the rpm.
If operating in extremely cold, ambient conditions, allow the engine at
least seven minutes to warm up before increasing the engine speed or
placing any load on the machine.
Water Coolant
Temperature Temperature
Gauge Oil Pressure Fault Light
Rod
Fault Light
Torque
Overspeed Feed
Voltmeter Gauge
Fault Light Pressure
Tachometer Gauge Auxiliary Circuit
Emergency Pressure
Stop Gauge
Oil Pressure Fault Light Secondary
Gauge Pressure Gauge
Bit Weight Gauge

Hour Meter
Lamp Test
Light Switch Wireline Hoist
Control Lever
Engine Mainline Hoist

Start Switch Control Lever
Ignition Switch Fast Feed

Directional
Rotation Control Lever
Protection
Directional
Bypass Switch
Control Lever
Emergency
Stop Switch Feed Control
Selector Valve
Engine Hydraulic
Pre-heat Switch Rod
Mud Mixer
Making/Breaking
Valve
Valve
Rod Making
Torque Limiter Valve Feed Rate Control Valve
Feed Pressure
➚
Hydraulic Rod
Engine Speed Reducing Control
Clamp Valve
Switch (Throttle) Rod Making
Float Control
Mast
Rod Making/Breaking
Chuck Raising/Lowering
Check Valve
Open/Close Valve
Valve Mud Mixer
Mainline Brake Speed Control
Release Control Mast Raising
Adjustment Control
Chuck Rod Clamp
Rotation Speed Control
Adjustment Adjustment
Control Control
Mast Installation and Raising

1 Prior to starting the machine, ensure the drill is level, and firmly supported
by the four levelling jack legs (i.e. not resting on the wheels if these are
left on the base).
If there is any doubt that some weight may be on the tyres, remove them
to ensure the four levelling jack legs are supporting the drill in a level
manner. If necessary, use timber planks under the levelling jack legs.
2 Add the required mast sections (i.e. upper and middle, or upper only) and
make sure they are firmly secured with their respective mounting bolts.
3 Attach the cable between the centralizer plate pivot rod and the rod guide
actuating lever on the lower mast.
4 Route the mainline hoist and wireline hoist cables through the sheave
wheels of the crown block assembly, making sure to replace the cable
retaining spacers and bolts.
Wireline Cable Retainer

Spacers and Bolts
Mainline Cable Retainer

Spacers and Bolts
5 Secure the overshot and hoisting plug, if connected (or mainline hoist
and wireline hoist cables) to the mast, to prevent them from falling during
the raising operation.
6 Start the drill as described in the previous section and position the head
over the mast pivot blocks.
7 Loosen the four bolts on the mast swivel mounting blocks (do not
completely unscrew, loosen only two turns).
8 Before raising the mast, loosen the nuts which hold the mast support legs
in their travelling position. (Do not remove completely.) Also, loosen the
Ensure there are no overhead locknut and set screw on the mast support leg clamping jaws.
power lines, trees or structures
which could foul the mast
Accomplishing these steps prior to raising the mast will avoid any
during the raising, drilling or unnecessary delays in securing the mast support legs, once the tower
lowering operations. has been raised.
9 Prior to raising the mast, make sure that all hoses, fittings, and cables are
free and will not get caught on anything during the raising operation.
10 Slowly begin to raise the mast by moving the mast raising control lever
forward, sending oil to the mast raising cylinders, and causing the mast to
raise.
Raising the mast should be accomplished in a gentle, smooth fashion.
Avoid jerky and erratic stop and start motions.
Once mast raising has commenced, under no circumstances should
any person (or part there of) get under or perform any work in that
area until the mast raising is complete (as detailed in this section)
and the tower is firmly secured by the mast support legs.
During the raising operation, double-check that no hoses, fittings,
or cables are hanging up or getting caught.
11 Continue to raise the mast until it is in the vertical position.
As the mast nears the vertical position, the resultant action changes
the mast raising cylinder geometry. As the mast breaks over center
it causes an acceleration in the mast travel speed. Because of this,
reduce the raising speed when nearing vertical to allow the mast to
come to a smooth, gentle stop.
12 Stop the diesel engine.

13 Once the mast has broken over center and is in the vertical position,
release the outside mast support leg (i.e. furthest away from the control
panel) from its retaining bracket on the lower mast section and position it
in its respective bracket on the rear of the drill base.
14 Secure the clamping jaw firmly.
15 Once the mast is firmly supported in a vertical position by the outside
mast support leg, remove the inside mast support leg from its retaining
bracket and position in its respective bracket on the drill base (do not
tighten the clamping jaw set screw).
16 Next loosen the outside mast support leg clamping jaw set screw.
17 Restart the diesel engine and place the mast to the desired drilling angle
by slowly moving the mast raising control valve forward to lower the mast.
18 Once the desired angle has been reached return the mast raising control
valve to the neutral position, firmly secure the outside mast support leg
clamping screw and locknut before doing the same to the inside mast
support leg clamping jaw.
19 Tighten the four mast pivot block bolts.
Collaring the Hole

If the LF90 drill is supplied with a rod clamp, clamp a short (2 ft) section of
casing in the rod clamp to use as a guide bushing, to help collar the hole.
(For example, if the hole is to be collared with NW casing, use a short
section of HW casing in the rod clamp as a guide.)
Ensure that the top of the casing being used as a guide is even with the top
of the rod clamp to prevent interference with head travel. Once the hole is
collared the guide casing may be removed.
When collaring larger diameter holes (HW size and up) the foot clamp slips
will have to be removed and a casing guide bushing can be bolted under the
rod clamp casing positioner weldment. Take care to start the casing slowly
to minimize any hole misalignment as the drilling progresses.
Casing Guide Bushing

The bores of these bushings are very close to the O.D. of the particular
casing string that is being used to collar the hole (ie. BW, NW, etc.). The
casing guide bushing is designed to stabilize the casing string and maintain
hole alignment. The casing guide bushing should be used throughout the
entire casing run.
The casing should be firmly seated into bedrock before reducing to the coring
system that will be used. As both the casing guide bushing and casing adapter
collar are designed to be used together, operators should follow the
procedures outlined in this section to ensure the drill is set up correctly.
Casing
Casing Guide
Adapter Bushing
Collar
Casing Adapter Collar

To avoid a possible pinch point, The casing adapter collar has the same shoulder to shoulder length as the
when installing the casing casing guide bushing. When drilling the casing, the operator should advance
adapter collar into the casing the casing joint he intends to disconnect at, until it is flush with the bottom of
positioner base, the casing the casing guide bushing. Once the casing is firmly seated in bedrock (after
adapter collar should be the casing has been disconnected), the casing guide bushing is replaced
threaded onto the casing from with the casing adapter collar.
the underside of the casing
positioner base.
The previous step of drilling the casing joint to the bottom of the casing guide
bushing will now allow the casing adapter collar to connect to the casing
string and bolt to the lower mast casing positioner base.
Rod Handling
Inserting the Core Barrel
1 Run the drill head to the base of the mast and open the chuck and rod
clamp.
2 Attach the water swivel or hoisting plug to the core barrel.
3 Attach the main hoist cable to the water swivel or hoisting plug bail.
4 Lift the main hoist lever which will raise the core barrel (guide the water
swivel or hoisting plug into the rod slide when doing this) above the drill
head.
5 Depress the main hoist lever to lower the core barrel assembly into the
casing.
6 Securely clamp the core barrel in the chuck or rod clamp.
7 Remove the water swivel or hoisting plug from the core barrel and attach
to drill rod.
8 Using the mainline hoist control lever, raise the rod above the drill head
and attach the rod to the core barrel .
Rod Making Procedure

1 Follow steps described in Chapter 3 to adjust the rod making torque limiter
valve.
2 Set engine at 1800 rpm, place transmission in 1st gear and turn the rotation
speed control fully clockwise.
3 Add a rod through the chuck and start the threads by hand into the rod
being held in the foot clamp.
4 Engage the rod making/breaking valve forward to allow the head to float
down while the threads are being made up.
5 Slowly lift the rotation directional lever upward to rotate the rod clockwise
to make up the rod joint.
Rod Breaking Procedure

1 Position the rod joint to be broken above the rod clamp using the mainline
hoist control lever.
2 Close the rod clamp on the rod.
3 Slacken the mainline hoist cable slightly
4 Close the chuck on the rod
5 Engage rod making/breaking valve rearwards to allow the head to float
up while the threads are being broke.
6 Slowly press the rotation directional lever downwards to rotate the rod
counterclockwise breaking the rod joint.
Stacking Drill Rods

The lower end of rod should be placed on a suitable wooden platform
Use extreme caution when
covered with a heavy rubber mat located beside the drill. Stack the rods in
opening the head on angle
lengths at an angle slightly steeper than the mast angle to ensure that they
holes due to potential
remain secure against the rod rack under their own weight.
interference problems around
the mast and leveling jack.
Opening the Head
If it is necessary to open the head to handle large casing, ensure that the
rod is rmoved from the chuck.
Never allow the head to travel up
or down the mast while in the Yoked Rod Centralizer
open position.
Both the middle and upper mast sections have yoked rod centralizers which
are activated by the cable from the operator’s platform. If the middle mast
When opening the head on
section is being used for a 20 ft pull, only the yoked centralizer closest to the
angle holes support the weight
of the head using a suitable pry
lower mast is used to help thread joint alignment when adding or removing
bar due to the increase weight rods from the hole.
as the head pivots open.
Force on Diamond Bit

The force exerted on the diamond bit while drilling is approximately equal
to the weight of the rods plus the down force exerted by the hydraulic feed
cylinder.
Measuring the weight on the bit requires two different pressure readings.
1 Suspend the rods a short distance above the bottom of the hole with the
rods rotating.
2 With the fine feed control valve closed, engage the fine feed directional
valve to the feed down position.
3 Note the pressure reading on the bit weight gauge, The gauge will read
the maximum pressure that can be exerted on the bit.
4 Slowly open the fine feed control valve. As the bit contacts the rock at
bottom of the hole the reading on the bit weight will reduce. The difference
between the suspended rod pressure and the reduced pressure reading
with the bit in contact with the rock at the bottom of the hole while drilling
is called the “OFF PRESSURE”.
NOTE: 5 The OFF PRESSURE, when multiplied by the effective area of the hydraulic
The lower the bit weight pressure cylinder of 7.06 in2 (45 cm2), will give the downward force in pounds exerted
on the gauge the higher the actual on the diamond bit.
pressure on the bit.
EXAMPLE:
Hydraulic Pressure w/rods suspended
1500 PSI (10.343 MPa)
Hydraulic Pressure w/bit contacting bottom of hole
1000 PSI (6.895 MPa)
Off Pressure is the difference
500 PSI (3.448 MPa)
Total force on bit =

12.56 in2 x 500 PSI 6,280 lbf.
(81 cm2 x 3.448 MPa) (27,934 N)
Shutdown Procedure
1 If the drill string is rotating, close the fine feed valve and allow any drill
string compression or stretch to “drill out”. You will notice the bit weight
gauge needle begin to rise as the weight comes off the bit.
2 Return the fine feed selector to neutral (center position) and close the
feed rate control valve.
3 Lower the diesel engine rpm to about half, then wind the rotation speed
control counterclockwise to reduce the drill string rpm. Next, feather the
rotation control level back to neutral making sure the mechanical lockout
is in position to prevent the lever from going into reverse.
4 Use the fast feed lever to raise the drill head to break the core and pull the
bit at least 12 in (30 cm) off bottom.
5 Retention the winch cable and apply the mainline winch brake.
6 Allow the fluid pump to flush the hole for about 5 minutes before turning
the water pump control completely clockwise to stop the fluid pump.
7 Reduce the diesel rpm and allow the unit to idle for 5 minutes. This is very
important. It allows the turbocharger sufficient time to slow down prior to
stopping the engine.
8 Press down the ignition switch toggle switch to stop the diesel engine.
If an emergency shutdown
is required, depress the
EMERGENCY STOP
immediately, regardless
of the drilling operation.
Lowering the Mast

1 Position the head over the mast pivot blocks.
2 Stop the diesel engine.
3 Loosen the clamping jaw set screw on the inside mast support leg (i.e.
closest to the diesel engine) and detach the sliding section from the front
Under no circumstances should of the drill base.
any individual (or part there of)
Now push the telescoping inner support leg section into the outer support
be directly underneath the mast
leg section and fold the support leg back to its travelling position on the
when attaching the outside
mast support leg.
lower mast section and retain it in the bracket provided.
4 Repeat step 3 with the outside mast support leg (i.e. furthest from the
diesel engine) and retain it in its travelling position.
5 Loosen the four mast swivel mounting block bolts, two (2) turns.
Ensure that no one is in the

6 Start the diesel engine and adjust to 1500 rpm. Slowly move the mast
vicinity of the mast lowering raising/lowering control lever rearwards to begin lowering the mast.
area and that there are no Mast lowering should be accomplished in a smooth, steady fashion. Avoid
overhead power lines, trees or jerky stop/start motions.
structures that may foul the
When lowering the mast, ensure no hydraulic hoses, fittings or cables will
mast during the lowering
get caught or snagged during this operation, or that the hoisting and
operation.
wireline cables and accessories are firmly secured to the mast and cannot
fall off.
7 Once the mast has come to rest on its support brackets at the front of the
drill base, remove the spacers and bolts from the cable retainers on the
crown block assembly and remove the mainline hoist and wireline hoist
cables.
8 Next, remove the middle and upper mast sections, then tighten the four
mast swivel mounting block bolts.
Hydraulic Explanation
5-4 Valves
5-5 Pumps
5-5 Actuators
5-6 Cautions and Warnings
Operation
5-7 Component Explanation

Valves
V1 Mainline Winch Section - Main Control Valve
V3 Wireline Winch Section - Main Control Valve
V4 Fast Feed Section - Main Control Valve
V5 Head Rotation Section - Main Control Valve
V7 Fluid Pump Speed Control - Remote Manifold
V9 Fine Feed Direction Control Section - DO3 Valve
V10 Mud Mixer On/Off Control Section - DO3 Valve
V11 Side Shift Direction Control Section - DO3 Valve
V13 Rod Clamp Open/Close Control Section - DO3 Valve
V14 PQ Chuck Open/Close Control Section - DO3 Valve
V15 PQ Chuck Reducing/Relieving Section - DO3 Valve
V16 Brake Release Direction Control Section - DO3 Valve
V18 Rod Clamp Reducing/Relieving Section - DO3 Valve
V21 Side Shift Pressure Reducing Section - DO3 Valve
V22 Side Shift Counter Balance Section - DO3 Valve
V23 Mud Mixer Flow Control Section - DO3 Valve
V24 Mud Mixer Sequencing Section - DO3 Valve
V25 Fine Feed Checked Pressure Reducing Section - DO3 Valve
V26 Fine Feed Flow Control Section - DO3 Valve
V27 Head Float PO Check Section - DO3 Valve
V28 Head Float Reducing/Relieving Section - DO3 Valve
Head float up adjustment.
Head float down adjustment.
V29 Head Float Direction Control Section - DO3 Valve
V30 Pre-Torque Manifold - Remote Manifold
Pre-Torque Manifold Relief Setting
V31 Wireline Counter Balance Valves - Winch Mounted
V32 Mainline Counter Balance Valve - Winch Mounted
V40 Auxiliary Valve - Remote Mounted
Check and set auxiliary valve inlet relief.
BOART LONGYEAR Hydraulic Explanation 5-2
V41 Mast Raising Counter Balance Valves - Cylinder Mounted

V42 Mast Dump Counter Balance Valves - Cylinder Mounted
V43 Diverter Valve - Remote Mounted
V44 Inlet Pressure Relieving Section - Main Valve
V45 Rotation Speed Pressure Relief Valve - DO3 Manifold
5-27 Pumps
P1 Primary Pump - Engine Flywheel Mounted
Setting high pressure compensator.
Setting stand-by pressure compensator.
P2 Secondary Pump - Mounted to Primary Pump
Setting high pressure relief.
P3 Auxiliary Pump - Mounted to Secondary Pump
P4 Cooling Pump - Mounted to Engine PTO
P5 Head Cooling Pump - Head Gear Drive Mounted
P6 Hand Pump - Remote Mounted
Bench Setting of Counter Balance Valves section
Setting procedure counter balance valves.
Connect counter balance valve, pump and pressure gauge as
shown below.

