LS250 - OM - Oct2 English (12934)

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Copyright © 2015 Boart Longyear. All rights reserved. ISSUE No. 20150301
Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
DO NOT START or OPERATE THE MACHINE until you have READ
this manual and UNDERSTAND the contents.
Non-authorised personnel MUST NOT under any circumstances

attempt to operate or repair the machine.
Safety Precautions listed in the manual are intended to alert the

operator and helpers to physical dangers inherent in various phases
of operating and maintaining mobile drilling equipment of this kind.
Safety First must always be the primary consideration of all

personnel when operating or maintaining the drill rig under normal,
and especially in unusual conditions.
Since these Safety Precautions cannot cover every possible

situation, everyone is expected to exercise good judgement and
common sense while working with, on or near the drill rig.
Hazard signal Words and Warnings
Hazard signal words are used throughout this manual. They appear
in the narrow left-hand column of several pages and, with their
additional text description, are intended to alert the reader to the
existence and relative degree of hazard.
The signs DANGER, WARNING, CAUTION and NOTICE are

defined as follows :-
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Figure 1–1: General view 1 ................................................................................. 7
Figure 1–3: Assembly Drawing ......................................................................... 11
Figure 1–4: Lifting Points Elevation .................................................................. 15
Figure 1–5: Lifting Points Plan View ................................................................. 15
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2.1.1 Safety Labels .................................................................................. 23
2.2.1 Cautions and Warnings .................................................................. 28
2.4.1 In the event of an Emergency Stop ................................................ 35

2.4.2 Restarting after an Emergency Stop .............................................. 35
2.6.1 Danger Zone ................................................................................... 40

2.6.2 Safety requirements for hydraulic lines....................................... 43
Figure 2–1: Location of Warning Signage......................................................... 22

Figure 2–2: Electrical Shock ............................................................................. 23
Figure 2–3: Winch Cable .................................................................................. 23
Figure 2–4: Rotating Parts ................................................................................ 24
Figure 2–5: Master Disconnect ......................................................................... 24
Figure 2–6: Name Plate .................................................................................... 25
Figure 2–7: Personal Protective Equipment ..................................................... 26
Figure 2–8: Lockout/Tagout .............................................................................. 27
Figure 2–9: Lift Point ......................................................................................... 27
Figure 2–10: Crush/Pinch Point ........................................................................ 27
Figure 2–11: Stop Warning ............................................................................... 28
Figure 2–12: Do Not Climb ............................................................................... 28
Figure 2–13: Body Crush Hazard ..................................................................... 28
Figure 2–14: Manual ........................................................................................ 29
Figure 2–15: Crush Hazard............................................................................... 29
Figure 2–16: Extend retract .............................................................................. 29
Figure 2–17: Hot Surface .................................................................................. 30
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Figure 2–18: Pressure Vessel........................................................................... 30
Figure 2–19: Loaded Springs............................................................................ 30
Figure 2–20: Diesel Fuel ................................................................................... 31
Figure 2–21: Corrosive Hazard ......................................................................... 31
Figure 2–22: Fire Extinguisher .......................................................................... 32
Figure 2–23: In case of fire ............................................................................... 32
Figure 2–24: Electric Panel Emergency Stop Switch ........................................ 33
Figure 2–25: Driller Panel Emergency Stop Switch .......................................... 34
Figure 2–26: Front, Safety Cage & Right Side E - Stop Switches .................... 34
Figure 2–27: Radio Remote Emergency Stop Switch ....................................... 34
Figure 2–28: Safety Cage Gate Power Reduction Switch ................................ 35
Figure 2–29: Danger Zone- 2.5 metres (8ft) All round the Rig. ......................... 40
3.6.1 General rules for Feed chains: ....................................................... 54
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4.1.1 Equipment Description and Identification ....................................... 67
4.1.2 Safeguards .................................................................................... 67
4.1.3 Routine Checks .............................................................................. 68
4.4.1 Stabilizer Jacks ............................................................................... 77
4.5.1 Travelling on Slopes ....................................................................... 77
4.6.1 Prior to Start up .............................................................................. 79

4.6.2 Start-Up Procedures ....................................................................... 80
4.7.1 Tramming Tracking Hazards ........................................................ 82
4.9.1 Safety Cage – Restricted Operation ............................................... 84
Figure 4–2: General View of Driller Panel ......................................................... 72

Figure 4–3: Engine Controls on Driller Panel ................................. 73
Figure 4–4: Hydraulic Controls on Driller Panel ................................................ 73
Figure 4–5: Feed / Rotation Controls on Driller Panel ...................................... 74
Figure 4–6: Gauge and Ancillary Arrangement................................................. 74
Figure 4–7: Water Controls below Driller Panel ................................................ 75
Figure 4–8: Electric / Engine Control Panel ...................................................... 75
Figure 4–9: Rig SetUp Control Panel................................................................ 76
Figure 4–10: Rear Gauge Control Panel. ........................................................ 76
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5.1.1 Operational Requirements .............................................................. 89
5.1.2 Safety Requirements ...................................................................... 89
5.4.1 Repairs to Hydraulic Components .................................................. 94

5.4.2 Mast Dump and Wiggle Frame ....................................................... 95
5.4.3 Mast Assembly ............................................................................... 96
5.4.4 Rod Presenter and Wrenches ........................................................ 98
5.4.5 Minisonic Head and Flushing Swivelt ........................................... 100
5.4.6 Drilling Services Annex for Sonic Head ........................................ 102
5.4.7 SPT Auto Hammer Assembly ....................................................... 107
5.4.8 Main Winch ................................................................................... 108
5.4.9 Levelling Jacks ............................................................................. 109
5.4.10 Main Frame ................................................................................ 110
5.5.1 Pre-Shift Inspection Form (Example only) .................................... 112

5.5.2 Maintenance - First 100 hrs with New Machine ........................... 114
5.5.3 Maintenance - Every 100 hrs ....................................................... 114
5.5.4 Maintenance - First 250 hrs with New Machine: .......................... 114
5.5.6 Maintenance - First 500 hrs with New Machine: ........................... 114
5.5.7 Maintenance - Every 500 hrs ...................................................... 115
5.5.8 Maintenance - Every 1000 hrs ..................................................... 115
5.5.10 Maintenance - Every 2000 hrs ................................................... 116
5.5.11 Changing the Hydraulic Oil ......................................................... 116
5.5.12 Recommended Oils and Lubricants............................................ 117
5.5.13 Gear Oil & Greasing Table ......................................................... 118
5.5.14 Typical Lubricant Capacities ....................................................... 119
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Figure 5–2: Metric Bolt Torques and Safe Loads ............................................. 93
Figure 5–3: Imperial Bolt Torques and Safe Loads .......................................... 93
6.1.1 No Pressure .................................................................................. 123

6.1.2 Flow low or Pressure fluctuating ................................................... 124
6.1.3 Valves not operating correctly ...................................................... 124
6.1.4 Hydraulic oil temperature too high ................................................ 124
6.1.5 Leakage from drillhead ................................................................. 125
6.1.6 Noises from pumps, no oil supply ................................................. 125
6.1.7 Engine stalling .............................................................................. 126
Table 6–1: Troubleshooting “No Pressure” Situations ....................................... 123

Table 6–2: Troubleshooting “Fluctuating Pressure” .......................................... 124
Table 6–3: Troubleshooting Valve Operation .................................................... 124
Table 6–4: Troubleshooting High Oil Temperature ........................................... 124
Table 6–5: Troubleshooting Drillhead Leakage ................................................. 125
Table 6–6: Troubleshooting Pump Noises ........................................................ 125
Table 6–7: Troubleshooting Engine Stalling ...................................................... 126
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Figure 1–3: Assembly Drawing ......................................................................... 11
Figure 1–4: Lifting Points Elevation .................................................................. 15
Figure 1–5: Lifting Points Plan View ................................................................. 15
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• This manual is a general description of the operation and maintenance
requirements of the LS250 Minisonic Drill Rig.
• Pictures, descriptions and technical data may therefore not match your
drill rig in every aspect.
• You are the one who is responsible for your personal safety when
• operating the LS250 rig.
• This manual is only a general guide to essential operating procedures,
safety precautions, etc.
• The procedures described in this manual do not relieve you of your
responsibility to exercise caution and common sense.
• You must comply with all safe working procedures and instructions
• relevant to your drill site at all times!.
3
a. Consumables. Boart Longyear warrants for a period of one
(1) year after the date of shipment of the consumable products
manufactured by it, or the performance of related services, under
the Contract, that such consumable products are free from defects
in materials and workmanship and such services are performed in a
professional and workmanlike manner; provided, however, with respect
to consumable products purchased through an authorized Boart
Longyear distributor, the warranty period shall commence on the date of
purchase by the end-user.
b. Capital Equipment. Boart Longyear warrants that the capital

equipment manufactured by it is free from defects in materials and
workmanship for a period equal to the lesser of (i) one (1) year after
the date of shipment, or (ii) the initial 1,000 operating hours. Boart
Longyear warrants for a period of six (6) months after the performance
of related services that such services are performed in a professional
and workmanlike manner.
c. General Terms. Boart Longyear further warrants that, to the

extent applicable, as of the date of shipment or performance, all
goods manufactured by it and services performed shall conform to the
written specifications agreed between the parties. THIS IS BOART
LONGYEAR’S ONLY WARRANTY. BOART LONGYEAR MAKES
NO OTHER WARRANTY, INCLUDING WITHOUT LIMITATION,
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. As a condition to Boart Longyear’s warranty
obligations, Purchaser must:
(i) contact Boart Longyear and request authorization to return any goods
claimed to be defective promptly upon Purchaser’s discovery of the
alleged defect,
(ii) upon receipt of an approved authorization code from Boart Longyear,

return any goods claimed to be defective under the foregoing warranty,
at Purchaser’s expense, to the facility designated by Boart Longyear,
and
(iii) with respect to consumable products purchased through an

authorized Boart Longyear distributor, the party making the warranty
claim must also deliver to Boart Longyear reasonable evidence of the
date of purchase. Boart Longyear shall perform its examination of
the goods so returned by Purchaser and shall report the results of its
examination to Purchaser within thirty (30) days following its receipt of
such goods from Purchaser, or, if longer time is required to complete
such examination, within such time as would be required through
the exercise of reasonable diligence. As a further condition to Boart
Longyear’s obligations hereunder for breach of warranty, Purchaser
shall offer its reasonable cooperation and assist Boart Longyear in the
course of Boart Longyear’s review of any warranty claim. If requested
by Purchaser, Boart Longyear will promptly repair or replace, at Boart
Longyear’s expense, goods that are confirmed to be non-conforming
as a result of Boart Longyear’s examination and according to Boart
4
Longyear’s warranty as set forth herein. All removal and installation
of goods shall be at Purchaser’s expense; provided, however, Boart
Longyear will reimburse the Customer for an amount equal to the
reasonable expenses incurred by the Customer and attributable to the
removal and shipment of any defective goods. Boart Longyear reserves
the right to reimburse Purchaser for an amount equal to the purchase
price of any defective goods in lieu of providing repaired or replacement
goods. Anything contained herein to the contrary notwithstanding, in no
event shall Boart Longyear be liable for breach of warranty or otherwise
in any manner whatsoever for:
(i) normal wear and tear;
(ii) corrosion, abrasion or erosion;
(iii) any goods, components, parts, software or services which, following

delivery or performance by Boart Longyear, has been subjected
to accident, abuse, misapplication, modification, improper repair,
alteration, improper installation or maintenance, neglect, or excessive
operating conditions;
(iv) defects resulting from Purchaser’s specifications or designs or those

of its contractors or subcontractors other than Boart Longyear;
(v) defects associated with consumable parts or materials, the lifetime of

which is shorter than the warranty period set forth in this Section;
(vi) defects associated with Purchaser’s specifications or designs or

those of its contractors or subcontractors other than Boart Longyear;
(vii) defects resulting from the manufacture, distribution, promotion or

sale of Purchaser’s own products; or
(viii) accessories of any kind used by the Purchaser which are not
manufactured by or approved by Boart Longyear.
(d) Sourced Goods. If the defective parts or components are not

manufactured by Boart Longyear, the guarantee of the manufacturer of
those defective parts or components is accepted by the Purchaser and
is the only guarantee given to the Purchaser in respect of the defective
parts or components. Boart Longyear agrees to assign to the Purchaser
on request made by the Purchaser the benefit of any warranty or
entitlement to the defective parts or components that the manufacturer
has granted to Boart Longyear under any contract or by implication
or operation of law to the extent that the benefit of any warranty or
entitlement is assignable.
Boart Longyear Global Headquarters,

10808 South River Front Parkway,
Suite 600,
South Jordan, Utah 84095,
United States of America,
Info@boartlongyear.com
Tel: +1 801-972-6430
Fax: +1 801-977-3374
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This manual describes the BOART LONGYEAR LS250 series
Minisonic Drill Rig and outlines its operational and maintenance
procedures . It also includes a number of procedural hints.
The manual must be retained in its storage box on the rig, so that it is
always available.
The Manual set includes a spare parts catalogue depicting and
describing the individual components of the rig.
In the interests of technical development, Boart Longyear reserves
the right to modify the drill rig and the data in this manual without
prior notification.
Minisonic SPT Test Rig Hinged Safety Safety

Drillhead Option Gate Guard
Drill Mast Crawler Front Stabilisers Driller Panel

Tracks one each side
The LS250 Minisonic Rig is a self contained, drill rig especially designed
to work in areas otherwise inaccessible by standard drill rigs.
The LS250 Minisonic drill rigs are designed to operate fully

independently, and are therefore suited to all types of drilling
applications, in a variety of ground conditions. The mast can be
positioned vertically and is adjustable fore, aft and sideways for perfect
alignment of the drill, even in areas of restricted access.
7
Rod
Presenter
Safety Grout Pump Water Pump Engine Compartment

Cage
The main power source is an liquid-cooled diesel engine, which drives

the hydraulic circuit. The hydraulics power all operating functions,
tramming, set-up, and drilling. The hydraulic system on the LS250
drill rig consists of a combination of open centre and closed centre
hydraulics. The track drives of the carrier the drill head oscillator and
rotation utilize piston pumps in a closed centre system and all the other
hydraulics use load sense pumps in an open centre system.
The drill mast carries a Minisonic drill head, together with the entire
drill string. The drill mast is attached to the mast carrier by means of
adjustable trappings. Holding and thread breaking clamps allow for rapid
rod changes.
All control and monitoring elements of the fully hydraulic drill are
conveniently positioned. Self-explanatory graphic symbols are used to
indicate control functions. The LS250 Minisonic drill is Crawler mounted,
all tramming is controlled from a Radio Remote control.
The drilling control panel is mounted on the front right hand side of the
machine and swings across the front for tramming. The set-up control
panel is mounted halfway down on the right side.
Emergency STOP buttons are fitted on the Driller control panel and on
the Radio Remote control. The operator is protected from the rotating
drilling elements by a wire mesh guard with interlocked door that
reduces rotation speed and power when opened. Activating any of these
switches immediately stops all drilling and tracking functions.
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The diesel engine is fitted with a soundproof cover for operating in areas
with stringent noise regulations.
The drill rig electrics are:- 24V DC
Features
Mast with feed cylinder and extension to enable 3 m (10 ft) rod pull.
Rod holding and thread break-out clamps with variable clamping
force.
Minisonic head rotate.
Surface drilling operations of large diameter (3” to 12”) holes.
Provides highly representative, continuous core samples in difficult
ground.
New generation diesel engine power supply.
Hydraulic mast raising with mast shift compensates for uneven drill
site conditions.
Three hydraulic independent Stabiliser Jacks
Enhanced Safety - Interlocked safety cage rotation barrier - head
rotation slows when open for enhanced safety.
Compact Footprint - Fits in shipping container and makes the LS250
MiniSonic perfect for smaller drill pads.
Enhanced Safety - Rod presenter allows the casing to be loaded
horizontally.
Easy Operation and Maintenance - Pilot operated hydraulic system is
easy to operate and maintain.
Increased Precision - Eliminate time consuming moves with the
articulated mast and wiggle tail which allows the mast to shift from left
to right and front to back enabling the mast to be positioned precisely
over the hole. The articulated mast allows for drilling from 90 to 45
degrees.
High Efficiency Rotation and Oscillation Unit - Patented airbag
system isolates the vibration from the rig and transfers it down the
hole for more efficient drilling.
Increased Accessibility - Wide track mounted and low ground
pressure (.28 bar/4 psi) - perfect for increased accessibility in the
most sensitive terrains.
9
4.75 in (121 mm ) 78 m 255 ft
6 in (152 mm ) 61 m 200 ft
7 in (178 mm ) 52 m 170 ft
8 in (203 mm ) 45 m 150 ft
9.25 in (235 mm ) 39 m 130 ft
10.5 in (267 mm ) 34 m 110 ft
12 in (305 mm ) 30 m 100 ft
*Depths based on normal drilling conditions. Varying ground conditions
and drilling styles may give varying results.
Maximum Drilling Diameter 305 mm 12 in
Pull Back 66 kN 14838 lbf
Down Force 24 kN 5395 lbf
Maximum Casing Length 3m 10 ft
Sonic Head
Drill Head Type - MiniSonic
Vibration Motors - Fixed displacement piston motors
Frequency Range - 0-75 Hz
Output Force @ 150 Hz - 182 kN 41,000 lbs
Maximum Torque - 2,400 Nm 1,700 ft.lb
Rotation Speed - 0-80 RPM
DIMENSIONS AND WEIGHTS
Dry weight - 11,500 kg (25,300 lbs)

Consists of:
Undercarriage
Hydraulic Module
Main winch
Hydraulic mast raising
Minisonic head
Wiggle Frame
Hydraulic levelling jacks / outriggers
Foot clamps
Grout pump
Compressor
Water pump
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CRAWLER CHASSIS
Crawler - Standard Unit - Track One

Max speed - 6.25 k/h 3.9 m/h
Track width - 600 mm 24 in
Ground pressure - 0.028 MPa 4.0 PSI
* Dimensions and weights may vary depending on options and should

be checked before crating or lifting
11
PRIME MOVER
Engine -
Standard Unit - Cummins QSB liquid cooled, turbo charged, charge

air cooled engine.
Displacement - 4.5 L 272 cu.in
Power(maximum) at - 119 kW 160 hp
Emissions - Stage IIIb [tier 4(i)]
Fuel Tank Capacity - 193 L 51 gal
HYDRAULIC SYSTEM - Closed Loop:
2 X 75 cc (/rev = 150 l/min @ 2000 rpm (Crawler + Sonic

Oscillation&Rotation)
Maximum pressures: Crawler max: 410 (6000 psi) Sonic 275 bar(4000
psi)
HYDRAULIC SYSTEM - Open Loop:
1 Load Sense Pump 75 cc/rev 205 bar (3000 psi)
1 Gear pumps 19+16 cc/rev 205 bar (3000 psi)
DRILL MAST AND FEED SYSTEM WITH FEED CYLINDER
Total Length 7,18 m (23,56 ft)

Feed stroke 4 m (13.12 ft)
Feed speed -
Back 0,681 m per sec (2,235 ft/sec)
Down 1,111 m per sec (3.647 ft/sec)
Pull Back - 66 kN (14838 lbf)
Down Force - 24 kN (5395 lbf)
Drilling Inclination 45 degrees below horizontal to
90 degrees vertically down
Main Winch
Line Pull - Bare Drum 11,000 N 2,472 lb

Full Drum 9,000 N 2,023 lb
Rope speed - Bare Drum 27.5 m/min 90 ft/min
Full Drum 34 m/min 111.5 ft/min
Main line winch cable dia.- 8 mm 5/16 in
Rope length - 65 m 213 ft
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Foot Clamp/Breakout System
Rod Clamps - 2 (dual cylinders-top and bottom)

Max clamp diameter (clamp/breakout tool) - 305 mm 12 in
Clamping Force - 129 kN 29,000 lb
Max breaking torque - 23 kNm 17,000 lb.ft
Max breaking angle - 20°
GROUT PUMP
Type - SPX40 Hose Pump