C1 Hydraulic tank - Frame Mounted
Tank filling procedure
C2 Primary Return Filter - Tank Mounted
Filter change procedure
C3 Primary Pump Pressure Filter - Tank Mounted
C4 Hand Pump Filter - Tank Mounted
C5 Tank Breather- Tank Mounted
C6 Head Gear Drive Pressure Filter - Tank Mounted
C7 Head Gear Drive Cooler - Engine Cooling Package Mounted
C8 Cooler - Frame Mounted
C9 Large Return Manifold - Tank Mounted
C10 Small Return Manifold - Tank Mounted
C11 Rotary Pressure Gauge Display - Console Mounted
C12 Dash Mounted Pressure Gauges - Console Mounted
Filter Element Replacement Chart
5-41 Lubrication Chart

Lubricant Code
Engine Oil
Hydraulic Oil
Gear Oil
MPG - MultiPurpose Grease
Notes
5-43 Actuators
A1 PQ Chuck Cylinders
A2 Rod Clamp Cylinders
A3 Side Shift Cylinder
A4 Mud Mixer Motor
A5 Rotation Motor
Minimum displacement adjustment procedure
Maximum displacement adjustment procedure
Rotation speed control range adjustment
A6 Feed Cylinder
A7 Mainline Winch Motor
A8 Wireline Winch Motor
A9 Cooler Fan Motor
A10 Water Pump Motor
A11 Outrigger Cylinders
A12 Jack Cylinders
A13 Mast Extend Cylinder
A14 Mast Dump Cylinder
A15 Mast Raising Cylinders
Valves
Item # Description
V2 Not Used
V6 Not Used
V7 Water Pump Speed Control - Remote Manifold
V8 Not Used
V12 Not Used
V17 Not Used
V19 Not Used
V20 Not Used
V25 Fine Feed Checked Pressure Reducing Section - DO3 Valve
V30 Pre Torque Manifold - Remote Manifold
V31 Wireline Counter Balance Valve - Winch Mounted
V33 Not Used
V34 Not Used
V35 Not Used
V36 Not Used
V37 Not Used
V38 Not Used
V39 Not Used
V41 Mast Raising Counter Balance Valves - Cylinder Mounted
V42 Mast Dump Counter Balance Valve - Cylinder Mounted
V44 Inlet Pressure Relieving Section - Main Vale
Pumps
Item # Description
P2 Secondary Pump - Through Driven By Primary Pump
P3 Auxiliary Pump - Through Driven By Secondary Pump
P4 Cooling Pump - Engine Auxiliary Drive
P6 Hand Pump - Frame Mounted
Fluid Conditioners
Item # Description
C1 Hydraulic Tank - Frame Mounted
C5 Tank Breather - Tank Mounted
C7 Head Gear Drive Cooler - Engine Cooling Package Mounted
Actuators
Item # Description
A4 Mud Mixer Motor
A5 Rotation Motor
A6 Feed Cylinder
A9 Cooler Fan Motor
A12 Jack Cylinders
Cautions and Warnings

Operation
1. Read and understand the drill operation section of this manual before
using your drill rig.
2. Always keep the pump suction line ball valves completely open when drill
rig engine is turning. Use a zip tie to lock ball valves in the open position
and check the zip ties are still in place prior to starting engine.
3. Move all control levers to their neutral position prior to starting the engine
on the drill rig.
4. Do not remove or defeat guards and safety devices.
5. Keep loose clothing away from moving parts and watch for pinch points.
6. Periodically check the drill rig for oil leaks and repair as required. Check
oil level after repairing an oil leak.
7. Keep an oil spill kit and first aid kit at the drill site.
Component Explanation
Valves
When setting hydraulics, make sure all mast restraining devices and jack
leg pins are installed, and all hanging loads are removed from both winches.
Operating temperature for the LF90D is 60øC to 90øC.

Controls speed and direction for the mainline winch for hoisting or lowering
operations. This valve section is in the main control valve and is a load
sensing type of section. The spool is spring centered and is shifted manually
with a lever on the console. The function is proportional and varies the
speed of the drum.
Push the lever to spool in and pull the lever to spool out.
No adjustments required.

Controls speed and direction for the wireline winch for hoisting or lowering
operations. This valve section is in the main control valve and is a load
sensing type with a relief valve to limit the maximum supplied pressure
(load sense relief). The spool is spring centered and is shifted manually
speed of the drum.
Push the lever to spool in and pull the lever to spool out.
Check and set wireline winch load sense relief.
• Run drill until hydraulic oil is at operating temperature and then lower
drill head until it bottoms out using fast feed.
• With engine off and all controls in their neutral position, install the wireline
winch pin to restrain the winch from turning.
• Start engine and increase speed to 2200 rpm.
• Push only the wireline winch lever to full travel.
• Reading the rod torque gauge, adjust the wireline load sense relief to
2500 psi.
- Adjust pressure with 5/16 inch Allen key.
- Clockwise to raise pressure, counterclockwise to lower pressure.
• Move wireline winch control lever back to neutral, and slow engine to
idle before shutting down.

Controls the speed and direction of extension for the feed cylinder to raise
and lower the head. This valve section is in the main control valve and is a
load sensing type with a relief valve to limit the maximum supplied pressure
(load sense relief). The spool is spring centered and is shifted manually
speed of the feed cylinder.
Note, this circuit is intended for fast traversing of the feed cylinder. It is not
intended to be used to control feed speeds while drilling.
Push the lever to raise the head and pull the lever to lower the head.
Check and set fast feed load sense relief.
• Set engine speed to 2200 rpm.
• Pull only the fast feed control lever to full travel.
• Reading the rod torque gauge, adjust the fast feed load sense relief to
3000 psi.

• Move fast feed control lever back to neutral and slow engine to idle
before shutting down.

Controls the speed and direction of rotation for the head motor while drilling
or making/breaking rods. This valve section is in the main control valve and
is a load sensing type with an external relief valve to limit the maximum
supplied pressure (load sense relief). The spool is detented in the forward
direction, spring centered in the reverse direction, and shifted manually
speed of rotation of the head motor. The section also has port reliefs with
anti-cavitation make-up checks to protect the circuit from over loads due to
external forces. Note these reliefs are non-adjustable. A procedure to adjust
the external load sense relief is provided in the V30 Pre-Torque Manifold -
Remote Manifold section.
Push the lever for forward rotation and pull the lever for backward rotation.
V7 Fluid Pump Speed Control - Remote Manifold
Adjusts the flow of water from the water pump. Controls the amount of
pressure drop from the secondary pump outlet port to the load sense port
by running the pump flow across an adjustable needle valve.The load
sense pressure is taken after the adjustable needle valve and connected to
the secondary pump controller where the delta pressure adjusts the
operating pressure of the secondary pump. The pump flow is determined
by the speed at which the water pump rotates to develop a torque that the
hydraulic motor can over come using the secondary pump operating
pressure minus the pressure drop across the needle valve.
Turn the needle valve adjustment knob clockwise to reduce flow and counter
clockwise to increase flow.
All adjustments are made during drilling, based on running conditions.

Controls the direction of extension for the feed cylinder to raise and lower
the head during drilling. This valve section is in the DO3 manifold valve and
is a three position four way valve with cylinder spool. The spool is detented
in both activation directions and is shifted manually with a lever on the
console.
Push the lever to lower the head and pull the lever to raise the head.

Controls the activation of the mud mixer. This valve section is in the DO3
manifold valve and is a two position four way valve with motor spool. The
spool is detented in both directions and is shifted manually with a lever on
the console.
Push the lever to shut off mud mixer and pull the lever to activate the mud
mixer.

Controls the direction of extension for the side shift cylinder to open or
close the head. This valve section is in the DO3 manifold valve and is a
three position four way valve with motor spool. The spool is spring centered
in both activation directions and is shifted manually with a lever on the
console.
Push the lever to close the head and pull the lever to open the head.

Controls the engagement of the rod clamp. This valve section is in the DO3
manifold valve and is a two position four way valve with P connected to a
work port in either position. The spool is detented in both directions and is
shifted manually with a lever on the console.
Push the lever to close the rod clamp and pull the lever to open the rod
clamp.

Controls the engagement of the PQ chuck. This valve section is in the DO3
manifold valve and is a two position four way valve with P connected to a
work port in either position. The spool is detented in both directions and is
shifted manually with a lever on the console.
Push the lever to close the PQ chuck and pull the lever to open the PQ
chuck.

Reduces the pressure of the secondary pump to the PQ chuck only. Also
provides a pressure relief from external loads applied to the PQ chuck.
This valve section is in the DO3 manifold valve and is manually adjustable
and internally pilot assisted. Position 2 of the rotary pressure gauge display,
reads the output pressure of this valve.
Check and set reducing and relieving valve for the PQ chuck section of the
DO3 manifold.
• Turn the rotary pressure gauge display to position 2.
• Leave PQ chuck clamp closed.
• Reading the rotary pressure gauge display, adjust the reducing/relieving
valve to 1400-1450psi.
- Loosen jam nut with 9/16 wrench and adjust pressure with
5/32 Allen key.
- Tighten jam nut and make sure pressure has not changed.
• Slow engine to idle before shutting down.
• Note it may be necessary to adjust this pressure based on current drilling
conditions.

Controls the engagement of the mainline winch brake. This valve section is
in the DO3 manifold valve and is a two position three way valve. The spool
is detented in both directions and is shifted manually with a rotary lever
under the console.
Rotate the lever clockwise to engage the brake and counter clockwise to
disengage the brake.

Reduces the pressure of the secondary pump to the rod clamp only. Also
provides a pressure relief from external loads applied to the rod clamp.
Check and set reducing and relieving valve for the rod clamp section of the
DO3 manifold.
• Leave rod clamp open.
• Reading the rotary pressure gauge display, adjust the reducing/relieving
valve to 750-850psi.
5/32 Allen key.
• Note it may be necessary to adjust this pressure based on current drilling conditions.

Reduces the pressure of the secondary pump to the side shift cylinder only.
Check and set pressure reducing valve for the side shift section of the DO3
manifold.
• Move the control lever so the head shifts to full open and back to full
closed.
• When the head is shifting open, lower the pressure until the head will no
longer move.
5/32 Allen key.
• Reading the rotary pressure gauge display, pull the control lever to hold
the head open and increase the reducing valve pressure by 400 psi.
conditions.

Prevents external forces from driving the cylinder faster than the pump can
fill the opposite side of the cylinder. Also provides a high pressure relief
from applied external loads. This valve section is in the DO3 manifold valve
and is manually adjustable and internally pilot assisted.
The counter balance valve is factory set and does not need to be adjusted.
However, if the cartridge does need to be adjusted, refer to the Bench
Setting of Counter Balance Valves section and follow the procedure using
the appropriate values for the side shift counter balance valve from the
included chart.

Limits the oil flow to the mud mixer motor. This valve section is in the DO3
manifold valve and is a manually adjustable needle valve that acts on the
pressure supply gallery to the mud mixer only. No adjustments are necessary
for commissioning.
Rotate the adjustment knob clockwise to slow down the mud mixer and
counter clockwise speed up the mud mixer.

Artificially raises the mud mixer work pressure to make sure oil flows to
higher pressure parallel work circuits. This valve section is in the DO3
manifold valve and is manually adjustable and internally pilot assisted.
Check and set sequencing valve for the mud mixer section of the DO3
manifold.
• With engine off, disconnect the hydraulic hoses from the mud mixer
motor and connect them together with a union. Place caps on the motor
ports as well. If installed, leave the quick disconnects on the motor ports.
- Use a suitable container to capture the oil that runs out of the open
ports.
• Completely open the mud mixer flow control valve by turning counter
clockwise.
• Engage the mud mixer and adjust the sequencing valve until the pressure
on the rotary pressure gauge reads 1900 psi. Note, cartridge is adjusted
from back side of DO3 manifold valve.
5/32 Allen key.
V25 Fine Feed Checked Pressure Reducing Section - DO3

Valve
Reduces pressure to the rod side of the feed cylinder while using fine feed
only. When fine feeding on the base side, the return oil from the rod side
goes around the pressure reducing valve through a check valve. This valve
section is in the DO3 manifold valve and is manually adjustable and direct
acting.
Check and set pressure reducing valve for the fine feed section of the DO3
manifold.
• Run drill until hydraulic oil is at operating temperature, and then with
mast fully extended, raise drill head until it tops out using fast feed.
• Completely close the fine feed flow control by turning clockwise until it
bottoms out.
• Push the fine feed control lever and open the fine feed flow control until
the head just starts to descend.
• When the head is lowering adjust the fine feed pressure reducing section
to 2000 psi reading the bit weight gauge on the console.
5/32 Allen key.
• If adjustment can not be completed while head is lowering, then raise
head to top of mast and repeat above two steps.
conditions.

Limits the oil flow from the feed cylinder while using fine feed only. This
valve section is in the DO3 manifold valve and is a manually adjustable
needle valve that acts on the tank return gallery from the fine feed only.
Rotate the adjustment knob clockwise to slow down the feed cylinder and
counter clockwise speed up the feed cylinder.