Max flow - 160 lpm 42 gpm
Max pressure - 16 bar 232 PSI
WATER PUMP
Type - Triplex FMC E0413

Max flow - 80 lpm 21.1 gpm
Max pressure - 41 bar 595 PSI
WELDER GENERATOR (Optional):
Type - Hydraulic Driven Getec
Voltage: 120 v
Frequency: 60 Hz
Power: 4000 W 5.36 hp
Current: 200 Amps
Voltage: 12-30 V DC
Duty Cycle: 68%
WELDER GENERATOR - European Version - Hydraulic driven Dynaset
Voltage - 230 V / 400 V

Frequency - 50 Hz
Power 230 V - 3,500 W 4.7 hp
Power 400 V - 6,500 W 8.7 hp
Welder
Current - 180 A
Voltage - 22 - 32 V
Duty cycle @180 A - 50%
Duty cycle @110 A - 100%
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SPT (Standard Penetration Test) Auto Hammer
Type - Hydraulic motor/chain driven automatic release Hammer.
Motor type: Gerotor - low speed high torque
Chain type: Roller chain A60 3/4”Pitch
Maximum pressure: 124 bar (1800 psi)
Maximum flow: 60 l/min (15.9 US gpm)
Impact rate: 1 to 30 Blows/min.
Hammer size: 63.5 kg 140 lbs
Hammer fall height: 762 mm 30 inch
All up weight: 226 kg 498 lbs
Certified Hammer efficiency: 64% to 72%
!
Offloading.
The Rig may need to be off-loaded either by Lifting or by Driving,

depending on the transporter. Check that all transport bindings are
removed.
Offloading by Lifting the rig.
Consult with a specialised lifting company for suitable spreader

beams and lifting pallets. Ensure that the lifting appliance is capable
of carrying the weight of the rig - 11,500 kg (25,300 lbs) plus any
drilling tools.
Offloading by driving the rig.
Before attempting to operate the rig for off-loading, read and

understand the instructions given in Sections 2 and 4 of this manual.
The Crawler mounted LS250 Drill Rig is an off -road vehicle and
therefore should not be driven on public roads except for access to site.
Always consult local laws.
Transport Dimensions.
Length: 7100 mm (279in)

Width: 2200 mm (87in)
Height: 280 mm (110in)
Weight: 11,500 kg (25,300lbs)
14
Ensure all local road heights/weights are obeyed.
Always use the proper rated lifting device to lift or raise the rig.
Never work underneath any part of the rig without proper support.
Never use a forklift to lift the rig, always lift using the proper overhead
lifting device and the lift points provided.
Lifting Points Plan View
15
The picture shows a typical rig equipped with an automatic, hydraulically
operated SPT (Standard Penetration Tester) Auto-Hammer. The weight
of the drop hammer is 63Kg, and the free fall height is 75 cm.
The SPT Auto-Hammer is mainly used for obtaining an indication of
Auto-Hammer (SPT)
the density and compressibility of granular soils, it can also be used

to check the consistency of stiff or stony cohesive soils and weak
rocks. The test consists of driving a sampler into soil at the bottom of a
borehole by using the automatically raised and released hammer, then
counting the number of blows to achieve a penetration of 300mm, after
a seating drive of 150mm. The advantage of the Boartlongyear SPT
is that it can be mounted to any suitable Drill rig and used in routine
exploration bore holes of varying diameters, so that there is no need to
bring special equipment to site.
Note - The code of practice for site investigations is subject to prevailing

standards (such as ASTM D1586-08, BS 5930 and BS 1377), which
should be referred to. The SPT should be re-tested and certified every
year - contact the BLY agent for details of this service.
16
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2.1.1 Safety Labels .................................................................................. 23
2.2.1 Cautions and Warnings .................................................................. 28
2.4.1 In the event of an Emergency Stop ................................................ 35

2.4.2 Restarting after an Emergency Stop .............................................. 35
2.6.1 Danger Zone ................................................................................... 40

2.6.2 Safety requirements for hydraulic lines....................................... 43
Figure 2–1: Location of Warning Signage ......................................................... 22

Figure 2–2: Electrical Shock ............................................................................. 23
Figure 2–3: Winch Cable .................................................................................. 23
Figure 2–4: Rotating Parts ................................................................................ 24
Figure 2–5: Master Disconnect ......................................................................... 24
Figure 2–6: Name Plate .................................................................................... 25
Figure 2–7: Personal Protective Equipment ..................................................... 26
Figure 2–8: Lockout/Tagout .............................................................................. 27
Figure 2–9: Lift Point ......................................................................................... 27
Figure 2–10: Crush/Pinch Point ........................................................................ 27
Figure 2–11: Stop Warning ............................................................................... 28
Figure 2–12: Do Not Climb ............................................................................... 28
Figure 2–13: Body Crush Hazard ..................................................................... 28
Figure 2–14: Manual ........................................................................................ 29
Figure 2–15: Crush Hazard............................................................................... 29
Figure 2–16: Extend retract .............................................................................. 29
Figure 2–17: Hot Surface .................................................................................. 30
19
Figure 2–18: Pressure Vessel........................................................................... 30
Figure 2–19: Loaded Springs............................................................................ 30
Figure 2–20: Diesel Fuel ................................................................................... 31
Figure 2–21: Corrosive Hazard ......................................................................... 31
Figure 2–22: Fire Extinguisher .......................................................................... 32
Figure 2–23: In case of fire ............................................................................... 32
Figure 2–24: Electric Panel Emergency Stop Switch ........................................ 33
Figure 2–25: Driller Panel Emergency Stop Switch .......................................... 34
Figure 2–26: Front, Safety Cage & Right Side E - Stop Switches .................... 34
Figure 2–27: Radio Remote Emergency Stop Switch ....................................... 34
Figure 2–28: Safety Cage Gate Power Reduction Switch ................................ 35
Figure 2–29: Danger Zone- 2.5 metres (8ft) All round the Rig. ......................... 40
20
21
Maintenance note - To ensure that all personnel are continually aware
of the dangers of the rig, examine all signs during routine maintenance
and replace as required.
22
Become familiar with machine safety labels and locations. The following
illustrations show safety label locations on the machine.
Contact with overhead electrical power lines will cause serious injury or
death.
DO NOT position mast within 100 m of power transmission lines.
Use the main winch cable in a single line pull only.
23
DO NOT operate this machine without head guard in place. Operator
may be drawn into rotating parts.
The electrical system of this drill is 24 Volts DC. The maximum

allowable load is 100 AMPS.
24
A name plate listing the model number, serial number, machine weight
and power. Please record the information so that it will be available
should the name plate become lost or damaged.
When ordering parts or requesting information, always specify the

model number and serial number.
The removal of the type plate is strictly forbidden, and will invalidate any
warranty claims.
25
PPE - Personal Protective Equipment
1. Read and understand manuals
2. Wear approved safety glasses
3. Wear gloves
4. Wear safety boots
5. Wear hard hat
6. Wear fall arrester when working at heights
7. Wear hearing protection
This is a typical list of Personal Protective Equipment and must be

amended to meet YOUR on site requirements.
Figure 1–7: Safety HarnessAlways wear fall protection when working on

elevated areas of the machine.
26
Always use Lockout /Tagout procedures before working on the electrical
system when servicing the rig.
Always use an appropriate lifting device at the designated lifting points.
Moving parts of the machine have the potential to crush or pinch.

Always use extreme caution when near these areas.
27
Stop and observe surrounding warning decals
No climbing activity to occur without appropriate PPE
Moving parts of the machine have the potential for injury.
28
Indicates to refer to the manual before proceeding with any activity.
This part of the machine has a rotating crush potential.
Component extends and retracts unguarded.
29
Surfaces adjacent to this warning can be too hot to touch.
The component is pressurised
Warning that springs inside component are loaded and disassembly

should be done with caution.
30
Diesel fuel connection site.
Battery acid is highly corrosive, therefore:
Wear protective gloves and eye protection during all operations on the
battery.
Do not tilt battery, acid may leak from the degassing openings.
31
Fire fighting and further measures:
For best results use available fire extinguishers.
On each fire extinguisher there are simple operating instructions.

Get portable extinguishers in addition from neighbouring locations if
required.
Prevent burning people from running away and extinguish fire by means
of fire-extinguishing cover or powder fire extinguisher.
Fight fire together with other people if possible in order to minimise your
own endangerment.
Do not force your way into rooms already full of smoke.
Keep unauthorised persons away from the danger area.
Remove endangered objects and important documents. Turn off mains

and media, as far as this is safely possible.
Inform arriving fire-brigade and auxiliary workers about the conditions

and about potential dangers. Instructions from the fire-brigade must be
adhered to.
The following figures show the correct extinguishing tactics:
Extinguish with the wind.
32
Extinguish at the flame root from front to back
Extinguish dripping or flowing fires from the output point to the

burning pool.
Fight larger fires with multiple fire extinguishers.

Use the fire extinguishers simultaneously and not sequentially.
After extinguishing the fire, do not leave the fire location, maintain
observation on the fire location in case of flash-backs.
LS 250C rigs are fitted with 6 Emergency STOP switches.

Familiarize yourself with the position and operation of all Emergency
STOP switches and Check the operation of each stop switch DAILY.
33
34
This is a safety cage (guard) that covers the Mast and Drillhead in the
area within reach of the operator. The Cage Gate has a switch that
when opened reduces the drillhead rotation speed and torque to a safe
level. Other interlock configurations are available.
Immediately investigate the cause of the Emergency Stop

In the event of personal injury, assist if you feel able to do so,
otherwise seek medical assistance or contact the emergency
services.
If the stop was initiated to prevent mechanical damage, assess the
situation before continuing. If in doubt, seek advice from the Site
Supervisor.
If the cause of the stop was unknown, walk around the drill rig and
check for any unsafe conditions before continuing.
Ensure all controls are in neutral.

Turn the ignition switch to the OFF position
Re-set the activated STOP buttons by pulling or twisting and pulling.
Check the operation of all lights and warning devices.
Report all defects to the Site Supervisor.
Visually inspect and assess the work area for potential hazards.
Re-start the engine.(See section 4).
35
.
Do not attempt to operate the drill rig unless you are fully familiar with
all rig controls, gauges, functions and operational sequences.
Failure to comply with the detailed instructions contained in the
Operating Manual could result in physical injury or even death.
Always wear an approved helmet, safety shoes or boots, safety
glasses,nose mask, and hearing protection when near an operating
drill rig.
Keep hands, arms, legs and clothing away from all moving parts of
the drill and its accessories. Failure to comply could result in physical
injury or even death.
Do not touch rotary heads, drifters, shank adapters,couplings, drill
steels, casing, bits, and crowns with your bare hands during drilling.
These parts usually get hot and a severe burn may result. Be sure to
wear work gloves when you are handling any of these components.
Dry Nitrogen is the only gas used to charge accumulators on drifters
and rotary heads. Never use Oxygen to charge accumulators
because a mixture of Oxygen and Oil may ignite to produce an
explosion.
Make sure that accumulators are always in perfect condition. Inspect
regularly and thoroughly to ensure that accumulator components
have no cracks or signs of excessive wear.
When pressurised, damaged accumulators could burst, scattering
metal fragments throughout the area, and severely injuring
personnel.
Be sure to bleed the accumulator before attempting to disassemble
it, and only replace with accumulators that have been tested and
approved.
Always operate the rig from the operator position.
Make sure all other persons are clear of the rig before moving or
starting any operation.
Tram only with the jacks fully retracted, the mast fully retracted and
resting on its support bracket. The drill head should be centred in the
middle of the mast.
Use extreme caution when tramming or setting up on uneven ground.
Always ensure that the stability of the rig is not impaired.
36
Drills have many moving components. Keep yourself and all other
persons clear of moving drill heads, feed mechanisms, drill strings,
and moving tools.
Know where you are drilling! Make sure you do not drill into any
utilities, such as buried electric cables, gas, or water mains.
Use only purpose-made craneage lugs and/or lifting holders when
lifting the rig.
Do not remove or disable protective guards and safety devices under
any circumstances.
Pay particular attention to the accident prevention devices and
ensure that they are always fully functional. Defective devices
may delay stopping rig functions, and may therefore cause severe
personal injury or even death.
Exhaust fumes from internal combustion engines are deadly. Be
sure to only operate the drill rig in well ventilated areas.
If you must operate the rig in a confined area, consult your
occupational health and safety representative to ensure safe drill
operations at all times.
Noise and Vibration levels -
The sound power level ratings are . Lpa=84dB , Lwa=109dB.
The maximum measured Vibration level at the driller position is

2,49m/s2.
Always wear Ear Defenders and always observe exposure times.
Specific Safety Instructions for Drilling
Drilling operations frequently expose operators to imminently

hazardous situations which, if not avoided, could result in death or
serious injury. The following safety instructions must be observed
at all times.
Never walk alongside the rig, not even for short distances (e.g. to the
next bore hole). You could tram the rig over your own feet.
Always check that all helpers are well clear of the tramming and
swing radius of the drill rig prior to moving or setting up.
When using level or angle indicator to make the final adjustment of
mast rake, only allow helpers to enter the area after the drill mast has
been aligned and inclined to the approximate degree required.
Be sure that all hoses (e.g. for flushing - grouting) are cleared from
the path before moving the drill rig.
Care must be taken when handling drill string sections. They are
often cumbersome and very heavy (especially Duplex Strings).
Always ensure there are adequate foot holds (mud-sludge).
Special care is required when placing Duplex Drill String Sections
(casing and inner rods) on the drill mast. The inner string threads
must be connected first.
37
Keep the casing section firmly secured to prevent it from sliding
down and squashing fingers during this process. Care must be taken
when flushing with compressed air because pressurised air can drive
cuttings with extreme force and great velocity.
Ensure that all persons are at a safe distance before opening air to
the drill string.
Always relieve pressure on the flushing medium in the drill string
durings steel changes (i.e. extending the drill string and tripping-out
the hole).
When using DHD drill tubes (API, etc.) always ensure that clamps are
placed directly alongside couplings (joints).
DHD tubing is manufactured using relatively thin-walled tubes, which
may deform or be damaged by hydraulic pressure.
Never stand beneath drill bits when inspecting for wear and removing
plugs when flushing holes. Plugs may be forced out by flushing
pressure, or the bit may drop out causing severe injury.
Use a mirror for inspection if the bit cannot be removed for checking.
Do not hit drill bits with a hammer when cleaning strings of concrete
residue. Carbide inserts may break and cause severe injury.
Remember that some cleaning solvents used for removal of oil and
grease develop dangerous fumes when they vapourise. Be sure to
use solvents only in well-ventilated areas.
The rig must be secured against inadvertent and unauthorised
movement prior to each operational interval.
To avoid inadvertent or unauthorised start up once the engine is
stopped, ensure the starter key is taken out of the ignition lock and all
covers, doors and lids are locked and secured.
If the vehicle is parked on a slope or incline, the crawler tracks must
be secured using wedges, in addition to engaging the hydraulic
brakes.
Drilling operations frequently expose workers to imminently hazardous

situations which, if not avoided, could result in death or serious injury.
The following safety requirements must be observed at all times.
Settings for pressure limiting valves in the hydraulic circuits of the

crawler rig must only be changed by Boart Longyear approved
personnel
The hydraulic components of the rig must be checked regularly.
38
Always use original Boart Longyear parts to replace worn
components. For safety reasons this specific requirement must be
complied with. It applies to:
- hydraulic hoses and other components.
- all static and bearing components, e.g. screws, bolts,

springs and washers, and undercarriage components.
Repairs and replacement of worn parts must only be carried out by

qualified personnel.
Standard maintenance and service intervals must be complied with.
If in any doubt, contact your nearest Boart Longyear service centre.
The safety devices on the drill rig must only be changed by or with
the permission of Boart longyear approved personnel.
Welding of static and bearing components on the drill rig is only to

be carried out by the manufacturer or by Boart Longyear approved
personnel.
Safety devices and protective equipment incorporated within
moving machine components must only be opened, removed, or
disabled with the engine stopped and secured against inadvertent or
unauthorised start up. (Safety devices include engine covers, lids,
caps, doors, gratings and panels.) All safety devices and protective
equipment must be reinstalled after completing maintenance service
and repairs.
Boart Longyear drill rigs must be used only as directed and described
in the Operating Manual. The drill rig must not be used for :- Towing
other machines, lifting parts other than for the the drilling duties,
carrying passengers or materials other than drilling tools, or for
clearing debris from the drill site.
The rig functions must be activated only from the control panel.
Operating instructions must be complied with for all operations,

maintenance, service, repairs, and transport.
A copy of the current operating instructions (with all approved
amendments) must be retained on the working site.
The contractor is obliged to amend safety regulations to meet local
requirements.
39
Be sure that no one is within the Danger Zone of the vehicle.
This is the area around the rig, within which persons may be
endangered by slewing the rig or moving any of its operational
components.
The operator can work the rig only if no-one is within the Danger
Zone. If someone enters the Danger Zone the operator must
immediately give appropriate warning signals. These are usually
made with hooters, but pre-determined hand signals can be used to
warn other people if on-site noise is liable to drown audible signals.
The operator must immediately terminate all operations if other
people do not leave the Danger Zone, despite having been warned.
A safety clearance of 0.5 metres (2ft) must be kept from buildings,

scaffolding, and other equipment to prevent the danger of being
squashed.
At all times keep in mind the rig slewing requirements.
If the safety distance cannot be complied with the area must be
cordoned off.
Using the rig to transport persons is strictly forbidden
Independent and unassisted operation and maintenance of the drill

rig must only be entrusted to persons who:
- Are at least 18 years of age
- Have been instructed in operating and maintaining the crawler

rig and have demonstrated their ability to the contractor.
40
- Can be expected to perform responsibly and are designated for
the job by the contractor.
The crawler rig must only be operated when it is in a stable position.

The stability of the rig may be impaired by:
- Excessive load
- High Winds
- Unsecured ground
- Incorrect drill mast position
- ‘Jerky’ acceleration and stopping during tramming,
- Slewing movements, and
- Operating on slopes and inclines.
Drilling, jacks down, full load - Lateral 9 Degrees
- Longitudinal 10 Degrees
Tramming - Lateral 29 Degrees
Tramming worst case scenario- - Longitudinal 18 Degrees
Parking (brake) worst case scenario - 18 Degrees
The operator is responsible at all times for the operation of the rig
and must modify procedures to allow for any likely instability and
ensure a safe work area.
To avoid the danger of falling and crashing, the crawler rig must
always keep a safe distance from ledges, pits and slopes.
It is the contractor’s responsibility to assess the ground bearing
capacity and state a safety distance for the rig.
Check the bearing capacity of bridges, floors and any structures prior
to moving the rig onto them.
SIGNALLING
If the operator’s vision is impaired during tramming and working,

someone must give signals for assistants or the tramming/working
area must be cordoned off.
Only reliable persons should be designated to give signals. They
must receive instruction and be aware of this responsibility.
Communication must be co-ordinated and exclusively used between
the operator and the signaller.
The signaller’s attention must not be diverted by any additional tasks.
41
The contractor is responsible to determine if utility lines are buried on
the drill site, and the site owner is obliged to supply this information.
If utility lines are present their location must be clearly marked. Plans
clearly detailing the location (run and depth) of utility lines must be
kept for reference on the working site.
The operator must stop working immediately and inform the site
manager if a utility line or its protective cover is detected.
Uncovered utility lines must be secured against swaying or slipping.
Unless local or national stipulations require otherwise, the following