Isolates the head float function from fine feed and fast feed when not in
use. This valve section is in the DO3 manifold valve and has one PO check
per work port and cross senses to the opposite work port.

While making or breaking rod joints, the reducing relieving cartridges are
adjusted to balance the weight of the components that would need to be
supported by the rod threads. Also provides a pressure relief from external
loads applied to the feed cylinder, only when head float is engaged. This
valve section is in the DO3 manifold valve and is manually adjustable and
internally pilot assisted. Each of the work lines has a separate reducing
relieving valve.
All adjustments are to be made under the following conditions.

• Hydraulics at operating temperature.
• Engine speed set to 1800 rpm.
• Transmission in first gear.
• Drill set to correct working angle.
• One drill rod clamped in the PQ chuck.
Head float up adjustment.

• With the above conditions met, move the head midway up the mast
using fast feed and return fast feed to neutral.
• Pull head float up and adjust the reducing relieving cartridge until the
head just stops rising.
5/32 Allen key.
- Tighten jam nut.
• Note it may be necessary to adjust this pressure based on changing
drilling conditions.
Head float down adjustment.

• With the above conditions met, re-center the head midway up the mast
using fast feed and return fast feed to neutral.
• Push head float down and adjust the reducing relieving cartridge until
the head just stops dropping.
5/32 Allen key.
- Tighten jam nut.
• Note it may be necessary to adjust this pressure based on changing
drilling conditions.

Controls direction of head float for making or breaking rods. This is
accomplished by controlling which side of the feed cylinder pressure is
applied too. Note, it is not intended to be used for fine feeding or fast
feeding. This valve section is in the DO3 manifold valve and is a three
position four way valve with motor spool. The spool is spring centered in
both activation directions and is shifted manually with a lever on the console.
Push the lever for head float down (rod making) and pull the lever for head
float up (rod breaking).
V30 Pre-Torque Manifold - Remote Manifold
Limits the operating pressure of the rotation function while head float down
is engaged. This manifold contains a solenoid operated, two position, two
way cartridge and a manually adjustable relief cartridge placed in series.
The load sense signal (LSR port) from the main valve rotation section is
connected to this manifold. The rotation load sense is only reduced when
the head float down is engaged and presses a switch to energize the
solenoid. This manifold is mounted behind the console with the adjusting
knob protruding through the console.
Check and set pressure reducing valve for the pre-torque manifold.
• Completely lower the pre-torque manifold pressure by turning the
adjustment knob counter clockwise until it stops.
• Place the transmission in fourth gear.
• Completely lower the rotation torque by turning the rotation speed
pressure relief valve clockwise until it stops.
• Insert a rod into the chuck and foot clamp and engage both clamps.
• Push the head float lever to engage head float down.
• Push the rotation lever for forward rotation.
• Watching the rod torque gauge on the console adjust the relief valve in
the pre-torque manifold to the pressure appropriate for the rod being
used. See chart below.
- Turn knob clockwise to increase pressure and counter clockwise to
decrease pressure.
Pre-Torque Manifold Relief Setting
Rod Size BQ NQ HQ HWT
Pressure (psi) 460 690 1150 1600
* Slow engine to idle before shutting down.
V31 Wireline Counter Balance Valves - Winch Mounted

Prevents external forces from driving the wireline winch faster than the
pump can supply oil to the motor. Also provides a high pressure relief from
applied external loads. The wireline winch has counter balance valves on
both work ports to prevent run away loads while hoisting and lower. This
manifold valve is mounted directly to the wireline winch motor.
the appropriate values for the wireline counter balance valve from the
included chart.

Prevents external forces from driving the mainline winch faster than the
pump can supply oil to the motor while lowering. Also provides a high
pressure relief from applied external loads that act to pull cable off the
drum. The manifold also contains logic elements to allow the brake to be
released either internally or externally. If the brake is release
externally, then PO check valves are opened to allow oil to flow from the A
to B port of the motor. This manifold valve is mounted directly to the mainline
winch motor.
the appropriate values for the mainline counter balance valve from the
included chart.
Provides directional control of the four jacks and four outriggers (if installed),
and for the mast extend, mast dump and mast raise. The inlet section of
the stackable section control valve has a direct acting relief cartridge. All
spool sections are spring centered, manually controlled, with load holding
checks and arranged in parallel. This valve is mounted on the left hand
side of the base frame in front of the console.
Check and set auxiliary valve inlet relief.

• Fully retract the mast extend cylinder.
• With engine off and all controls in their neutral position, turn the auxiliary
pump compensator clockwise half a revolution.
- Loosen jam nut with 7/16 inch wrench and adjust pressure with
7/64 inch Allen key.
- Clockwise to raise pressure
• Connect gauge capable of 2500 psi onto the diagnostic port located at
the diverter valve.
• Pull diverter valve actuator to send flow to the auxiliary valve.

• Slowly engage the retract direction of the mast extend cylinder.
• While watching the gauge connected to the diverter valve, adjust the
auxiliary inlet relief to 2300 psi.
- Remove guard nut with 1/2 inch wrench.
- Replace guard nut.
• Go back to the auxiliary pump and adjust compensator back to 2000
psi.
• Return all levers to neutral and slow engine to idle before shutting down.
V41 Mast Raising Counter Balance Valves - Cylinder

Mounted
Prevents external forces from driving the mast raising cylinders faster than
the pump can supply oil to the cylinder. Also provides a high pressure relief
from applied external loads. The mast raising cylinders have counter balance
valves on both work ports of both cylinders to prevent run away loads. This
manifold valve is mounted directly to the base end of the cylinders and are
hard plumbed to the rod side of the cylinders.
the appropriate values for the mast raising counter balance valve from the
included chart.
V42 Mast Dump Counter Balance Valves - Cylinder Mounted

Prevents external forces from driving the mast dump cylinder faster than
the pump can supply oil to the cylinder. Also provides a high pressure relief
from applied external loads. The mast dumping cylinder has counter balance
valves on both work ports to prevent run away loads. This manifold valve is
mounted near the base end of the cylinder.
the appropriate values for the mast dump counter balance valve from the
included chart.
Directs flow from the auxiliary pump to the closed center DO3 manifold
valve or to the open center auxiliary valve. The valve contains a manually
adjusted, detented, two position three way spool. This valve is mounted to
the base frame, on the right hand side of the auxiliary valve.
Push the spool in to connect the auxiliary pump to the DO3 manifold valve
and pull the spool out to connect the auxiliary pump to the auxiliary valve.
V44 Inlet Pressure Relieving Section - Main Valve
Provide a high pressure relief for the primary pump. The relief cartridge is
a direct acting relief that drains to the tank gallery in the main valve. The
inlet relief section is the left most section of the main valve when facing the
operators side of the console.
Check and set main valve inlet relief.
• Place the transmission in fourth gear.
• Completely lower the motor rotation torque by turning the rotation speed
pressure relief valve clockwise until it stops.
• Insert a rod into the chuck and foot clamp and engage both clamps.
• With engine off and all controls in their neutral position, turn the main
pump compensator clockwise, half a revolution.
- Loosen jam nut with 1/2 inch wrench and adjust pressure using
thumb screw.
- Clockwise to raise pressure.
• Slowly lower the rotation lever to engage reverse.
• While watching the rod torque gauge, on the console, adjust the main
valve inlet relief to 4800 psi.
• Go back to the main pump and adjust compensator back to 4500 psi.
thumb screw.
• Return all levers to neutral, and slow engine to idle before shutting down.
V45 Rotation Speed Pressure Relief Valve - DO3 Manifold

Adjusts the speed and torque of the drilling motor by controlling the
displacement of the drilling motor. A relief valve limits the control pressure
to the drill motor. As the relief setting is increased, motor speed is increased.
This valve section is in the DO3 manifold valve and is a manually adjustable,
pilot assisted, relief cartridge. The cartridge relieves the pressure gallery
to the tank gallery. A small orifice is installed prior to the relief cartridge to
limit the oil loss from pressure to tank gallery.
Rotate the adjustment knob clockwise to increase motor speed and counter
clockwise to decrease motor speed. Note, since the method of changing
speed is by adjusting motor displacement, an increase in speed will result
in a decrease in motor torque.
Pumps
Provides pressure to the main control valve proportional to the load sense
signal received from the main valve. The pump has an axial piston rotary
group with high pressure compensator and stand-by pressure compensator.
This pump is driven directly by the engine off the flywheel and receives flow
from the hydraulic tank. The pump can be isolated from the tank by a large
ball valve. Note, do not close or partially close the ball valve when the pump
is turning.
Starting procedure for primary pump after suction hose or case drain hose
has been temporarily disconnected.
• With a full hydraulic tank slowly open the case vent plug and wait until
gravity fills the inlet line and pump case. When oil runs with out bubbles
retighten plug.
• Start engine and leave at low speed until air is out of system.

• With engine off and all control levers in the neutral position, disconnect
the rotation motor hoses and cap and plug all open ports.
- The hose plugs will need to resist primary pump pressure.
ports.
• Start the engine and adjust the speed to 1300 rpm.
• Raise the rotation control lever to fully engage forward rotation.
• Adjust the high pressure compensator to 4500 psi while reading the rod
torque gauge on the console.
thumb screw.

• Return all control levers to neutral and slow engine to idle before shutting
down.
• Reconnect rotation motor hoses.
• Start engine, increase throttle, and run rotation forward until air is pushed
out of the circuit.

the load sense line from the main valve and plug the valve port but
leave the hose open to atmosphere.
ports.
• Place a gauge capable of 500psi on the main valve diagnostic port.
• Ensure all control levers are in the neutral position.
• Adjust the stand-by compensator to 300 psi while reading the rod torque
gauge on the console.
thumb screw.
• Reconnect load sense hose.
• Start engine, increase throttle, and run rotation forward until air is pushed
out of the load sense line.
P2 Secondary Pump - Mounted to Primary Pump

Provides pressure proportional to the load produced by the water pump
through a load sense line. The pump has an axial piston rotary group with a
load sense relief and stand-by pressure compensator. This pump is through
driven by the primary pump and draws flow from the hydraulic tank. The
pump can be isolated from the tank by a large ball valve. Note, do not close
or partially close the ball valve when the pump is turning.
Starting procedure for secondary pump after suction hose or case drain
hose has been temporarily disconnected.
• With a full hydraulic tank slowly open the case drain line and wait until
gravity fills the pump case. When oil runs with out bubbles retighten
plug.
• Loosen four bolt flange bolts to suction line and allow air to escape from
suction plumbing. When oil runs without bubbles retighten bolts.
• Rotate water pump control valve counter clockwise to lower the pump
load.
• Start engine and leave at low speed until air is pushed out of system.

• With engine off, rotate water pump control valve counter clockwise to
open.
• Disconnect the pressure side hose from the mud motor and cap and
plug all open ports.
- The hose plug will need to resist secondary pump pressure.
ports.
• Connect a pressure gauge capable of 3500 psi to the diagnostic port on
the water pump control valve.

• Adjust the high pressure relief to 3000 psi while reading the gauge.
thumb screw.
• Reconnect mud motor hoses.
• Start engine, and increase throttle, until air is pushed out of the circuit.

the load sense line from the water pump control valve and plug the
valve port but leave the hose open to atmosphere.
ports.
• Place a gauge capable of 500psi on the water pump control valve
diagnostic port.
• Adjust the stand-by compensator to 280 psi while reading the gauge.
7/16 inch wrench.
• Reconnect load sense hose.
• Start engine, increase throttle, and run until air is pushed out of the load
sense line.
P3 Auxiliary Pump - Mounted to Secondary Pump

Provides flow required for the DO3 manifold valve or the auxiliary valve at a
constant pressure. The pump has an axial piston rotary group with a high
pressure compensator. This pump is through driven by the secondary pump
and receives flow from the hydraulic tank. The pump can be isolated from
the tank by a large ball valve. Note, do not close or partially close the ball
valve when the pump is turning.
Starting procedure for auxiliary pump after suction hose or case drain hose
has been temporarily disconnected.
• With a full hydraulic tank slowly open the case drain line and wait until
gravity fills the pump case. When oil runs with out bubbles retighten
plug.
• Loosen motor fitting to suction line and allow air to escape from suction
plumbing. When oil runs without bubbles retighten bolts.
• Pull diverter valve knob to direct the pump oil to the auxiliary valve.

• With engine off, push diverter valve knob to direct oil to the DO3 manifold
valve.
• While watching the auxiliary pressure gauge on the console, adjust the
high pressure compensator to 2000 psi.
P4 Cooling Pump - Mounted to Engine PTO

Provides flow to circulate oil through oil cooler. The pump is an external
gear type with a pilot assisted, adjustable relief valve built into the end
plate. This pump is driven by the engine PTO and draws from the hydraulic
tank. The pump can be isolated from the tank by a large ball valve. Note,
do not close or partially close the ball valve when the pump is turning.
Starting procedure for cooling pump after suction hose has been temporarily
disconnected.
• Loosen motor fitting to suction line and allow air to escape from suction
plumbing. When oil runs without bubbles retighten bolts.

• With the engine off, disconnect the pressure hose from the pump and
install a pressure gauge directly into the pressure port of the pump.
Insert a steel plug into the hose left open.
ports.
• Turn the relief adjustment screw counter clockwise as far as it will go to
lower the pressure.
• Install gauge capable of 500 psi onto the outlet of the cooling pump.
• While watching the pressure gauge, adjust the high pressure relief to
200 psi.

• Remove gauge and replace hose.

Provides flow to circulate oil through oil cooler. The pump is an internal
gear type with a direct acting, fixed relief valve built into the end plate. This
pump is driven by the head gear box and draws from the head gear case.
Starting procedure for head cooling pump after suction hose has been
temporarily disconnected.
• Start engine and leave at low idle.
• With transmission in 1st gear engage head rotation forward and let spin
until air is pushed out of the system.
P6 Hand Pump - Remote Mounted

Hand pump used to fill hydraulic tank from oil source. Prior to oil entering
the tank, the oil is pumped through a filter to help maintain system
cleanliness. This pump is supplied loose and is not mounted to the drill.
Bench Setting of Counter Balance Valves section

Body part number to be purchased from Sun Hydraulics
Component Body # Setting value
V22 Side Shift Counter Balance Section ECI 4000 psi
V31 Wireline Counter Balance Valves BCI 4000 psi
V32 Mainline Counter Balance Valve HCL 5000 psi
V41 Mast Raising Counter Balance Valves ECI 5000 psi
V42 Mast Dump Counter Balance Valves ECI 4000 psi
Setting procedure counter balance valves.