minimal safety distances must be complied with.
Rated Voltage Proximity
If working near overhead power lines:
Up to 1000V 1 metre (3.25ft)
Above 1KV 3 metres (6.5ft)
Above 110KV 4 metres (13ft)
Above 220KV 5 metres (16ft)
If rated voltage unknown 5 metres (16ft)
For overhead tram lines:
Up to 1000 V AC / 1500 V DC 1 metre (3.25ft)
Above 1000 V AC / 1500 V DC 1.5 metres (5ft)
The operator must park the drill rig on bearing and level ground, and
secure against inadvertent or unauthorised movement, prior to each
operational break and at the end of each working day.
The drill rig must be parked on a slope or incline, the crawler tracks
must be secured with wedges in addition to the hydraulics brakes.
Drill rigs should be parked only where they do not impede public or
site traffic.
If necessary it must be secured with warning triangle signalling lines
or warning lights.
During working breaks and at the end of each working day the
operator must rest drill mast and drill string on the ground, and
secure them against inadvertent or unauthorised movement.
The operator must not leave site if drill rig and tools are not secured.
42
The operator must set all operating levers in
“o” position prior to leaving the control console.
The operator must stop the drill rig engine and secure it against
inadvertent or unauthorised start-up, prior to leaving the drill rig.
Inadvertent or unauthorised start-up is avoided, if the engine is
stopped , the starter key taken out of the ignition lock, and covers
doors and lids are locked.
Markings:
Hydraulic hoses must carry continuous markings, at intervals not

greater than 500 mm.
These markings must be clearly readable, and supply the following
data:
Name of the manufacturer
Type
Nominal diameter
Working pressure (Max. Permissible dynamic pressure is 4 times
more)
Date of manufacture example - ”1q 11”= 1st. Quarter 2011
Storage:
Hydraulic hoses must be stored tension free, in a dry and clean

environment.
One end of the hydraulic hose must always be prepared with a
straight fitting.
Direct sunlight and UV-irradiation must be avoided.
Storage time should not exceed four years.
Operation OF hydraulic lines
After 6 years operation hydraulic lines must be exchanged for safety

reasons, even if there are no apparent technical faults.
Hoses are subject to a natural ageing process, their lifetime is limited.
Hoses which have been operated as part of a hydraulic line, must not
under any circumstances be reprocessed.
Inspection
Hydraulic lines must be inspected by qualified personnel to assess

their operational safety, before the initial start up, and subsequently,
at least once every year.
43
Defective and faulty lines must be exchanged immediately.
Repair of hose assemblies

The European Standard din en 982 ‘Safety of machinery – Safety
Requirements for Fluid Power Systems and their Components –
Hydraulics’ gives the following detailed comment on the repair of
hose assemblies:
”Hose assemblies must not be produced from hose material which
has already been used for production purposes. Hose assemblies
must comply with the relevant specifications given in the respective
european and / or international standards. Recommendations for
storage periods of hose assemblies should be considered.“
Due to its status Din EN 982 can be considered as the legal base
for a judicial decision, this should be considered for compensation
claims.
Din EN 982 also specifies: Hose assemblies must be connected to
hydraulic systems as follows:
They must have the necessary length to avoid mechanical stresses
caused by movements during operation.
Hose assemblies shall not be twisted, i.e. by defective rotary
fittings.
Hose assemblies must be protected from excessive abrasion of the
cover.
They must be adequately fixed to avoid stresses caused by their
own weight.
Fittings must be adequately fixed to avoid a whipping of the hose in
case of accidents.
Hose assemblies must be properly shielded if streaming oil
leakages are likely to cause personal injuries.’
44
3.6.1 General rules for Feed chains: ....................................................... 54
45
46
Rod Handler. Safety Cage Sonic
Drillhead
Hydraulic Stabilisers 2 at Engine

front, 1 at centre rear Crawler Tracks Compartment
Water Pump Fire

Extinguisher Mast in
Tramming
position
Engine Panel Rig Set-up Panel Driller Control Hold Clamp and
Panel Breakout Clamp
47
Engine Exhaust Mast in Raised
position
Rear Stabiliser Storage Driller panel

compartments in working
position
Grout Pump Grout Pump Water/Mud Minisonic Head Tub

Inlet Outlet Pump Relief Lube Valve (Alternate
Valve mounting on Rear
Gauge Panel)
48
Air and Water Driller Panel Rod Handler
control valves swung out Ready for use
ready for use
Driller Panel
49
Read all instructions prior to tramming the rig.
Engine rev Low Speed High Speed

Control selector selector
Left Track Emergency Track Right Track

control Stop Oscillate Control
50
Top Winch
51
The Drill Mast assembly carries the Sonic drill head, and is capable
of drilling from 45° off horizontal to 90° vertical down. The travel of the
sonic head is infinitely variable in forward drilling mode and features fine
and fast feed and return. The drillhead vibration and rotational speed
are manually adjustable; being infinitely variable.
The drillhead assembly, complete with side tilt, is traversed up and

down the mast by a hydraulic cylinder acting through a leaf-chain and
pulley system. All pulley wheels are roller bearing mounted. All chains
and pulley wheels are made from high grade steel. The drill mast is
raised and lowered by hydraulic cylinders equipped with load control
valves. The mast is automatically locked in the 90° vertical by hydraulic
grippers, and release is made when pressure to lower is applied. The
drill mast is designed to handle full strings of casing and drill pipes.
The hydraulically controlled feed system allows full control of the drilling
speed and bit weight. The drill mast has a facility to move sideways and
fore and aft for positioning adjustment over the drill string.
Mast
Side Tip-out Cylinder
Minisonic head
Head Frame and Cradle
Side Slide Cylinder
Head Air Cushions

The Mast Assembly is a rolled steel fabrication which houses the
major Mast components.
The Head Frame and cradle is the assembly of the Sonic head
Cradle and the slide frame which carries the Chain anchors and the
Feed cylinder guides. The head has lateral side shift and sideways
tip-out for the extraction of core samples. Drill tools are connected
to the Minisonic head from the Rod handler.
52
The SONIC Head provides the vibration and rotation to the drill string.
The head comprises of a single motor driven Rotation system, a tub
Lube system, and an oscillator system - all controlled from the control
panel. Air cushions isolate the vibrations to the head and drill string. The
whole Head has Side Shift and Side Tilt
The Side Shift allows for unobstructed winch use down the drill hole.
The Side Tilt facilitates extraction of the samples.
Minisonic head Side Tilted for

Sample extraction
Minisonic head Side shifted.
53
Feed Chains should be tightened to give a 6 mm to 12 mm(1/4”-1/2”)
deflection (approximately 5 to 10 kg(10-20lbs) of force applied by
hand), both sides must be equal and the deflection is measured 600
mm(2ft) from the cradle. If there is excessive deflection in the feed
chain, tighten the chains at the anchors. The feed chains will also need
to be adjusted if the drill cradle is not running parallel with the mast as
shown below.
Feed chains should not be allowed to run dry. A good quality chain
lubricant is recommended. Do not use old motor oil to lubricate the feed
chains.
The chain pulleys are mounted on roller bearings.
Feed chains have to be checked daily for cracks and fissures. Pins and
links with wear marks and grooves or mechanical deformations must be
replaced. Feed chains have to be checked weekly for elongation.
Excessive lengthening of the chains should be avoided. They should be

adjusted by tightening the adjusters. As a general rule, the useful life of
chain is when the percentage extension reaches 2 per cent, then the
chain should be replaced.
The gauge distance must consider at least 17 double-links in the

working range of the chain and should be done as follows:
Fix the total length of 17 double-links of a new chain within the pitch
distance (roller to roller / link to link) The test procedure compares the
total length of the new chain and the used chain and if the used chain
shows increased lengths of 161/2 double-link gauge, the chain must be
replaced.
Nominal length values of chains: Type LL2066

1 double link 31.75 mm
17 double links 539.75 mm
54
A special valve in the hydraulic system automatically balances the load
applied to the up and down movement of drill head.
Chain Adjuster
Leaf Chain
Sonic Head
55
Mast horizontal with
Grippers released
Mast vertical with

Grippers engaged
The Mast is raised to vertical by two Lift cylinders which are complete
with over centre counter balance valves to lock the cylinders in the
event of hose failure. There are two automatically applied Grippers that
maintain the mast in the vertical position during long working cycles.
The Grippers automatically release under hydraulic pressure when the
Mast is lowered.
Mast stiff legs are required for all mast operating angles except vertical
if the maximum pullback force 6710kg (14,800lbs) is applied. Mast stiff
legs are to be used at all mast angles other than vertical. If the mast
is supported by a rigid and strong soil condition, the stiff legs are not
required in the vertical configuration
56
This device is for holding, making up and breaking out the drill pipes,
core barrels and casing tubes. It includes:-
1. Holding Clamp - for holding the drill string during thread making
or breaking.
2. Breakout device - with a clamp for gripping the upper drill pipe
then a breakout cylinder for breaking the thread by rotating up
to 19 degrees.
Standard clamps have a capacity of up to 305mm(12”) Dia.
Breakout Clamp Holding Clamp

(position 2) (position 1)
57
The rig is equipped with a Rod Positioner for the safe loading and
un-loading of rods when extension drilling
Rod Positioner
Stowed and
Guarded
Rod Positioner In
Pick-up Position
Rod Positioner
moving to Loading
position
58
Mounted to the top of the Mast assembly the winch is used for lifting
core barrels and drill pipes, also for setting up the SPT tester. The winch
is hydraulically driven by a planetary motor controlled from the driller
control panel.
Main Winch
59
The rig is equipped with a hydraulically powered Crawler Tracks. These
comprise of a Left and Right hand pair. See crawler Instructions section
at the back of this manual
Crawler Tracks
The Bredel Grout Hose type Pump is a direct hydraulic motor operated
pump. The outlet is connected into the drilled hole. The flow from the
grout pump is variable up to approximately 160 l/min (42 gpm) at 16
bar(232 psi)
Pump Outlet Pump Inlet
60
FMC E04 Water/Mud pump shown. (BLY will also offer an FMC E09
water pump as an option).
Relief Valve
Pump Inlet
FMC Pump
The rig is equipped with an electrically powered Air Compressor. This

comprises of a close coupled rotary unit complete with an unloader
valve and reservoir. This delivers air through a Filter - Regulator to the
Mini-sonic air cushions. See section at the back of this manual.
Air Receiver Unloader Regulator Compressor

Valve
61
Battery
Battery Switch
62
Most of the operating controls are on the main control panel. Please
refer to the Operation section 4 for a full description of the control panel
and the location of the valves,gauges and lights.
There are three stabilisers used to level and stabilise the drill rig, two at
the rear near the Drilling mast and one at the centre of the front of the
rig.
Rear Stabilisers Front Stabiliser
63
The pumps are mounted directly on the diesel engine The hydraulic
system on the LS250 drill rig consists of a combination of open and
closed loop hydraulics. The track drives of the carrier and the drill head
oscillator and rotation utilize piston pumps in a closed loop system and
all the other hydraulics use piston pumps in an open loop system.
All pumps are protected against excessive pressure by safety valves.

The fixed pressure rating must not be changed.
The Oil Tank is fitted with the following:-
Oil level and temperature sensor which shuts down the system if the
temperature exceeds 80C(180F).
Oil filter with a visual signal device. When this shows red the
filter cartridge must be replaced. The filter grade is 10 micron.
Recommended oil 17/15/13 class (ISO 4406).
A filling tap with breather and pre-filter.
A ball-valve to close the oil circuit in case of a shutdown or repair,
avoiding the loss of oil.
One heat exchanger is incorporated in the return circuit and is driven
by hydraulic motor.
All the control and monitoring elements of the drill are assembled in the
control panels.
64
4.1.1 Equipment Description and Identification ....................................... 67
4.1.2 Safeguards .................................................................................... 67
4.1.3 Routine Checks .............................................................................. 68
4.4.1 Stabilizer Jacks ............................................................................... 77
4.5.1 Travelling on Slopes ....................................................................... 77
4.6.1 Prior to Start up .............................................................................. 79

4.6.2 Start-Up Procedures ....................................................................... 80
4.7.1 Tramming Tracking Hazards ........................................................ 82
4.9.1 Safety Cage – Restricted Operation ............................................... 84
Figure 4–2: General View of Driller Panel ......................................................... 72

Figure 4–3: Engine Controls on Driller Panel ................................. 73
Figure 4–4: Hydraulic Controls on Driller Panel ................................................ 73
Figure 4–5: Feed / Rotation Controls on Driller Panel ...................................... 74
Figure 4–6: Gauge and Ancillary Arrangement................................................. 74
Figure 4–7: Water Controls below Driller Panel ................................................ 75
Figure 4–8: Electric / Engine Control Panel ...................................................... 75
Figure 4–9: Rig SetUp Control Panel................................................................ 76
Figure 4–10: Rear Gauge Control Panel. ........................................................ 76
65
66
The LS250 Sonic drill rigs are designed to operate fully independently,
and are therefore suited to all types of drilling applications, in a variety of
ground conditions.
- contains the main hydraulic directional control

valves and circuitry.
- Pressure gauges monitor the system by measuring

main pressures at any time while the machine is running.
- The hydraulic reservoir is 300 l (80 gal)capacity

and is fitted with an indicator to show hydraulic oil level and temperature
sensor.
- provides cooling of hydraulic oil by hydraulic driven fan

blowing air across Heat Exchanger.
- maintain continual particle filtration through 10

micron, beta-rated elements. A visual clogging indicator is fitted, which
changes colour to warn of an element servicing requirement.
- refer to engine section for details of starting

procedure.
- has a capacity of 193L (51gal), and is fitted with a fuel

gauge on the Starter panel. The tank is filled via a filler cap on the mid
left side of the rig.
- The diesel engine is situated in the Engine

Compartment. The speed of the diesel engine is controlled from the
Radio Remote, the Main Engine control panel and from the Driller
Control panel.
The pictures on the following pages locate the main components of the
LS250.
Note: The hydraulic reservoir can be filled with a wide range of oils. See
the Oil Selection Chart in section 5 to determine the oil most suited to
your conditions.
All operators must be familiar with the equipment and its proper care. If
adjustments or repairs are necessary, or if any damage is known, the
operator must report the details promptly to an appointed person and
must notify the next operator upon changing shifts.
67
During tramming operations it is essential that the Mast is laid down and
all items are securely anchored. A slow practical tramming speed must
be applied at all times.
Design modifications or welding on the rig are prohibited without the

approval of Boart Longyear.
Inspection of welds for cracks and other signs of deformity.

Check unit for level and correct placement before operation.
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 application, check the bolts for correct
torque.
Ensure that the Load Rating and Warning decals are installed on the
rig and are in good condition.
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 structure may no longer hold the rated load. Frequent
visual inspection of members and welds is even more critical at these
temperatures, see inspection list.
Ensure stabilizer feet are located on a solid footing and will not sink
in soft ground.
68
The following is a checklist for a visual inspection of the LS250. Ensure
that the inspection is performed by an individual with knowledge of
all operational procedures. Each section has a pass or fail choice. If
there is a problem, it should be noted and corrected immediately. Make
copies of this checklist and file away for future reference. The list is not
exhaustive and the inspection may take into account aspects of the rig
that are not listed.
1 Mast Assembly:
Condition:
Frame: Damaged Cracked Welds OK
Cylinders Bad OK
Pulleys Warped OK
Grooves Worn OK
Chains Bad OK
Spacers or Seals Bad OK
Comments: Rusty Needs Repair
Needs Painting Other:
2 Main Winch Assembly:

Condition:
Pulleys Warped OK
Grooves Worn OK
Spacers or Seals Bad OK
Comments: Rusty Needs Repair
Needs Painting Other
3 Stabilisers:
A. Front Left
Condition:
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
B. Front Right
Condition:
Bow Slight Bad OK
C. Rear Centre
Condition:
Bow Slight Bad OK
Comments: Need Repairs Other:
4 Driller Panel
Condition:
Frame & Pivots: Damaged Cracked Welds OK
Valve Levers Damaged OK
Valve Knobs Missing Damaged OK
Nameplates Missing Damaged OK
Comments on Cabinet Rusty Needs Repair
69
5 Rig Setup Panel
Condition:
Frame Damaged Cracked Welds OK
6 Engine Panel
Condition:
Frame & Pivots: Damaged Cracked Welds OK
Display screen Damaged OK
Lights Damaged OK
7 Radio Remote Panel

Condition:
Housing: Damaged Cracked OK
Control Levers Damaged OK
Control Knobs Missing Damaged OK
Display screen Damaged OK
Lights Damaged OK
8 Bolt Connections
All bolted connections are to be inspected, tightened, and missing
parts replaced or visibly marked as missing or damaged and in
need of repair.
9 Summary of Inspection
Appearance: Good Fair Poor
Repairs Needed: None Minor Major
Number of Missing Parts:
10 List of work to be completed:

..........................................................................................................
..........................................................................................................
..........................................................................................................
..........................................................................................................
Signature : ........................... Date:...........................
Ref No.: .....................
70
Minisonic SPT Test Rig Rear Gauge Hinged Safety Safety
Drillhead Control Panel Gate Guard
Electric Rig Crawler Rear Stabilisers Driller Panel

Panel Setup Tracks one each side
Panel
Rod Drill Mast
Handler
Safety Grout Pump FMC Mud Fire Engine

Cage Pump Extinguisher Compartment
71
!
The following is a full description of the control panels and the location
of the valves,gauges and lights.
72
Engine Engine Engine Emergency
Diagnostic Warning Light Warning Stop Button
Screen Light
Pre-heat
Glow Plug
Light
Reset
Button
Engine
Start/Stop
Switch
Fast/Slow Speed Engine Speed Oil Level Temperature

Selector Switch Control Switch Warning Light Warning Light
Main Water Grout Mixer Auxiliary Head Head

Winch Pump Pump Slide Tilt
Fine Feed Fast Feed Wrench Rotate Top Clamp Bottom Clamp
Working Clockwise
Light / Counter
Switch clockwise
Spare Pressure
Switches Selector
Rod Switch
Presenter Head
Clamp Rotation
Rod
Presenter Head
Swing Vibration
73
Feed Feed Feed Counter clockwise Clockwise
Speed Pressure Balancing Rotation Pressure Rotation Pressure
Control Control Control Control Control
Balancing Water Pump Feed Tub Tub

Pressure Pressure Pressure Temp. Pressure
Open Loop Radio Brake Brake On
System Rotation
Remote Off Light Light
Pressure Pressure
Light
Work Light Winch Welder/ Drill/RP/ Re-set Drill/Drive

Swing/ Generator Restricted Confirm Selector
Extend Selector Button Switch
Switch
74
Water Pressure Dump/ Washer Inlet Valve from Outlet to Sonic
Pressure Return to Tank Valve Water Pump Head
Gauge
Engine Engine Electrical Box / Engine Emergency

Diagnostic Warning Control Panel Warning Stop Button
Screen Light Selector Light
Pre-heat
Glow Plug
Light
Reset
Temperature
Button
Warning
Light
Engine
Fast/Slow Start/Stop
Speed Selector Switch
Switch
Engine Speed Brake On

Control Switch Light
Temperature Driving Driving Radio Brake Off

Warning Light Start Light Stop Light Remote Light Light
75
Front Left Right Mast Side Mast Front / Mast Mast
Jack Rear Rear Slide Rear Slide Dump Raise
Jack Jack
Radio
Remote
Battery
Charger
Power Spirit Level

Take-off
Top Clamp
Pressure
Gauge
Bottom Clamp
Pressure Top Air Bag
Gauge Pressure
Top Air Bag Control
Pressure
Gauge Bottom Air
Bag Pressure
Bottom Air Control
Bag Pressure
Gauge
Head Lube
Control
Head Lube
Pressure
Gauge
76
There are three stabilizers used to level and stabilize the drill rig, two at
the rear near the Drilling mast and one at the front of the Cab.
Front Rear
Stabilizer Stabilizer
Jack Jacks
When moving the rig, always follow these safety precautions:
Obey posted speed limits

Never move with unsecured rods on the deck
Always ensure all loose items are secured
Ensure all local road heights/weights are obeyed.
Always use the proper rated lifting device to lift or raise the rig.
Never work underneath any part of the rig without proper support.
Never use a forklift to lift the rig, always lift the rig using the proper
overhead lifting device and the lift points provided.
When travelling on hills or slopes, always follow the precautions below.
Do not travel at an angle on a hill or slope, or parallel to the slope.