• Remove counter balance valve from the drill.
- Ensure all loads held by the counter balance valves are support
prior to removal.
- Plug open cavity with a clean rag.
ports.
• Install counter balance valve into body according to chart above.
Connect counter balance valve, pump and pressure gauge as

shown below.
• Raise the operating pressure of the counter balance valve to maximum.
- Counter clockwise to raise pressure.
• Pump hand pump until pressure exceeds value given in chart.
• Adjust the counter balance pressure to value given in chart.
- Counter clockwise to raise pressure, clockwise to lower pressure.
• Remove counter balance valve from body and reinstall into drill.
• Start engine, increase throttle, and run function until air is pushed out of
the circuit.
Fluid Conditioners
C1 Hydraulic tank - Frame Mounted
Provides common volume for oil returning from the hydraulic circuits and
for the pumps to draw oil from. The tank volume also allows time for some
heat rejection and de-aeration. The tank has an electrical temperature and
level switch, as well as a thermometer and level gauge. On the side surface
of the tank is a cleanout cover. Note do not open the cleanout cover unless
the tank has been drained of oil. The tank is mounted to a frame that
locates the tank directly above the three pumps.
Tank filling procedure

• Ensure all hoses and fittings are connected to the system as described
in the parts book.
• Connect the quick coupler on the bottom of the hydraulic tank to the
hand pump quick coupler. Place the other end of the hand pump into
the bucket of new oil. Open ball valve and start pumping oil into tank.
- Tank fill capacity is 50 gallons of Imperial Oil’s Nuto hydraulic oil.
See Lubrication chart at the end of the hydraulic section for
acceptable alternatives and viscosity grades.
- Note, do not remove the tank mounted filter and pour oil directly
into tank. When oil is hand pumped into system, it is filtered prior to
entering the tank.
• Fill tank until oil reaches 1 inch from top line on the sight gauge and
stop.
• If pump suction lines have been previously removed go to the pump
sections and perform the starting the pump procedure before continuing.
• While monitoring the tank level start engine and leave at low idle and
move all functions, one at a time, full stroke three times.
- While moving the functions and if the oil level in the tank drops
below the top of the thermometer, stop the engine and add more oil
to fill to within 1 inch from the top line on the sight gauge.
-
The tank level drops when oil starts to fill the empty hoses, cylinders
and other components.
• Repeat this until all functions can be moved and the oil level stays
between the bottom of the sight gauge and full mark.
• Close the hand pump ball valve and disconnect the hand pump.

Filters all the return oil flow prior to entering the tank. The primary return
filter has a pressure by-pass and a clog indicator. The filter housing is
mounted to the top surface of the tank, with the filter head above the tank
and the filter bowl protruding into the tank. See the Filter Element
Replacement Chart at the end of the Conditioners section for element part
number.

• All filter element changes are to be completed with the engine off.
• Sweep away all debris from the top surface of the tank and protect from
falling debris. Since the removal of the filter will open the tank to the
atmosphere, care must be taken to clean the work area to protect the
hydraulic system.
• Remove the cover from the filter housing.
- Loosen the four bolts using a 1/2 inch wrench.
- Lift the cover slowly to allow the vacuum to be broken and the oil to
drain back into the tank.
• Remove filter element by turning counter clockwise and pulling up.
- Note, you may need to remove the filter and the filter bowl from the
tank before the two parts can be separated.
- Take care to keep debris from falling into tank.
- Take care to prevent filter element from dripping on the drill rig or
ground.
• Reverse process to replace filter.
- Make sure filter element is seated and locked into the filter bowl
correctly.
• Replace cover and tighten bolts in a criss-cross pattern.
- Tighten the four bolts using a 1/2 inch wrench.
• Pull diverter valve knob out to allow flow through the open center auxiliary
valve.
- This will allow the oil to push the air through the filter.
• Start engine and turn engine speed up to approximately 1500 rpm for 5
minutes.
• Slow engine to idle before shutting down and allow the tank oil to de-
aerate for 30 minutes prior to drill use.

Filters all pressurized oil leaving the primary pump. The primary pressure
filter has a pressure by-pass and a clog indicator. The filter housing is
mounted to a bracket on the side surface of the tank. See the Filter Element
number.

• Sweep away all debris from the top surface of the filter housing and
protect from falling debris. Since the removal of the filter will open the
tank to the atmosphere, care must be taken to clean the work area to
protect the hydraulic system.
• Remove the plate from the top of the filter bowl.
- Unscrew plate from filter bowl using 1 1/16 inch wrench.
• Remove filter element by lifting straight out.
- Take care to keep debris from falling into tank.
- Take care to prevent filter element from dripping on the drill rig or
ground.
• Replace filter element by lowering straight into filter bowl.
- Make sure filter element is seated into the filter bowl correctly.
• Replace cover and tighten.
- Tighten plate to filter bowl using 1 1/16 inch wrench.
• Start engine and increase engine speed to approximately 1500 rpm
and run fast feed up and down for 5 minutes to push the air out of the
filter housing.
• Slow engine to idle before shutting down and allow the tank oil to de-
aerate for 30 minutes prior to drill use.

Filters all oil prior to entering the tank. The hand pump filter is a spin-on
element and is mounted below the hydraulic tank. See the Filter Element
number.

• Make sure the ball valve to isolate the hand pump filter from the hydraulic
tank is closed.
protect from falling debris.
• Turn the element counter clockwise by hand, as viewed looking up, to
remove from filter head.
- Take care to prevent filter element or filter head from dripping on
the ground.
• Replace with new element by turning element clockwise by hand, as

viewed looking up.
- Wet the rubber element of the filter with clean hydraulic oil prior to
filter installation.
• Make sure filter element is seated into the filter head correctly.
C5 Tank Breather- Tank Mounted

Filters all air prior to entering the tank. The tank breather is a spin-on
element and is mounted to the top surface of the hydraulic tank. See the
Filter Element Replacement Chart at the end of the Conditioners section
for element part number.

• Sweep away all debris from the top surface of the tank and protect from
falling debris.
• Turn the element counter clockwise by hand, as viewed looking down to
remove.
- Take care to prevent filter element from dripping on the ground.
• Replace with new element by turning element clockwise by hand, as
viewed looking down.

Filters oil in the gear drive head. The gear drive head pressure filter has a
pressure by-pass and a clog indicator. The filter housing is mounted to a
bracket on the side surface of the tank. See the Filter Element Replacement
Chart at the end of the Conditioners section for element part number.

• Lower drill head using fast feed until it is lower than the filter.
protect from falling debris.
• Slowly unscrew one of the hoses that connects to the filter head to allow
the vacuum to be broken.
- Retighten hose once air stops rushing in.
• Remove the filter bowl from the filter head by turning counter clockwise,
as viewed from the bottom.
- Unscrew filter bowl using 1 1/16 inch wrench.
• Remove filter element by pulling off of filter head.
- Take care to prevent filter element from dripping on the ground.
• Replace filter element by pushing element back onto filter head.
- Make sure filter element is seated onto the filter head correctly.
• Replace filter bowl and tighten.

- Tighten filter bowl using 1 1/16 inch wrench.
• Start engine and turn engine speed up to approximately 1500 rpm.
• Engage 4th gear on the gear box and slowly engage rotation forward
for five minutes to push the air out of the filter housing.
• Disengage rotation and slow engine to idle before shutting down and
allow the gear drive head oil to de-aerate for 30 minutes prior to drill use.
C7 Head Gear Drive Cooler - Engine Cooling Package

Mounted
Rejects heat from the head gear drive oil to the ambient air to help maintain
operating temperatures. The cooler is mounted in series to the front of the
engine cooling package.

Rejects heat from the hydraulic oil to the ambient air to help maintain
operating temperatures. The cooler is mounted above, and in front of the
diesel tank.

Combine all tank line flows prior to entering the primary return filter. The
large return manifold is mounted to the hydraulic tank frame.

Combine all case drain line flows prior to entering the hydraulic tank. The
small return manifold is mounted to the hydraulic tank frame below the
large return manifold.

Pressure gauge to selectively display the following pressures.
1. Auxiliary pump pressure
2. Chuck pressure
3. Rotation speed pressure
4. Mainline winch brake release pressure
5. Rod clamp pressure
6. Side shift pressure
The pressures are selected by turning the outer control knob to the numbers
that correspond to the pressure descriptions above. The gauge is mounted
to the console below the DO3 manifold valve.

Pressure gauges to display the following information from left to right.
• Feed pressure
• Bit weight pressure
• Rod torque pressure
• Secondary pressure
• Auxiliary pressure
The gauges are mounted in the console above the main valve.
Filter Element Replacement Chart

Component Filter location Boart Longyear
Designator Element Part #
C2 Primary Pump Pressure Filter 3543987
C3 Primary Return Filter 100236
C4 Hand Pump Filter 3547872
C5 Tank Breather 3547872
C6 Head Gear Drive Pressure Filter 3542297
Lubrication Chart
Item Description Location Number Lubricant Lube Quantity Quantity Service Level
of Lube type Method (U.S.) (metric) Interval Check
Points (hrs) Interval
(hrs)
Standard Equipment
1 Power Unit See Manufacturer’s Operation and Service Manual 8
© 2005 Boart Longyear Inc. Boart Longyear

2 PQ Head Reservoir Rotation Unit 1 NUTO H 46 Change * 10.5 Quarts * 10 Liters 250 8
3 PQ Head Bearing Cap 2 MPG Grease Gun 2-3 Shots 2-3 Shots 8 N/A
BOART LONGYEAR
4 PQ Chuck* Chuck Bowl/Body 10 MPG Grease Gun 2-3 Shots 2-3 Shots 8 N/A
5 Hydraulic Reservoir Hydraulic Module 1 Hyd Oil Change * 60 Gals * 227 Liters as req’d 8
6 Flange Bearing Wireline Hoist 1 MPG Grease Gun 2-3 Shots 2-3 Shots N/A N/A
7 Mainline Hoist Draw Works Group 1 Gear Oil Change * 2 Quarts * 1.9 Liters 250 168
8 Sheave Block Ass’y* Top of Mast 0 MPG Hand Packed 6 months
9 Lower Mast/Draw Near Control Panel 2 MPG Brush/Hand Coat Shaft Coat Shaft Upon Ass’y N/A
Works Pivot
10 Wireline Sheave Top of Mast 2 MPG Grease Gun 2-3 Shots 2-3 Shots Every N/A
Wheel* Setup
Optional Equipment
11 Water Pump* See Pump Manufacturer’s Specifications
12 Mud Mixer* Separate 2 MPG Grease Gun 2-3 Shots 2-3 Shots 60 N/A
13 Rod Clamp* Base of Drill 2 MPG Grease Gun 2-3 Shots 2-3 Shots 60 N/A
Hydraulic Explanation
5-41
is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
Lubricant Code
Season Winter Summer Hot Climate
Low Ambient (øC)** -26 -22 0
High Ambient (øC) 20 25 31
Engine Oil
SAE Grade See Engine Manufacturer’s
Specification
Hydraulic Oil
ISO Grade*** 32 46 68
Imperial Oil Nuto H32 Nuto H46 Nuto H68
Shell Tellus T32 Tellus T46 Tellus T68
Chevron AW MV 32 ISO VG 46 ISO VG 68
Mobil DTE13M DTE15M DTE16M
Gear Oil
SAE Grade 80W90
Imperial Oil GX-80W-90
Shell Spirax 80W-90
Chevron Delo 80W-90
Mobil Mobilube HD 80W90
MPG - MultiPurpose Grease

Imperial Oil Unirex EP 2
Shell Darina XL EP 2
Chevron Ulti-Plex EP2
Mobil Mobilux EP2 or Mobilith AW 2
Notes
Note Colder start up, preheat engine and hydraulic oil in a safe
manner (no open flames)
* Note Note Shown
** Note Upon cold start up allow the engine to run at low idle until
the hydraulic tank is warm to the touch before operating at
high idle, otherwise damage to the hydraulic system and/or
power unit may occur.
*** Note Do not mix brands of oil, flush completely before changing.
Hydraulic system is filled with Imperial Oil, Nuto H46 from
the factory.
Note Liquid volumes are original factory fill quantities only, they
are not refill quantities. Refer to Operations and Service
Manual for proper procedure to check oil levels.
Actuators
Provides force to move chuck jaws which holds or releases drill rods. The
seven cylinders have a nitrogen pre-charge applied to the base side that
acts to close the chuck jaws. Hydraulic pressure is used to release the
chuck jaws against the nitrogen pre-charge. These cylinders are built into
the PQ chuck.

These double acting cylinders open and close the rod clamp jaws. The
jaws close when oil is applied to the rod side of the cylinders. Note, the
jaws have a slope on the backside to allow the jaws to apply more clamping
force with increased rod string weight. The two rod clamp cylinders are
built into the rod clamp assembly.

This cylinder is a double acting cylinder used to side shift the head. Oil is
applied to the base side to move the head into the drilling position.
A4 Mud Mixer Motor

This motor only turns in one direction and provides rotation to the mud
mixer impeller. The motor is an external gear type.
A5 Rotation Motor
This motor is a bi-directional, bent axis, variable displacement, piston type
used to drive the rotation of the drill head. The motor displacement is
controlled by varying a pilot signal sent to the motor displacement controller.
Minimum displacement adjustment procedure

The minimum displacement of the motor is factory set and should not need
to be adjusted. How ever, if the motor minimum displacement does come
out of adjustment use the following procedure to reset the minimum
displacement.
• With the engine at 2200 rpm and the rotation lever in the neutral position,
engage 1st gear and turn the rotation speed knob clockwise until it stops.
• Using a photo tachometer adjust the minimum displacement screw until
the head turns at 199 rpm.
- Loosen jam nut with 3/4 inch wrench and adjust displacement with
1/4 inch Allen key.
- Clockwise to lower speed, counter clockwise to raise speed.
- Tighten jam nut and make sure speed has not changed.
• Disengage rotation and slow engine before shutting off engine.
Maximum displacement adjustment procedure

The maximum displacement of the motor is factory set and should not need
to be adjusted. How ever, if the motor maximum displacement does come
out of adjustment use the following procedure to reset the maximum
displacement.
• With the engine at 2200 rpm and the rotation lever in the neutral position,
engage 1st gear and turn the rotation speed knob counter clockwise
until it stops.
• Using a photo tachometer adjust the maximum displacement screw until
the head turns at 122 rpm.
- Loosen jam nut with 3/4 inch wrench and adjust displacement with
1/4 inch Allen key.
- Counter clockwise to lower speed, clockwise to raise speed.

• Disengage rotation and slow engine before shutting off engine.
Rotation speed control range adjustment

The speed control range adjustment is factory set and should not need to
be adjusted. How ever, if the speed control range adjustment does come
out of adjustment use the following procedure to reset the speed control
range.
• With engine off disconnect the B side hose from the motor and cap and
plug the open ports.
- The plug and cap will need to resist primary pump pressure.
ports.
• Start engine and set speed to 2200 rpm, and engage full forward rotation.
• Adjust the rotation speed knob on the DO3 manifold valve until the rotary
pressure gauge reads 190 psi.
• Using a photo tachometer adjust the motor speed control range until
the head speed just starts to decrease.
- Break off tamper proof cap if still installed.
- Loosen jam nut and adjust speed control range with Allen key.
- Counter clockwise to raise speed, clockwise to lower speed.
• Disengage rotation, slow engine before shutting off engine, and reconnect
the B side motor hose.
A6 Feed Cylinder
This cylinder is double acting and is used to move the head up and down
the mast. The rod side of the cylinder is fed through the hollow rod. The oil
enters the rod side of the cylinder from the hollow rod through a passage
near the piston. The base side is fed through a smaller tube within the
hollow rod. The tube separates the rod side oil from the base side oil and
passes through the piston into the base side cylinder volume. The manifold
threaded onto the rod end of the cylinder contains a pilot operated check
valve that locks the base side oil when the drill rig is off.

This motor provides the torque to turn the mainline winch. The motor is a
fixed displacement, bent axis, axial piston motor.
Oil Check and Fill Procedure for winch housing.
Refer to the H20R Braden Recovery Winch Installation, Maintenance, and
Service Manual (Braden Manual) for service intervals, Oil check and fill
procedures, and alternate oil types allowed. The Braden Manual has been
included in the Boart Longyear parts manual.

This motor provides the torque to turn the wireline winch. The motor is an
internal gear type.
A9 Cooler Fan Motor

This motor provides the torque to turn the hydraulic cooler fan. The motor
is an external gear type with case drain line and turns in one direction only.

This motor provides the torque to turn the water pump. The motor is an
internal gear type and turns in one direction only.

These four cylinders are used to extend and retract the jack cylinders. The
cylinders are double acting and have external ports on the rod and base
end of the cylinder barrel.
A12 Jack Cylinders

These four cylinders are used to level the drill rig. Each cylinder has a pilot
operated check valve to lock the base side oil in the cylinder until oil is
forced into the rod side. Each cylinder also has an external manual locking
pin which acts as a back-up cylinder lock in the event of a cylinder seal or
pilot operated check valve failure. Note, leveling of the drill rig is controlled
manually by manipulating the auxiliary valve. The drill rig does not auto
level.
No adjustments required
If jack cylinders have been removed for shipping, reassemble the jack legs
and hydraulic plumbing as per the parts manual.

This cylinder is double acting and is used to extend or retract the telescoping
section of the mast. The rod side of the cylinder is fed through the hollow
rod. The oil enters the rod side of the cylinder from the hollow rod through
a passage near the piston. The base side is fed through a smaller tube
within the hollow rod. The tube separates the rod side oil from the base
side oil and passes through the piston into the base side cylinder volume.

This is a double acting cylinder used to slide the mast assembly down to
allow the foot plate to touch the ground.

These cylinders are double acting and are used to raise or lower the mast
assembly.
General Maintenance and Troubleshooting

7-2 Head Slide Wear Bars
Field Maintenance Check and Adjustment
7-3 LF90 Lubrication Chart

7-4 Engine - Powerview Monitor Fault Codes
7-8 PQ Head Drive Group
7-9 PQ Head Disassembly Procedures
7-21 PQ Head Reassembly Procedures
Intermediate Gear Assembly
Intermediate Shaft and Gear Assembly
Input Pinion and Shaft Assembly
Output Shaft Assembly (Spindle)
Output Carrier and Pump Mounting
Transmission Assembly
7-57 Transmission and Head Box Lubrication

Head Bearing Caps
7-58 PQ Nitro Gas Chuck Planograph

7-59 PQ Nitro Gas Chuck Assembly Procedures
7-67 Installation of New Jaws
7-68 Nitrogen Gas Springs
BOART LONGYEAR General Maintenance and Troubleshooting 7-2
Head Slide Wear Bars

Field Maintenance Check and Adjustment
As the head slide wear bars wear down, the head movement will increase to
a point where replacement shims (p/n 100172) 0.015" and 0.018" (0,38 mm
and 0,45 mm) should be used to correct head movement.
Depending on the wear pattern or location, the shims can be used as is (full
length) or cut into shorter sections in order to fill gaps that may occur between
wear bars and lower mast slide surfaces.
This will maintain head positioning and extend the service life of the wear
bars.
Shims and
Nylatron Wear Bars
Shims and
Nylatron Wear Bars
Item Description Location Number of Lubricant Lube Quantity Quantity Service Level Check
Lube Points Type Method (U.S.) (Metric) Interval (hrs) Interval (hrs)
1 Power Unit See Manufacturer’s Operation and Service Manual 8
2 PQ Head Reservoir Rotation Unit Group 1 NUTO H46 Change † 10.5 Quarts 10 Litres 250 8
3 PQ Head Bearing Cap 2 MPG Grease Gun 2-3 Shots 8 N/A
4 PQ Chuck* Chuck Bowl/Body 10 MPG Grease Gun 2-3 Shots 8 N/A
5 Hydraulic Reservoir Hydraulic Module 1 Hyd Oil Change † 60 Gals 227 Litres as req’d 8
6 Flange Bearing Wireline Hoist 1 MPG Grease Gun 2-3 Shots N/A N/A
7 Mainline Hoist Draw Works Group 1 Gear Oil Change † 2 Quarts 1.9 Litres 250 168
8 Sheave Block Ass’y* Top of Mast 0 MPG Hand Packed 6 months
© 2005 Boart Longyear Inc. Boart Longyear

9 Lower Mast/Draw Works Pivot Near Control Panel 2 MPG Brush/Hand Coat Shaft Upon Assembly N/A
10 Wireline Sheave Wheel* Top of Mast 2 MPG Grease Gun 2-3 Shots Every Setup N/A
Options
BOART LONGYEAR
11 Water Pump* See Pump Manufacturers Specifications

12 Mud Mixer* Separate 2 MPG Grease Gun 2-3 Shots 60 N/A
13 Rod Clamp* Base of Drill 2 MPG Grease Gun 2-3 Shots 60 N/A
Lubricant Code
Season Winter Summer Hot Climate
Start Up Temp Low (Celsius)** -26° -22° 0° * Not Shown
**Note: Upon cold start up allow engine to run at low idle until the
Operating Temp High (Celsius) 20° 25° 31° hydraulic tank is warm to touch before operating at high idle
LF90 Lubrication Chart
Engine Oil - SAE Grade See Engine Manufacturer’s Specifications otherwise damage to the Hydraulic system and/or Power unit
may occur .
Hydraulic Oil - ISO Grade*** 32 46 68 Note: Colder Start Up - preheat engine and hydraulic oil in a safe
- Imperial Oil Nuto H32 Nuto H46 Nuto H68 manner (No Open Flames)
- Shell Tellus T32 Tellus T46 Tellus T68
- Chevron AW MV 32 ISO VG 46 ISO VG 68 ***Note: Do not mix brands of oil, flush completely before changing.
- Mobil DTE13M DTE15M DTE16M Hydraulic system is filled with Imperial Oil “Nuto H46” from
Not Affected by Temp the factory.
Gear Oil - SAE Grade 80W90 † Liquid volumes are original factory fill quantities only, they are not
- Imperial Oil GX-80W90 refill quantities. Refer to Operations and Service Manual for proper
procedure to check oil levels.
- Shell Spirax 80W-90
- Chevron Delo 80W-90
All volumes are in US measure or litres.
- Mobil Mobilube HD 80W90
MPG - Multipurpose Grease
- Imperial Oil Unirex EP 2
- Shell Darina XL EP 2
- Chevron Ulti-Plex EP2
- Mobil Mobilux EP2
Mobilith AW 2
Filter Reference Chart
Item Filter Description Filtration Element Part No. Qty Service Remarks
General Maintenance and Troubleshooting
1 Main Pump Pressure 10 Micron 3543987 1 Change element when visual indicator displays Lubrication Chart
Bypass Valve to do so or @ Hydraulic oil change Next Generation LF90-PQ
2 Main Return Filter 10 Micron 100236 1 Change element when visual indicator displays
Drill Assembly
Bypass Valve to do so or @ Hydraulic oil change
3 Case Drain Filter 10 Micron 100236 1 Change element when visual indicator displays
7-3
Bypass Valve to do so or @ Hydraulic oil change

4 Drill Head Lube Filter 25 Micron 3542297 1 Change element @ 250 hour intervals or whenever
is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
Bypass Valve Drive Head hydraulic oil is changed BOART LONGYEAR
Engine - Powerview Monitor Fault Codes
SPN FMI Description

28 3 % ACCEL POS3 VOLT ABOVE NORM OR SHORT HIGH
28 4 % ACCEL POS3 VOLT BELOW NORM OR SHORT LOW
29 3 % ACCEL POS2 VOLT ABOVE NORM OR SHORT HIGH
29 4 % ACCEL POS2 VOLT BELOW NORM OR SHORT LOW
91 3 ACCEL PEDAL POS VOLT ABOVE NORM OR SHORT HIGH
91 4 ACCEL PEDAL POS VOLT BELOW NORMAL OR SHORT LOW
91 9 ACCEL PEDAL POS A VALID THROTTLE MSG NOT RCVD
91 14 ACCEL PEDAL POS THROTTLE SIG VOLT OUT OF RANGE
94 1 FUEL DELIVERY PRESSURE VERY LOW
94 3 FUEL RAIL PRESSURE VOLTAGE OUT OF RANGE HIGH
94 4 FUEL RAIL PRESSURE VOLTAGE OUT OF RANGE LOW
94 10 FUEL DELIVERY PRESSURE DROPPING TOO FAST
94 13 FUEL DELIVERY PRESSURE OUT OF CALIBRATION
94 16 FUEL DELIVERY PRESSURE HIGH
94 17 NO RAIL FUEL PRESSURE
94 18 FUEL DELIVERY PRESSURE LOW
97 0 WATER IN FUEL DETECTED
97 3 WATER IN FUEL INDICATOR VOLTAGE OUT OF RANGE HIGH
97 4 WATER IN FUEL INDICATOR VOLTAGE OUT OF RANGE LOW
100 1 ENGINE OIL PRESSURE LOW
100 3 ENGINE OIL PRESS VOLT ABOVE NORM OR SHORT HIGH SOURCE
100 4 ENGINE OIL PRESS VOLT BELOW NORM OR SHORT LOW SOURCE
100 16 ENGINE OIL PRESSURE READING INCORRECT
100 18 ENGINE OIL PRESS LOW
105 0 INTAKE MAN1 AIR TEMP HIGH
105 3 INTAKE MAN1 TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
105 4 INTAKE MAN1 TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
105 16 INTAKE MAN1 AIR TEMP HIGH
107 0 AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED
107 31 AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED
110 0 ENG COOL TEMP HIGH
110 3 ENG COOL TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
110 4 ENG COOL TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
111 1 LOW COOLANT LEVEL
158 2 KEYSWITCH INTERMITTENT
158 17 KEYSWITCH CIRCUIT PROBLEM
174 0 FUEL TEMP HIGH
174 3 FUEL TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
174 4 FUEL TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
SPN FMI Description

174 31 FUEL TEMP VOLT OUT OF RANGE
189 31 ENG SPEED DERATE CONDITION EXISTS DUE TO FAULT
190 0 ENGINE OVERSPEED
190 2 ENG SPD DATA ERRATIC, INTERMITTENT OR INCORRECT
190 3 ENG SPD VOLT ABOVE NORMAL OR SHORT HIGH
190 4 ENG SPD VOLT BELOW NORMAL OR SHORT LOW
190 5 ENG SPD CIRCUIT IS OPEN
190 16 ENGINE OVERSPEED
611 3 INJ WIRING SHORTED TO BATTERY
611 4 INJ WIRING SHORTED TO GROUND
620 3 SENSOR VOLT1 (+5VDC)ABOVE NORMAL OR SHORT HIGH
620 4 SENSOR VOLT1 (+5VDC)BELOW NORMAL OR SHORT LOW
627 1 POWER SUPPLY LOW VOLT TO INJECTORS
627 4 POWER SUPPLY INTERRUPTION
629 13 REPROGRAM CONTROLLER ECU PROBLEM
629 19 ECU NOT RECEIVING MSG FROM PUMP
632 2 FUEL SHUTOFF VALVE ERR DETECTED
632 5 FUEL SHUTOFF VALVE NON-FUNCTIONAL
632 11 FUEL SHUTOFF VALVE SOLENOID CKT OPEN OR SHORTED
636 2 ENG POS SENSOR TIMING SIGNAL ERROR
637 2 TIMING (CRANK) SENSOR TIMING SIGNAL ERROR
639 13 CAN BUS FAILURE
651 5 INJ CYLINDER1 CURRENT LESS THAN EXPECTED
651 6 INJ CYLINDER1 CURRENT INCREASES TOO RAPIDLY
651 7 INJ CYLINDER1 FUEL FLOW LOWER THAN EXPECTED
SPN FMI Description

676 3 GLOW PLUG RELAY STUCK ON
676 5 GLOW PLUG RELAY WILL NOT TURN ON
729 3 INLET AIR HEATER DRIVER1 STUCK ON
729 5 INLET AIR HEATER DRIVER1 WILL NOT TURN ON
833 2 RACK POSITION SENSOR ERROR
833 3 RACK POSITION SENSOR VOLT ABOVE NORMAL
833 4 RACK POSITION SENSOR VOLT BELOW NORMAL
834 2 RACK ACTUATOR ERROR BLEED AIR IN FUEL SYSTEM
834 3 RACK ACTUATOR CKT VOLT ABOVE NORMAL
834 5 RACK ACTUATOR CKT OPEN
834 6 RACK ACTUATOR CKT GROUNDED
834 7 RACK ACTUATOR POSITION ERROR
970 2 EXT AUX ENG SHUTDOWN SWITCH INTERMITTENT
970 11 EXT ENG PROTECTION SHUTDOWN ACTIVE
970 31 EXT AUX ENG SHUTDOWN SWITCH ACTIVE
971 31 ENG DERATE SWITCH ACTIVATED
1041 2 START SIGNAL MISSING
1041 3 START SIGNAL ALWAYS ACTIVE
1076 0 FUEL INJ PUMP CONT VALVE ERROR
1077 7 FUEL INJ PUMP ERROR
1077 11 FUEL INJ PUMP CONT VP44 INPUT VOLT OUT OF RANGE
1077 12 FUEL INJ PUMP CONT VP44 SELF TEST ERROR
1077 19 FUEL INJ PUMP CONT VP44 DETECTED CAN BUS FAILURE
1077 31 FUEL INJ PUMP CONT POWER DERATED
1078 7 FUEL INJ PUMP SPD/POS SENSOR ERROR
1078 11 FUEL INJ PUMP SPD/POS SENSOR ERROR
1078 31 FUEL INJ PUMP SPD/POS VP44 UNABLE TO ACHIEVE TIMING
1079 3 SENSOR VOLT1 (+5VDC)ABOVE NORM OR SHORT HIGH
1079 4 SENSOR VOLT1 (+5VDC)BELOW NORM OR SHORT LOW
1080 3 SENSOR VOLT2 (+5VDC)ABOVE NORM OR SHORT HIGH
1080 4 SENSOR VOLT2 (+5VDC)BELOW NORM OR SHORT LOW
SPN FMI Description