Such action could result in the machine tipping over or slipping.
77
When travelling up hills or slopes, always travel directly up the slope.
Set the travel speed to a low range and operate slowly.
Do not suddenly change speed on a slope. There is a danger that the
direction of the machine may suddenly change and the machine may
slip.
When travelling down a slope set the speed range to low, run the
engine at low idling, and operate the travel lever to a position less
than 1/2 of the full stroke. If the machine travels too fast there is a
danger that the engine will overrun and the machine may slip.
If a dangerous state occurs by any possibility, and when it becomes
necessary to stop the machine urgently, press the parking brake
switch to set it to STOP position or turn the enine starting switch to
the OFF position to stop the engine.
Power Unit
- Check that the main pump has been primed. If not, prime by
removing the case drain hose and adding Hydraulic oil until case is
full. Refit hose.
Check that the diesel engine levels of coolant, engine oil and diesel
fuel are correct.
Coolant
Type of coolant:
Freezing point
Oil
Type of engine oil:

Viscosity
Fuel oil
Check that there is sufficient for the job.
Hydraulic oil
Check that the hydraulic oil tank is full to the top of the sight glass,
fill by Hand Pump if necessary
Type of hydraulic oil:
Viscosity:
Check that the top winch is full
Type of oil:
Viscosity:
78
Check that the crawler track planetary gear boxes have been
primed.
Type of oil:
Viscosity:
Check that the tension of the crawler tracks is set correctly
See manual
Hydraulic Circuit
The pumps are mounted directly on the diesel engine. In the complete
version of the drilling rig there are two closed loop pumps and one load
sense pump. The number 1 closed loop pump powers the helper side
crawler track, and head oscillation. The number 2 axial piston pump
powers the driller side Crawler track, and head rotation
The load sense pumps power all other drilling and setup functions.
Two gear pumps are fixed to the engine one controls head lube and
the other runs the fan on the hydraulic cooler. All pumps are protected
against excessive pressure by safety valves mounted before the
distribution valves. The fixed pressure rating must not be changed.
The Oil Tank is fitted with the following:
Oil level and temperature sensor which turns a warning light on if the
temperature exceeds 80 degrees C (176 degrees F)
Be sure to check that all control elements (levers) are in the neutral
“O” position.
The Emergency STOP switches must not be activated.
Release any activated switches by rotating them slightly
All stopcocks for pump suction lines must be open.
Hydraulic hoses and lines must be securely connected and tightened.
Check for oil leaks.
Check oil levels in the engine, gearboxes, and hydraulic oil tank.
Check the diesel fuel level in the fuel tank. For further information see
the Engine Manual.
79
Prevent possible injury. Components can be hot. always wear the
proper personal protective equipment when working in and around oil
coolers.
Read the manual and become familiar with all the rig instructions prior
to starting or tramming the rig. Before operating any controls, know how
each control functions. Check that there are no persons or obstacles in
the surrounding area, sound the horn then start the engine.
Before starting the engine be sure to set the parking brake switch to
the ON (stop) position - the engine will not start without setting the
parking brake to this ON(stop) position. Selection of Drive on the
Drill/Drive selector automatically applies the brake.
Ensure the Battery is switched ON position (situated near the front of
the rig inside the door by the engine).
Set the selector near the top of the Electrical Box to the proper
location for starting the rig (Electric Box or Control Panel)
Set the accelerator control to slow position.
Turn on the starter key
Press the blue re-set button.
Start the rig
The oil pressure warning lamp and battery control (ignition) lamp
must light up.
After the engine starts release the key (the key will automatically
return to the ON position)
The oil-pressure warning lamp and battery control (ignition) lamp
must switch off.
Turn the Remote Controlon.
Switch to Drive (Constant Horn should sound).
Release the Brake, right hand button on thr Remote Control (Horn
should sound intermittently).
Low Temperature starting:
Set the engine speed to maximum and set the high speed position.
Turn the starter key to the PRE-HEAT position and hold until the
preheating lamp on the control panel box lights up - appox. 8
seconds. When the key is released it will return automatically to OFF.
When the resister on the instrument panel glows red, turn the key to
START the engine.
After the engine starts release the key.
Check for leaks, and rectify before proceeding.
80
After starting (warm-up operation.
Set the speed control to low speed and run for approx 5 minutes
under no load.
Set the speed control to mid range speed, and run for approx 5 mins
under no load.
Check that the instrument panel gauges, monitor, charge lamps.
Check that there is no abnormality in the exhaust gas colour, engine
noise or vibration.
Consult the operating manual for further instructions regarding driving
and steering the rig.
Run the engine under light load until the coolant temperature is within
the green range. Do not suddenly accelerate the engine
Not Used
Slow Speed Driving
Max: 0,6 m/s
Fast Speed Driving

Max: 4 m/s
(Half Force)
Emergency
Stop
Not Used
81
The Tracks are operated with the two large Joysticks. The left Joystick
steers the left chain, the right steers the right chain. Pushing the
Joysticks drives the rig forwards, and pulling drives in reverse. Push or
pull the joysticks together for in-line driving and in opposite direction for
steering
The tracks are steered by counter-activating control levers. Brakes

automatically apply when control levers are centered. To avoid
acceleration instability, operate the levers slowly
Sounding Horn
The driving panel

is switched on with
the rotary switch
Activation Button
Cable Connection
82
Hints for Optimum Drilling
Do not place excessive feed pressure on the drill because this

causes several problems:
The drill rig will be lifted off the ground and become unstable.
Increased wear of accessory components, drill string, hydraulic drill
head will result.
Always keep thread connections clean and well lubricated.
When tripping out of the hole, the time spent on this procedure is
regained many times over through faster penetration.
Make sure that all casing joints are screwed together.
Always maintain perfect alignment of all drill string parts and if
necessary re-adjust both during drilling and retracting.
Store drill string components, e.g. casing, drill steels, augers etc., in
the Mast Stow bracket (within the safety hoop) or on a purpose built
motorised tender.
Clean all threads with a wire brush and grease them with a high
quality thread compound.
!
Monitoring the pressure in the rotation circuit indicates how much
torque is being applied to the drill string.
If you notice that the pressure is reaching the set limit, you may be
getting stuck. Stop advancing and retract the drill string slightly. Shut
off the oscillation (if mounted) and allow the drill string to rotate with
the flushing flowing until the torque pressure drops back down. Then
proceed further.
Also watch the feed pressure gauge, as this will help to establish an
idea of how much force is on the bit.
Pay close attention to flushing pressure. A rise in pressure indicates
that either the bit is getting clogged or the annulus is collaring.
Take corrective action before it is completely clogged or collared.
Also, make sure that everyone is clear of the rig, as sometimes the
plug opens with considerable force and cuttings come up the annulus
at great speed.
83
Under some deep hole applications the Feed Balancing pressure and
Feed pressure tend to reach a balance point due to the weight of the
drill string. Decreasing Feed Pressure will slow down the penetration
rate and will overcome this balance point. Beyond this balance point
it will become necessary to increase the Feed Balancing pressure to
counter the increase in weight of the drill string.
When drilling, Boart Longyear recommends always to start with a low

torque setting, so that there will be sufficient in reserve.
Our aim is to ensure your rig is operating efficiently to help you achieve
maximum productivity with minimum of downtime, we offer the following
guide to reduce lost time during start up.
The most important aspect of efficient drilling is having the

correct system of accessories for your particular project.
REMEMBER:
The tooling does the actual drilling, the drill rig only powers the
drill head, which in turn only rotates/vibrates and guides the drill
string into the ground.
Should you have any queries or doubts about a particular
application, you can refer to the the selection of Boartlongyear
tooling brochures which are readily available from your
BL representative, or look up our web site
(www.boartlongyear.com).
If you need further assistance contact your Boart technical
representative.
Once you have decided which system and method will work best
on your particular site, it is very important to ensure that all
components required are actually on site.
The safety cage is in place to protect the operator from moving parts
of the drill string. If the safety cage is open then the drilling work can
only be performed in either Restricted Operating Mode or, under certain
conditions, in Rod Handling Mode.
84
Different Restricted Modes :
ROM - useful for when the operator needs to work directly on the drill
string, in this case the safety cage is open and not in a ‘rod handling
enable’ position. To activate the ROM mode set the drilling/driving
selector to drilling, normal/rod handling/ROM selector to ROM and
press START/RESET pushbutton. The fine feed handle is not active
in this operating mode and the rotation is only engaged (at speed
reduced to 30 rpm max.) with a ‘dead-man’ pushbutton de-pressed.
Fast feed speed is reduced to 15 m/min. max. This would apply when
core barrel handling.
Rod Handling Mode – when the safety cage is open and set in a
‘rod handling enable’ position, to allow for rod handling by means
a Rod Loader or Rod Presenter, the Rod Handling Mode can be
activated. In order for this, set the drilling/driving selector to drilling,
normal/rod handling/ROM selector to Rod Handling and press the
START/RESET pushbutton. The fine feed handle is not active in this
operating mode and the rotation is only engaged (at speed reduced
to 30 rpm max.) with a ‘dead-man’ pushbutton de-pressed. Fast feed
speed is not reduced.
Safety Process with Restricted Mode :
With the safety cage closed the drill rig works in normal drilling
operation: set the drilling/driving selector to drilling, normal/rod
handling/ROM selector to normal and press the START/RESET
pushbutton to activate,
When the operator opens the doors of the safety cage. The Rotation
and Feed stop directly and the failure indicator light on the control
panel will flash,
The operator must then switch to the ROM (or RH-Mode) and then
press the START/RESET push button on the operator’s control
panel. Please note that the indicator for ROM (or RH- Mode) will
illuminate in the colour mode shown below,
The operator can then start operation again, with reduced speeds of
rotation (by the simultaneous pressing of the dead-man button on top
of the rotation handle) and feed (only in the ROM).
If the operator closes the safety cage, then the operation Stops.
Normal drilling mode is resumed by switching back to Normal Drilling
Mode and pressing the START/RESET push-button. The indicator for
drilling mode will illuminate.
Active Fault Red Flashing Location