1109 31 ENG PROT SYSTEM APPROACHING SHUTDOWN
1110 31 ENG PROT SYSTEM SHUT ENG DOWN
1347 5 FUEL PUMP ASSY 1 CKT OPEN, SHORTED GROUND OR OVLOAD
1347 7 FUEL PUMP ASSY 1 RAIL PRESSURE CONT MISMATCH
1347 10 FUEL PUMP ASSY 1 LOW FUEL FLOW
1348 5 FUEL PUMP ASSY 2 CKT OPEN, SHORTED GROUND OR OVLOAD
1348 10 FUEL PUMP ASSY 2 LOW FUEL FLOW
1485 2 ECU MAIN RELAY PUMP POWER RELAY FAULT
1569 31 ENG PROT TORQ FUEL DERATE LIMIT CONDITION EXIST
2000 6 FUEL INJECTION PUMP CONT VALVE ERROR
2000 13 SECURITY VIOLATION PROPER CONT NOT INSTALLED
PV-04143N 9-04 (00-02-0586) Page 4 of 4.
PQ Head Drive Group

The PQ Head Drive Group is situated on the lower mast section. This drive
group consists of a two-speed variable displacement bent axis hydraulic
motor, a four-speed mechanical transmission, a 2:1 drive ratio gear box with
a straight cut gear set, PQ Chuck, and high pressure filter.
The final drive of the rotation unit is through the 2:1 gear box out to the
spindle. The PQ Chuck is used to transmit the rotary power of the drill head
to the drill string.
To check the maximum or full

level when the spindle is not
rotating, the oil level should be 1”
(25 mm) below the top elbow of the
sight tube when the head is in a ↓
vertical position. 1”
↑
To check the maximum or full level ↓
1”
when the spindle is rotating in 4th
gear at 1250 rpm, the oil level ↑
should be 1” (25 mm) above the
bottom elbow of the sight tube when
the head is in a vertical position.
Actual equipment may not be exactly as shown
PQ Head Disassembly Procedures

It is recommended that the head assembly be disassembled in a shop
environment. Overhead lifting capabilities are required to move and
support the PQ Head.
1 Remove the chuck — refer to the chuck disassembly instructions.

2 Drain the head and transmission of oil. This can be accomplished by
removing a return line hydraulic hose from the transmission. The position
of the drill feed frame will determine which hydraulic return line to remove.
3 Remove the head unit from the drill before starting to disassemble the
unit.
4 Place the head on a solid work table and block it up to support it. Lay the
head down so that the spindle is horizontal to the work table.
5 Remove all hoses, fittings, gear shift lever, etc., from the head (all external
components).
6 Remove the chuck — refer to chuck disassembly instructions.
7 Remove the mounting group brackets and/or bulkheads.
8 Remove the four bolts which hold the rotation motor assembly. The motor
is siliconed to the transmission and will have to be prised off to break the
seal.
9 Support the transmission, preferably with the aid of a crane and sling
arrangement. Remove the six mounting bolts that secure the transmission
NOTE: to the input carrier.
The silicone seal, between the
transmission and the input carrier
10 Carefully slide the transmission back and out of the main housing.
will have to be worked apart in 11 Remove the lock wire from the two bolt heads on the retaining washer on
order to remove the transmission. the transmission output shaft.
Splined Adapter
Lock Wire
12 Remove the two bolts, retaining washers, and shim pack.
13 Slide the splined adapter forward off the transmission output shaft.
NOTE: 14 Remove the spindle bushing adapter nut.

This is a right hand thread.
Spindle Bushing
Adapter Nut
15 Remove the bolts from the lower carrier seal. Using the existing 1/2"
UNC jack screw holes, remove the lower carrier seal.
16 Using a punch, drive out the two oil seals.

17 Remove the six 3/8" UNC bolts and internal tooth lock washers from the
outer locking ring.
18 Thread off the outer locking ring.
19 Remove the two 1/2" UNC bolts from the intermediate lock plate.
20 Remove the intermediate lock plate. This plate will have to be prised off
due to a silicone seal.
21 Remove the 3/4" NPT plug from the bottom of the main housing. This is
a magnetic plug and must be cleaned.
Magnetic
Drain Plug
22 Using a 3/8" Allen wrench, remove the six 1/2" UNC capscrews from the
input carrier.
23 Insert two bolts into the 1/2" UNC jack screw holes, and remove the input
carrier.
NOTE: 24 After removing the input carrier, remove the shim pack from inside the
input shaft bore.
25 Check to make sure all shims are located.
NOTE: 26 Remove inner lock ring from the spindle.

It may be necessary to install a
3/8" UNC x 3/4" bolt in one of
the existing bolt holes on the inner
lock ring to assist with removal.
The spindle thread is a right hand

thread.
NOTE: 27 Remove the bottom cone bearing from spindle.

If problems persist in the removal
of this cone bearing, you may
want to leave it on. It will drop
off the spindle by itself during
removal of the main housing
cover.
28 If the bearing is removed at this time, remove the large snap ring from
the spindle. This is the snap ring that holds the output gear in place.
Large Snap Ring
NOTE: 29 Using the appropriate lifting devices, lift the PQ head and rotate it so the
Blocks must not interfere with the spindle is vertical to the work bench. Lower the PQ head down on blocks
removal of the spindle. so that it is approximately 8" (200 mm) above the work bench.
30 Remove the six 1/2" UNC bolts and lock washers from the pump mounting
cover.
Pump Mounting Cover
NOTE: 31 Remove the pump mounting cover.

Break the silicone seal first. 32 Remove the 1/2" UNC bolts and lock washers from the output carrier.
NOTE: 33 Remove the output carrier.

Break the silicone seal first.
34 Place the output carrier face down on the work bench. Using a punch,
drive the two oil seals out of the output carrier bore.
35 If the large snap ring is removed from the spindle, the spindle can now be
removed.
3/4" UNC
Lifting Eyes
NOTE: 36 To remove the spindle, insert two 3/4" UNC lifting eyes into the 3/4" UNC
Caution is advised so as not to tapped holes in the chuck adapter flange. Connect a chain or sling and
damage the threads on the use an overhead hoist to lift the spindle up and out of the PQ head.
spindle.
37 With the threaded end of the spindle resting on the work bench, drive the
It is recommended that a punch output wear sleeve down and off the chuck adapter flange portion of the
made of a soft material be used, spindle.
preferably brass.
38 Now drive off the top cone bearing with the same punch.
NOTE: 39 Turn the spindle over so that the chuck adapter flange is resting on the
During the removal of the wear work bench. Remove the two wear sleeves.
sleeves, be careful to avoid
40 Remove the eighteen 1/2" UNC x 1-3/4" capsrews.
damaging the spindle O.D.
41 Locate and remove the four 1/2" UNC x 3/4" setscrews. These locations
are the four jack screw locations.
Jack Screw Holes
42 Install four 1/2" UNC bolts with approx. 2" of thread length.
43 Begin removal of the housing cap by tightening the jack screw bolts in a
cross hatch pattern.
44 When the housing cover has broke lose from the main housing by approx.
1/2" (13 mm), install a proper lifting arrangement so as to lift the housing
cover off the main housing as level as possible.
45 If the lower spindle cone bearing was left on the spindle, it will now drop
off and onto the work bench. The spindle, output gear and the intermediate
idle shaft and gear assembly will also be removed with the main housing
cover.
46 Lay the main housing cover down flat on the work bench with the output
gear exposed.
47 Remove the larger spindle snap ring, spacer and output gear.
48 Raise the cover up and off of the main spindle.
49 The intermediate idle shaft and gear assembly can be removed with a
soft punch or set up in a press and pressed out of the intermediate shaft.
50 Turn the cover upside down and blocked up approx. 2" (50 mm) above
the work bench.
51 Drive out the two remaining bearing races.
52 Slide the intermediate spacer off the intermediate idler shaft.
53 Slide the intermediate gear assembly off the intermediate idler shaft.
54 Remove the two intermediate idler shaft cone bearings.
55 Remove the cone bearing spacer.
56 Drive the bearing race down and off of the intermediate gear with a punch.
57 Remove the bearing race spacer.
58 Drive the second bearing race off of the intermediate gear with a punch.
59 Lift out the input pinion and shaft from the main housing. Place it input
side down on the work bench.
60 Remove the snap ring.
61 Drive out the 1/4" (6.4 mm) x 3-1/4 (82.6 mm) dowel pin.
62 Remove the pump adapter tang.
63 Remove the pump adapter.

64 Remove the two input pinion and shaft cone bearings using appropriate
bearing pullers.
PQ Head Reassembly Procedures

It is recommended that the PQ Head be serviced in a shop environment
with an overhead lifting device and appropriate shop tools.
All PQ Head internal parts must
be free and clean of any foreign 1 Place the main housing, bottom end facing up, on a solid work bench.
matter. Extreme caution is
advised in the handling and
assembly of the PQ Head due to
the size and weight of parts.
Watch for pinch points during
the disassembly and
reassembly procedure.
All parts must be cleaned and

free of dirt, burrs and RTV
sealant. All threaded holes must
be cleaned of Locktite and RTV
sealant using the appropriate
size taps.
2 Apply a film of oil on the bore diameter before installation.
Take care to ensure that all
internal oil galleries are clean
and unclogged.
Install the bottom spindle bearing race using an appropriate driver.

Make sure race is pressed tight against bottom of counter bore.
NOTE: 3 Apply a thin film of oil on outside diameter of bearing race before
Note direction of race installation to installation. Install bottom bearing input shaft race using appropriate driver.
accommodate shaft bearing. Install race approx. 1/4" (6.4 mm) into the bore.
NOTE 4 Clean and reinstall the magnetic pipe plug using an appropriate pipe
thread sealant.
5 Turn main housing over, face-up. Check dowel pins for signs of wear or
burrs.
6 Place housing cover face-up. Apply a film of oil on bore diameter before
installation. Install top spindle bearing race using an appropriate driver.
Ensure that bearing race is seated firmly at bottom of counter bore.
Apply a film of oil on bore diameter before installation. Install top input
shaft bearing race into bore approximately 1/4" (6.4 mm) deep.
Install the two 3/8" NPT pipe plugs using an appropriate pipe thread
sealant.
Intermediate Gear Assembly

7 Install snap ring into snap ring groove in gear.
NOTE: 8 Install bearing race spacer into gear.

This spacer must be installed
in the proper direction.
The measurement out to end of

the gear must be approximately
1-5/16" (3.33 cm) both sides.
NOTE: Press bearing races in, one on each side of snap ring.
Note the orientation of races. When the races are pressed in, they must be tight on spacer.
9 Place intermediate gear shaft on work bench, with the large diameter
down.
Slide the intermediate shaft tapered roller bearing down the shaft until it
bottoms out. Note the orientation of the bearing.
Install the intermediate gear on the shaft.
Install the bearing spacer.
Slide the intermediate shaft tapered roller bearing down the shaft and
into the intermediate gear.
Install the intermediate spacer.
Intermediate Shaft and Gear Assembly

10 With the PQ Head main housing resting flat on the work bench, place the
intermediate shaft and gear assembly into the bore. Using a soft-face
hammer, gently tap the intermediate shaft and gear assembly in the
housing bore. Ensure that the intermediate shaft and gear assembly is
square in the bore.
NOTE: Using a proper lifting sling, roll the main housing on its side, so as to
Take note of the orientation of have access to the bottom bore.
the two 1/2" UNC threaded holes,
they must be at right angles to the
main housing.
11 Use the intermediate lock plate and two 1/2" UNC bolts of the appropriate
length to draw the intermediate shaft into place in the main housing.
Tighten each bolt alternately, being careful not to bottom out the bolts in
the thread holes.
12 When intermediate shaft is drawn into position, remove the intermediate

lock plate. There must a gap of approximately .060" (1.5 mm) from the
end of the intermediate shaft and the bottom of the counter bore.
13 Apply RTV high temp silicone to the outer edge of the intermediate lock
plate.
Install lock plate with the 1/4" NPT thread hole on your left hand side.
Apply Locktite 242 to the threads of the two 1/2" UNC x 1-1/2" bolts.
Install the bolts part way, then apply RTV high temp sealant to the bolt
heads, to seal the bolt holes in the intermediate lock plate. Torque these
bolts to 50 lbf ft (67.79 Nm).
NOTE: 14 Roll the main housing face up on the work bench. Raise and block up the
Main housing must be blocked up in main housing approximately 8" (200 mm) off the work bench. Make sure
a way that is very rigid due to the not to block the main spindle bore or the input shaft bore. These bores
weight and amount of force that must be left open to accommodate the installation of the main spindle
must be applied to complete the and the input gear shaft assembly.
assembly.
Install a dial indicator inside the main housing. Position the dial point on
the face of the intermediate gear. Using a short pinch bar, check for
bearing end play of the intermediate gear assembly. It must be between
0.002" to 0.004" (0.05 mm to 0.10 mm).
In the absence of a dial indicator the following method can be used as a

coarse means of determining end play: Place the appropriate size feeler
gauge 0.003" to 0.005" (0.07 mm to 0.13 mm), down inside the bearing
and resting on top of the race (roller contact surface). Rotate the bearing.
The bearing rollers should roll over the proper feeler gauge size and should
not roll over a feeler gauge size greater than 0.005" (0.13 mm).
Input Pinion and Shaft Assembly

NOTE: 15 Using an appropriate driver and press, press the tapered roller bearing
The correct orientation of the onto the input pinion and shaft.
tapered roller bearing.
Make sure the bearing bottoms

out on the shaft.
The “cover” side of the input

pinion and shaft is the end of the
shaft that is shortest to the gear
face. The “main housing” side of
the input pinion and shaft is the
end of the shaft that is furthest
from the gear face
Install the second bearing in the same manner.
16 Install the pump adapter into the bore of the input pinion and shaft. Line
up the matching holes.
Install the pump adaptor drive tang. Push the 1/4" (6.4 mm) diameter
dowel all the way through the input pinion and shaft, pump adaptor and
pump adapter drive tang.
Install the snap ring in the snap ring groove.
17 Coat the input pinion and shaft bearing race, (in the main housing) with
a thin film of oil. Install the input pinion and shaft into the main housing,
Pinch-point condition in this meshing the pinion with the intermediate gear.
part of the assembly.
NOTE:
Make sure that the pump adapter
tang is in the vertical position.
18 Install the output gear inside the main housing while meshing with the
intermediate gear.
Pinch-point condition in this
part of the assembly.
Coat the face and the internal spline of the gear with a thin film of oil.
Place the output spacer on top of the spindle gear, centering it on the
bore diameter.
19 Install four 1/2" x 5" UNC bolts (remove the heads), one in each corner
of the main housing. These will act as lineup pins for the installation of
the housing cover.
20 Spread a coating of RTV high temp sealant in the groove in the top of
the intermediate shaft. Run a bead of RTV high temp sealant on the
face of the main housing, inside the bolt pattern.
21 Using an appropriate sling or chain method, sling the housing cover in

such a manner that it can be lifted vertically, while being balanced and
level.
22 Lower the housing cover onto the four line up pins, letting the cover down
slowly so as to rest square and level on the top of the intermediate shaft.
23 Using a suitable washer or bar and appropriate 1/2" UNC bolt, draw the
cap down evenly to the face of the main housing.
The cap must be drawn down
evenly or it will gall the
intermediate shaft. 1/2" UNC
bolts of the appropriate length
can be inserted into the
housing cover bolt holes in
order to assist with this
operation. Care must be taken
as not to bottom out the bolts in
the thread holes which would
damage the threaded holes of
the main housing. Once the
housing cover has seated firmly
to the main housing, remove all
bolts, line up pins and the
washer or bar from the 24 Coat the beginning of the thread on all 18 1/2" UNC x 1-3/4" capsrews
intermediate shaft. with RTV high heat sealant. Install the capscrews and torque to 50 ft lbs
in a cross-hatch pattern.
NOTE: 25 Install the five 1/2" UNC x 3/4" set screws. One in each of the four jack
Run a bead of RTV high heat screw locations and one in the center of the intermediate shaft. This will
sealant between the top edge of protect the threads of the holes for removal of the housing cover.
the intermediate idle shaft and the
mating bore chamfer of the main
housing cover.
Jack Screw Holes
Output Shaft Assembly (Spindle)

26 Place the spindle in a press. Apply a film of oil on the spindle bearing
shoulder. Assemble the top tapered bearing cone onto the spindle with
the large bearing O.D. towards the chuck flange on the spindle.
Place the output spacer over the spindle and on top of the bearing.
Now place the output gear onto the spindle, as the gear will only be
used to press the top bearing cone into position against the chuck adaptor
flange and then removed.
Position a suitable piece of hollow tubing over the threaded section of the
spindle onto the output gear.
Press the top bearing into position against the chuck adaptor flange.
NOTE: 27 Place the spindle with the threaded section resting on the work bench
Use a suitable material under the and the bearing up.
threaded end of the spindle so as Coat the top end of the spindle with a thin film of oil.
to protect the threads.
Install the output wear sleeve on top of the spindle.
Tap the output wear sleeve down the spindle chuck adaptor flange so
that it is approx. 0.030" (0.8 mm) below the face of the adaptor flange.
28 Turn the spindle so that the chuck adaptor flange is resting on the work
bench and the thread end is up. Coat the machined diameter between
Take care as not to damage
the two threaded portions of the spindle with a light film of oil.
spindle threads while installing
the wear sleeve. Place the first wear sleeve, lip down over the first threaded portion of the
spindle.
Using an appropriate driver, drive the wear sleeve down until it rests on
the shoulder of the beginning of the second threaded portion of the spindle.
Place the second wear sleeve, lip up over the first threaded portion of the
spindle.
Using an appropriate driver, drive the wear sleeve down till it is tight against
the first wear sleeve.
Take care as not to damage
spindle threads while installing
the wear sleeve.
Using a utility knife, re-score the existing score lines of the two wear
sleeves.
Care must be take to avoid
personal injury and external
damage to the wear sleeves in
this part of the assembly
procedure. The re-scoring of
the wear sleeves ensures a
good clean break of the wear
sleeve lip. Any sharp jagged
edges will cut the seals of the
lower seal carrier upon
installation.
Using an appropriate tool, cut through the lip of each wear sleeve.
Roll the lip off each wear sleeve by inserting a pair of needle nose pliers
into the lip and rolling the severed lip off the wear sleeve and around the
The lip being removed from the needle nose pliers.
wear sleeves is extremely
sharp, so caution is advised.
29 Turn the completed spindle up so that the threaded end of the spindle is
resting on the work bench. Using the 3/4" UNC tapped holes in the spindle
chuck adaptor flange, install the appropriate lifting aid. Sling the spindle
up and guide it through the main housing being careful not to damage the
threaded portions of the spindle. A slight twist of the spindle may be
required to line up the spline of the spindle with the internal spline of the
output gear. Be sure that the tapered roller bearing on the spindle is
completely seated in the bearing race of the housing cover.
Output Carrier and Pump Mounting

30 Place the output carrier, face down on the work bench. Install the first oil
seal lip down. Drive the seal down until it bottoms out on the bottom of the
counter bore.
NOTE: Install the second oil seal, lip up.

Make sure that the oil seal is Drive the oil seal down to a measurement of 1" (25.4 mm).
installed square and not blocking
the grease fitting port.
Install the 1/8" NPT grease fitting. It must be installed in the proper hole
location so that grease enters between the oil seals and not into the main
housing cavity.
Install the 1/8" NPT plug.
Pack the oil seals with a multipurpose EP2 grease.
Apply a bead of RTV high heat sealant to the flange area of the output
carrier, just inside the bolt circle.
31 Apply a film of grease to the chuck adapter flange on output spindle.
32 Install the output carrier with the 1/4" NPT port to the front of the main
housing.
Install the eight 1/2" UNC x 1-1/2" bolts and lockwashers.

Torque to 50 lbf ft (67.79 Nm), using a cross hatch tightening pattern.
33 Place the pump mounting cover upside down on the work bench. Apply a
bead of RTV high heat sealant inside the bolt circle. Install the pump
mounting cover.
NOTE:
The 1/4" NPT port must be on your
1/4" NPT Port
right hand side as viewed from the
front of the main housing.
Install the six 1/2" UNC x 1-1/2" bolts and lockwashers.

Torque to 50 lbf ft (67.79 Nm), using a cross hatch tightening pattern.
Check this oil galley to insure it is free of RTV high temp sealant.
NOTE: 34 Using the proper lifting devices, lift the PQ Head off the blocking and
Ensure the spindle is horizontal to rest it on the work bench.
the work bench. Install the snap ring in the snap ring grove in the splined portion of the
Care must be used during this spindle.
procedure so as not to damage
the oil seals in the output carrier.
The spindle is not secured in the
PQ Head and may be dislodged.
The output gear may have to be

tapped back tight against the
Snap Ring
output spacer and spindle
bearing.
Avoid oil seal damage and the

addition of any debris inside
the main housing.
NOTE: 35 Coat the bottom spindle bearing race and spindle threads with a film of
Observe correct orientation of the oil. Install the bottom spindle cone bearing.
cone bearing.
NOTE:
Use two 3/8" UNC x 5" bolts,
installed at 180° apart on the inner
lock ring bolt circle, tt thread the
lock ring onto the spindle, pressing
the cone bearing on the spindle,
square and inline.
With the aid of the inner lock ring, the cone bearing can be installed on
the spindle.
36 Tighten the inner lock ring until the cone bearing is seated in the bearing
race on the main housing.
Should be exercised so as not
to damage the threaded section
of the output shaft.
37 Clean and coat the original shim pack for the input pinion and shaft with a
film of oil. Install the shim pack in the input pinion and shaft bore of the
main housing.
38 Lay the input carrier flat on the work bench, lip up, and apply a bead of
RTV high heat sealant around the outside edge lip.
Install the input carrier in the input pinion and shaft bore of the main
housing. The correct position of the input carrier is with the large counter
bore on top with the input carrier protruding over the front of the main
housing.
Apply Locktite 242 to the threads of the six 1/2" x 1-3/4" capscrews.
Install and torque to 50 lbf ft (67.79 Nm).
39 Back off the inner lock ring one turn. Remove the two 3/8" UNC x 5"
bolts used for installation of the bearing. Install a 3/8" UNC x
3/4" bolt and flat washer. Torque the inner lock ring to preload the output
shaft for a rolling torque of approximately 70 lbf in (7.91 Nm).
After setting the proper torque

and before removing of the
3/8" UNC x 3/4" (1.91 cm) bolt,
scribe a line on the main
housing and inner lock ring.
NOTE: Fit the in/lb torque wrench with a 9/16" socket and by utilizing the 3/8"
The output shaft should be rotated UNC x 3/4" bolt and washer installed previously, thread the inner lock
and the inner lock ring tightened ring up against the bearing to the required torque.
alternately several times to ensure Remove the 3/8" UNC x 3/4" bolt, being careful not to disturb the position
that the bearings are indeed
of the inner lock ring.
seated in the housing and the
torque value is maintained. 40 Thread on the outer lock ring. Leave a distance of approximately 0.060"
(1.5 mm) between the inner and outer lock rings. Position the outer lock
Double check your scribe lines to
verify that the position of the inner
ring so that it can be bolted to the inner lock ring.
lock ring has not changed.
Apply “Locktite 242” and a 3/8" internal tooth lockwasher to each of the
six 3/8" UNC x 1-3/4" bolts. Install the bolts and washers and torque in a
cross hatch pattern to 120 lbf in (7.9 Nm).
41 Place the lower seal carrier face up on the work bench. Place the first oil
seal, lip down, into the lower seal carrier. Drive the first oil seal down until
it bottoms out on the bottom of the counter bore in the lower seal carrier.
NOTE: Place the second oil seal, lip up, into the lower seal carrier.
Check the gap between the two Drive the second oil seal down until it is flush with the top of the counter
seals to ensure that the grease bore in the lower seal carrier.
access port is clear.
Install the 1/8" NPT grease fitting, #8 ORB plug and the 1/4" NPT plug in
the lower seal carrier. Pack the oil seals with a multipurpose EP2 grease.
With the lower seal carrier sitting face up on the work bench, apply a
bead of RTV high temp sealant just inside the bolt circle and the lip of the
lower seal carrier.
Install the lower seal carrier with the notch in the proper location so as to
allow access to the main housing 3/4" NPT return port.
Use eight 1/2" UNC x 1-1/2" bolts and lock washers to fasten the lower
seal carrier to the main housing. Torque to 50 lbf ft (67.79 Nm) in a
crosshatch tightening pattern.
42 Put a bead of RTV high temp sealant around the flange of the service
cover. Put a bead of RTV high temp sealant around the thread of the four
5/16" UNC x 3/4" bolts. Install the service cover and hand tighten the
bolts.
43 Coat the remaining spindle thread with a film of multipurpose (EP2) grease
and then install the spindle nut. Four 3/8" UNC x 3/4" capscrews are
used in the spindle nut to secure the desired spindle bushing.
Transmission Assembly
44 Position the transmission, machined surface down and output shaft facing
horizontal on the work bench.
45 Slide the splined adapter on to the spline of the output shaft with the
machined O.D of the splined adaptor against the transmission output shaft
bearing.
Machined O.D.
of Splined Adapter
Install the shim pack and retaining washer with the two 7/16" UNF x
1-1/2" bolts to the end of the transmission output shaft. Torque these
two bolts to 40 lbf ft (54.23 Nm).
Using feeler gauges check the distance between the end of the splined
adapter and the retaining washer. There must be .005" to .010" (0.13 to
0.25 mm) end play. Lockwire these two bolts together.
46 Apply a Lithium based grease to the splined adapter and the internal
spline of the input pinion and shaft. Apply a bead of RTV high heat sealant
to the mounting face of the transmission, just inside the bolt hole mounting
pattern.
47 Using a suitable sling and lifting device mount transmission to the input
carrier.
Do not force the transmission
Apply “Locktite 242” to the threads of the six 1/2" UNC x 1-3/4" bolts.
into place. Line up the
Install with lock washers and torque to 50 lbf ft (67.79 Nm).
transmission and main housing,
and gently rock the
transmission until it slides
freely into place.
Transmission and Head Box Lubrication

Ensure the PQ head is to the correct level with hydraulic oil (original factory
fill quantity is approx. 10.5 quarts (10 litres)). The drill must be level in all
directions with head assembly in the vertical position when determining the
proper full level.
Do not overfill. To do so can result in overheating.
Schedule: Change Interval 250 hrs
Head Bearing Caps

The grease fittings on upper and lower bearing caps should have three (3)
shots of multipurpose grease from a hand operated grease gun every 8
hours while rotating slowly.
Grease Nipple –
Lower Bearing Cap
PQ Head
Spindle Nut
Grease Nipple –
Upper Bearing Cap
PQ Chuck
PQ Nitro Gas Chuck Planograph

1 Chuck Spindle 16 Backup Ring 28 Set Screw, 1/2-13 UNC X 1-1/4
2 Inner Cylinder 17 O-ring 29 Internal Retaining Ring
3 Chuck Piston 18 Backup Ring 30 External Retaining Ring
4 Outer Chuck Cylinder 19 Lower Spindle Wear Ring 31 Wear Sleeve, Upper
5 Labyrinth Seal 20 Oil Guide Pin Seal 32 N/A
6 Spring Retainer 21 Retainer Guide Bushing 33 Cap Screw, 3/8-16 UNC X 1-1/4 Lg
7 Jaw Retainer 22 Dowel Pin, 1 Dia X 3-1/2 Lg 34 Cap Screw, 3/8-16 UNC X 3/4 Lg
8 Mounting Adapter 23 Dowel Pin, 3/8 Dia X 1 Lg 35 Cap Screw, 1/2-20 UNF X 2 Lg
9 Ball Bearing 24 N/A 36 Cap Screw, 1/2-13 UNC X 1-1/2 Lg
10 Nitrogen Gas Spring 25 Bowl 37 Seal Kit
11 Internal Retaining Ring 26 O-ring 38 Support Plate
12 Inner Cup Seal 27 Grease Nipple 39 Grease
13 Outer Cup Seal
14 Piston Cup Seal
15 O-ring
34 35 21
28
36 7
22
31
20
26
25
10 27
29 5
33 15, 16
11
33 19 2
9
30 17, 18
4
12
13
3 23
11
33
8 1
PQ Nitro Gas Chuck Assembly Procedures

Refer to Planograph on previous page.
1 Install the three dowels (item # 23) into the piston (item #3).
NOTE: 2 Install the two urethane cup seals (item #13) on the piston (item #3) outside
The orientation of the seals should diameter grooves. Be sure to coat the seals with hydraulic oil before
be as shown in the planograph. installation.
NOTE: 3 Lubricate the inner urethane cup seal (item #12) with hydraulic oil and
The orientation of the seal should install it inside groove of the piston bore (item #3).
be as shown in the planograph.
NOTE: 4 Lubricate the urethane cup seal (item #14) and install in outer chuck
The location and proper orientation cylinder (item #4).
of seal should be as shown in the
planograph.
NOTE: 5 Lubricate the O-ring (item #17) and the backup ring (item #18). Install in
The installation order should be as the O.D. of the inner cylinder (item #2).
shown in the planograph.
6 Install the external retaining ring (item #30) on the PQ chuck spindle
(item #1).
7 Install the lower spindle wear ring (item #19) on the PQ chuck spindle
(item #1).
NOTE: 8 Lubricate and install the O-ring (item #15) and the back-up ring (item
The orientation and location should #16) on the PQ chuck spindle O.D.
be as shown in the planograph.
9 Install the upper spindle wear sleeve (item #31) on the PQ chuck spindle.
NOTE:
The piston dowel must align 10 Align dowel with the first hole to the right hand side of the O-ring bussport
with outer cylinder for proper of the outer cylinder (item #4).
assembly.
11 Install the piston (item #3) into the outer cylinder (item #4). Gently tap
piston down into place until piston is flush to the bottom of the outer cylinder.
NOTE: 12 Install the inner cylinder (item #2) into the outer cylinder assembly
Be sure to align the two oil ports as (item #11) from step 5. Tap into place using a soft face mallet. Use two
shown. 3/8" UNC bolts of the proper length to align the parts.
NOTE: 13 Install the 3/8" UNC x 1-1/4" long socket head cap screws (item #33)
There are twelve bolts required, using an “anti-seize”, and torque to 35 ft-lbs.
but only install ten bolts, leaving
14 Bolt the PQ chuck spindle (item #1) to the shipping plate, using 3/4" UNC
two bolts out to allow for the
bolts.
attachment of a lifting device for
ease and safety of further OR
assembly. Bolt the PQ chuck spindle (item #1) to the head spindle using 3/4" UNC
bolts supplied with the drive head module and torque to 280 ft-lbs.
15 Install the internal retaining ring (item 29) in the PQ chuck spindle bore
(item #1).
NOTE: 16 Grease the PQ chuck spindle O.D. with grease (item #39).
Boart Longyear strongly advises
the use of Chevron Ultra-Duty
Premium Grease (Item #39),
EP #NLG12, as the only
recommended grease for
the PQ Nitro Chuck!
17 Bolt adapter plate (item #8) to piston (item #3).
18 Install cylinder assembly over spindle.
19 Install bearing (item #9) starting with lower thrust bearing race (larger
O.D.).
20 Install bearing roller race. Pack bearing with grease (item #39) supplied.
21 Install upper thrust bearing race.

22 Install retaining ring (item #11).
23 Install Labyrinth seal (item #5).

24 Install the 3/8" UNC x 1-1/4" long socket head cap screws (item #33) and
torque to 35 ft-lbs.
25 Install bowl (item #25) onto spindle (item #1).
26 Install gas springs (item #10).
27 Install spring retainer (item #6).

28 Install 1/2"-20 UNC x 2" long socket head cap screws (item #35) and
29 Install inner bushing (supplied separately).

30 Install jaws (supplied separately).
31 Install jaw retainer (item #7).
32 Install 1/2"-20 UNC x 1-1/2" long socket head cap screws (item #36)
and torque to 80 ft-lbs.
33 Install upper bushing (supplied separately).
34 Install guide bushing retainer (item #21)
35 Install 1/2"-20 UNC x 3/4" long socket head cap screws (item #34) and
36 Chuck assembly shown on shipping plate.
37 For chuck disassembly, follow the instructions in reverse order.
Installation of New Jaws

NOTE: 1. Remove the top bushing.
The lower spindle bushing and 2. Remove jaws.
lower chuck bushing are NOT used 3. Remove the bottom bushing.
for HWT/PQ sizes. To insert PQ
4. Clean jaw slots with diesel fuel or a solvent and lubricate with EP2
core barrel assembly, the upper
grease.
chuck bushing will have to be
removed and replaced after
5. Reassemble using appropriate jaws and bushings.
insertion, otherwise cuttings will 6. Remove lower spindle bushing and replace with appropriate bush-
infiltrate the area around the ing.
mitogen gas springs.
Lubrication
Do not open chuck while rotating
otherwise bearing life will be greatly 1. Lubricate the chuck as per the lubrication schedule in chapter 9.
reduced.
Maintenance
1. Inspect and clean jaws regularly. Replace in sets of seven only,
when worn.
2. For replacement parts, refer to the chuck assembly drawing in your
Parts Manual.
Nitrogen Gas Springs

Nitrogen gas springs are designed to have a long service life. Inspect
the gas springs periodically while changing jaws (3 month intervals).
We do not recommend field re- 1. Remove the spring retainer to access the gas springs for inspection
charge of the gas springs, please and replacement.
contact your Boart Longyear
2. Measure the free length of the exposed piston rod above the barrel.
service representative for more
If the gas spring is still charged with nitrogen, the rod will be ex-
information.
tended 1” (25mm). Replace any spring that does not meet this
requirement.
BOART LONGYEAR APPENDIX A
Appendix A
See Attached
TECH DATA
No. 2 TECHDATA\MKT1728 Date: April 2007 Page: 1 of 6
LF90D Diamond Core Drill - Truck Mounted

DRILLING DEPTH GUIDELINES
The figures in these tables have been using a 7 258 kg (16,000 lb) hoist (single
calculated, based on field experiences, and line pull). Actual drilling capacity will depend
may be reasonably expected. Ratings are on in-hole tools and conditions, drilling
based on a vertical, straight, clean down hole techniques and equipment used.
METRIC SYSTEM U.S. CUSTOMARY SYSTEM

Hole Depth (meters) Hole Depth (feet)
DRILL ROD/CORE BARREL Dry Hole(Fluid Filled) Dry Hole(Fluid Filled)
BRQHP/BQ 1 220 (1 400) 4,000 (4,585)
BRQLW/BQTK 1 525 (1 755) 5,000 (5,755)
NRQHP/NQ/NQ2" 940 (1 080) 3,080 (3,530)
NRQHP Upset 1 110 (1 280) 3,640 (4,190)
HRQHP/HQ 635 (725) 2,080 (2,380)
HRQHP Upset 870 (1 010) 2,860 (3,305)
HWT/PQ 420 (480) 1,370 (1,565)
PRIME MOVER
Standard Unit (for altitude ASL) Cummins QSB 6.7 L, Tier III, turbo charged, after cooled, diesel engine
Displacement 6.7 L 409 in3
Power (maximum) at 2,200 RPM 153 kW 220 hp
TORQUE AND RPM RATINGS

(Hydraulic motor at maximum/minimum displacement, prime mover at 2,200 RPM)
Speed (no load) Torque (stall)
RPM Nm lbft
1st Gear 122 - 199 5 322 - 3 254 3,925 - 2,400
2nd Gear 246 - 400 2 648 - 1 620 1,953 - 1,195
3rd Gear 439 - 714 1 486 - 908 1,096 - 670
4th Gear 769 - 1,250 849 - 519 626 - 383
Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
© 2007 Boart Longyear Canada
TECH DATA

HYDRAULIC SYSTEM
Primary Pump Axial piston, variable displacement load sensing, pressure compensated with
low pressure standby.
Max Flow 165 L/m 43.5 gpm
Maximum Pressure 31 MPa 4,500 psi
(Factory setting)
Secondary Pump Axial piston, variable displacement load sensing, pressure compensated with
low pressure standby.
Max Flow 64 L/m 17 gpm
(Factory setting)
Auxiliary Pump Axial piston, variable displacement, pressure compensated with low pressure
standby.
Max Flow 42 L/m 11 gpm
(Factory setting)
DRILL HEAD
Rotation Motor Rexroth hydraulic motor - variable/reversible.
Mechanical Transmission Funk 4 speed
Ratios 1st 6.27:1
2nd 3.12:1
3rd 1.75:1
4th 1.00:1
Final Drive Straight cut gears.
Ratio 2:1
Head Opener Side shift style — hydraulically actuated
Hydraulic PQ Chuck Patented Nitro-Chuck® — hydraulically opened, nitrogen gas spring closed.
(patented) Axial holding capacity of 222 400 N (50,000 lbf)
TECH DATA

Drill Head Lubrication Force fed bearings, oil bath for gears
Drill Head Lubricating Oil Filtration 25 Micron high pressure oil filter
DRILL MAST AND FEED SYSTEM

Feed Stroke 3.35 m 11 ft
Feed Pull 111 797 N 25,133 lbf
Feed Thrust 58 957 N 13,254 lbf
Rod Pull 3 m (10 ft) or 6 m (20 ft)
Drilling Angle 45° off horizontal to 90° vertical down.
Mast Dump (Crowd) 2.34 m 7.7 ft
Mast Telescope 3.35 m 11 ft
DRAW WORKS
Main Line Hoist single speed motor
Hook Load (single part line)
Bare Drum 7258 kg 16,000 lb
Hoisting Speed (single part line)
Bare Drum 53 m/min 173 ft/min
Main Hoist Cable 14.3 mm cable 9/16 in cable
Minimum Breaking Strength 23 042 kg 50,800 lb
NOTE: Do not use multiple part lines with the main line hoist, use single part line ONLY.
Wireline Hoist
Line Pull Bare Drum 993 kg 2,190 lb
Full Drum 228 kg 502 lb
Line Speed Bare Drum 145 m/min 475 ft/min
Full Drum 433 m/min 1,422 ft/min
Drum Capacity 1 890 m 6,200 ft
(4.8 mm/3/16" swaged)
NOTE: Wireline Cable length to be specified at time of order.
TECH DATA

DIMENSIONS AND WEIGHTS *
Wet Weight :8 392 kg (18,000 lb)

Consists of: Power Unit Grp. Cummins QSB 6.7 L,
Tier III 6 cylinder
Hydraulic Module
Draw Works Grp. c/w 16,000 lb Main Line
Hoist and Cable, Wireline Hoist less Cable
Hydraulic Mast Raising
Hydraulic Mast Dump
Telescopic Mast Assembly
Rotation Unit Grp. c/w PQ Chuck/Head
Guard
Base Frame
Fuel Tank (265 L/70 US gal)
Battery
Hydraulic Leveling Jacks/Outriggers
Foot Clamp
Hydraulic Water Pump
Options:
- Truck 45°
- Catwalk, Railing and Access Stairs
- Rod Rack Platform*
- Decals available in any language
10 185 mm
(401 in)
Do not operate this drill with rods racked in

wind velocities in excess of 85 km/h.
Side view of drill with mast in 6 m (20 ft) pull
NOTE: Dimensions are with hydraulic leveling jacks

extended to ground level. Leveling jack full stroke is
914 mm (36 in)
* Dimensions and weights may vary depending on options and should be checked before crating or lifting.
TECH DATA

Side view of drill with mast in transport position
3 404 mm
(134 in)
282 mm (82 in)
8 433 mm
(332 in)
Side view of drill with no truck
7 010 mm
(276 in)
Rear End View of Drill - Outrigger Detail
2 350 mm
(92.5 in)
3 607 mm
(142 in)
Extended
TECH DATA

Drill Head (c/w patented Nitro-Chuck® )
Wet Weight: 658.6 kg (1,452 lb)
1082 mm
(42.6 in)
716 mm
(28.2 in)

LF90D Operations &amp; Service Manual

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LF90D

Hazard Signal Words

DANGER indicates an imminently hazardous situation which, if not

WARNING indicates a potentially hazardous situation which, if not

CAUTION indicates a potentially hazardous situation which, if not

CAUTION used without the safety alert symbol indicates a potentially

Read and understand all safety instructions carefully

Chapter 2 Drill Introduction

Chapter 3 Drill Components

Chapter 4 Drilling Operations

Chapter 5 Hydraulic Explanation

Chapter 7 General Maintenance and Troubleshooting

Ordering and Returning Parts

1 List the model and serial number of the drill.

In no event shall Boart Longyear be liable for consequential damages or

General Drill Arrangement

CROWN BLOCK TRANSMISSION

(Actual equipment may not be exactly as shown)

Drill Base Module

Weight: 3,096 lb (1,404.4 kg)

Drill Base Module

(Actual equipment may not be exactly as shown)

Power Unit - Cummins 5.9L QSB

Weight: 2,021 lb (916.7 kg)

(Actual equipment may not be exactly as shown)

Installation and Operations Manual

WARNING by the PowerView in English or Metric units as well as in Spanish, French,

GENERAL INFORMATION continued

Table of Contents Faceplate Features

Typical Mounting Dimensions

2.41 in. 0.125 in. R 0.063 in.

Typical Quick-Connect Diagram

Last PVA Gage or

Customer provided wire Optional PVW-A wire harness

PowerView Unit Back View

PIN 3 CAN LO PIN 4 CAN SHLD PIN 3 RS485+ PIN 4 RS485 –

PIN 1 V+ PIN 6 GRND PIN 1 V+ PIN 6 GRND

Installation 00-02-0528 page 3 of 18

TYPICAL WIRING DIAGRAMS

PowerView Deutsch DT06-6S Style Unit to PVA Gage

PowerView Deutsch DT06-6S Style Unit to MODBUS Output

characteristic impedance cable,

Red-V+ ex Belden 9841.

Ignition Note 5: RS485 shield connected

Installation 00-02-0528 page 4 of 18

Main Menu Navigation

1800 RPM ENGLISH ❋

2. The first seven items of the “Main Menu” will be displayed.

Installation 00-02-0528 page 5 of 18

POWERVIEW OPERATION continued

ENG RPM COOL TEMP 14.2 57 PSI

SETUP 1-UP DISPLAY

Engine Configuration Data

SPN110 FMI10 GO TO 1-UP DISPLAY

Installation 00-02-0528 page 6 of 18

POWERVIEW OPERATION continued

ENGINE OIL PRESSURE

5. Touch the "Menu Button" to return to the main menu.

ENGINE OIL PRESSURE

GAGE NOT RESPONDING

SETUP 1-UP DISPLAY

! Indicates Auxiliary Gage Fault

.! Indicates Fault Warning

98% 1000 RPM ENGINE OIL PRESSURE

LF90D Operations & Service Manual

LF90D Operations & Service Manual