Restricted Operating Mode (ROM) Orange Steady Beacon # 5305247
Rod Handling Mode Orange Flashing Beacon # 5305247
Normal Operation Drilling Green Steady Beacon # 5305247
Tramming Mode Amber Flashing with alarm when moving
85
86
5.1.1 Operational Requirements .............................................................. 89
5.1.2 Safety Requirements ...................................................................... 89
5.4.1 Repairs to Hydraulic Components .................................................. 94

5.4.2 Mast Dump and Wiggle Frame ....................................................... 95
5.4.3 Mast Assembly ............................................................................... 96
5.4.4 Rod Presenter and Wrenches ........................................................ 98
5.4.5 Minisonic Head and Flushing Swivelt ........................................... 100
5.4.6 Drilling Services Annex for Sonic Head ........................................ 102
5.4.7 SPT Auto Hammer Assembly ....................................................... 107
5.4.8 Main Winch ................................................................................... 108
5.4.9 Levelling Jacks ............................................................................. 109
5.4.10 Main Frame ................................................................................ 110
5.5.1 Pre-Shift Inspection Form (Example only) .................................... 112

5.5.2 Maintenance - First 100 hrs with New Machine ........................... 114
5.5.4 Maintenance - First 250 hrs with New Machine: .......................... 114
5.5.6 Maintenance - First 500 hrs with New Machine: ........................... 114
5.5.7 Maintenance - Every 500 hrs ...................................................... 115
5.5.10 Maintenance - Every 2000 hrs ................................................... 116
5.5.11 Changing the Hydraulic Oil ......................................................... 116
5.5.12 Recommended Oils and Lubricants............................................ 117
5.5.13 Gear Oil & Greasing Table ......................................................... 118
5.5.14 Typical Lubricant Capacities ....................................................... 119
87
Figure 5–2: Metric Bolt Torques and Safe Loads ............................................. 93
Figure 5–3: Imperial Bolt Torques and Safe Loads .......................................... 93
88
Cost consciousness and the call for greater efficiencies have led to an
ever-increasing use of machinery in the construction industry. This has
enabled contractors to dispense with expensive manpower, while at the
same time reducing time spent on-site.
This development is clearly shown by the fact - machine-related

construction costs show a substantially lower increase than labour
intensive operations.
Everybody must therefore be interested in further increasing the

efficiency of Construction Machinery.
The breakdown of machinery on-site always entails additional costs and

loss of precious time.
High availability of machinery and the reduction of downtime requires a

well geared system of maintenance.
The aim of planned servicing and maintenance must therefore optimise

the availability of machinery and accessories.
Maintenance measures are:
Regular Service - appropriate measures to maintain nominal

machine condition, e.g. cleaning, lubrication, oil changes, and minor
adjustments.
Inspection - measures to assess and review the actual condition of
the machine.
Preventive Maintenance - exchange of worn, but still used
components with the view to forestall greater damage.
Repairs - appropriate measures to restore the nominal condition of
the machine.
Care, maintenance and service of construction equipment are important

processes to help ensure safety at work sites. However, accidents
associated with work site maintenance often occur. This is primarily due
to:
Wrongly applied maintenance measures

Lack of operational safety due to inadequate maintenance
All relevant safety at work stipulations must be complied with.
89
Individual stipulations require checks:
When indicated or at specified intervals

By experienced operators/fitters or specialist experts.
Experienced operators/fitters are persons who, on the basis of their
qualification and experience, have adequate knowledge to assess the
operational safety of equipment.
Specialist experts are persons who, on the basis of their qualification,

experience and competence, have the special knowledge to assess the
operational safety of equipment and, if necessary, effect such repairs
required to restore the equipment’s operational safety.
For the purpose of care and maintenance instructions this means that:
Care, service and maintenance measures can be carried out by the

contractor’s personnel.
Structural changes, additions, mountings, adjustment of pressure
limiting valves, etc., which modify the equipment’s behaviour (and
stability) are only to be effected:
After consulting with and receiving written authorisation from Boart
Longyear, and/or
Under the supervision of a Boart Longyear technical expert.
90
Regardless of which system or method is used, make sure that the
following tools and equipment are available on-site.
A tub of grease and

application brush
A Wire Brush to clean

Thread Sections
A set of saw horses of sufficient strength to

hold drill rods and casings, and keep them
off the ground.
A set of Wrenches of the correct size
for all spanner flats on the drill string
A separate water line and nozzle to clean mud

off the drill rig and tools.
Two 36” (or larger) Wrenches
91
Shovel - to remove
cuttings from the area
Hammer - sometimes
necessary to strike the
casing to loosen thread
connections
Spirit Level or Angle

Indicator for Drill Mast
Alignment
Grease Gun
with Pressure
gauge for
Crawler Track
tensioning
Chain Wrench
Rod Lifter
Split Tube Loader
92
93
For replacement of irreparable or worn parts
consult the Parts List supplied with this Operating Manual for part
numbers and ordering. Consult the Manufacturers Manuals at the end of
this manual for in-depth explanations of maintenance of the proprietary
items of the rig. All maintenance aspects of these items are shown in
these manuals.
! Components of any assembly under

examination; must be supported prior to any attempt at repair. Lower the
drill mast onto the mast support. The drill mast must be supported prior
to any attempt at cylinder repair.
Be sure to include a healthy ‘running-in’ period for new components
after any repair and maintenance measures.
Always maintain recommended operating temperatures and check filters
at specified intervals
Utmost cleanliness must be observed when removing hoses and fittings.
All hoses must be kept under observation to avoid trapping and to
pre-empt any failure through abrasion.
Turn off Engine and take Ignition Key out.

Lock Engine control box with key
Turn off the main battery disconnection key inside the power pack.
All lines should be de-pressurised by moving the valve levers to and fro.
Cylinder load control valve blocks shall be slackened to depressurise
before removing any cartridges.
All items on an assembly should be secured against runaway prior to

working on any hydraulic connections.
94
Mast Tilt Cylinder Mast Slide Cylinder Mast Slide Grease
Pins - Grease Points Pins - Grease Points Points - 2 each end
Mast Dump
Slides
Grease
Points
Dump Cylinder Clevis Wiggle Frame Cylinder Wiggle Frame Slide

Grease Points Grease Points Grease Points
Daily - Thoroughly clean out any drilling debris in the Frames
Weekly - Clean and lubricate the all slides and pivots; also clean and
lubricate the Dump and Tilt cylinder clevises .
Observe the Tilting and sliding operation, look for any looseness or
seizure in the Pivots, Frames, Trappings and Slides. Examine the
Cylinder Rods for pitting or damage and look for oil leaks, observe the
cylinders for excessive sinking which could mean Piston seal internal
bypass leakage or damaged load control cartridges (a small amount of
sinking overnight is normal).
If any pivots or clevises are seized or loose consider the safety aspect,
ie. if severely ‘sloppy’ or totally seized, strip out the joint and re-new
the Pin, and fixings. Leaks in hydraulic cylinders can lead to unsafe
conditions (ie. sinking under load and oil contamination), prevent this by
re-sealing the affected cylinder.
Other than negligence of the Preventive Maintenance, this area should

be free from damage, however if a part is subjected to damage from
external forces, then the assembly will need to be examined thoroughly
and any distorted part replaced or refurbished.
95
.
Clamp/ Rope Pulleys

Rod Mast Slides -
Breaker - Lubricate
Presenter Lubricate
Assembly Assembly
Feed Chains
- Lubricate
Power Chain
- Clean Links
Mast Dump slide

rails - Lubricate
Daily - Thoroughly clean out any drilling debris in the Mast frame and
lubricate the Mast slides. Examine the Feed Chains and Pulleys for
wear and damage, re-tension the chain if necessary (see below) and
re-lubricate.
Weekly - Clean and lubricate cylinder clevises. Measure feeder chain

stretch and replace if more than 3%.
96
Chain specification LH2066 - Pitch = 31.75 mm
Use a gauge length of 20 pitches = 20x 31.75 mm = 635 mm
3% stretch will show a maximum length of 654.05 mm
If the chain exceeds this length replace it.
During operation observe the Mast Frame for distortion, and also the
slide ways and trappings for looseness or binding. Adjust or re-new
as required. Look for any looseness in the Mast Slide Pivot, and Feed
Chain Pulleys. Examine the Feed Cylinder Rod for pitting or damage
and look for oil leaks, observe the cylinder for excessive sinking which
could mean Piston seal internal bypass leakage or damaged load
control cartridges (a small amount of sinking overnight is normal).
ie. if severely ‘sloppy’ or totally seized, strip out the joint and re-new the
Pin, Bushes and fixings. Leaks in hydraulic cylinders or damaged load
control cartridges can lead to unsafe conditions (ie. sinking under load
and oil contamination), prevent this by re-sealing the affected cylinder or
replacing cartridges.
Observance of the Preventive Maintenance in this area should avoid

normal operational damage, however parts may be subjected to
damage as a result of the drilling process, ie. abrasion from drillings,
blows from drill rods and flushing medium corrosion etc. The operator
must monitor and initiate repair of any damage from these causes as
necessary.
97
.
Accumulator Rod Presenter

Cylinder Clevises
- Lubricate
Breakout
Bracket -
Lubricate
Break-out
Cylinder Clevises
- Lubricate
Break-out Wrench
Cylinder Clevises -
Wrench Jaws Lubricate
Holder Wrench
Check for wear - Cylinder Clevises
Lubricate round - Lubricate
insert pivots
Daily - Thoroughly clean out any drilling debris in the Wrench Jaws.
Examine the Jaws for wear and damage, replace if necessary.
Weekly - Clean and lubricate the Presenter pivots and clevises, the
Breakout cylinder clevises, Wrench cylinder clevises, Breakout bracket
and Jaws.
If the open and close movement of the jaws is unequal, then open
both jaws of the Wrench and /or breaking device completely against
pressure. The flow divider will be then be adjusted for equal and
simultaneous operation. During operation observe the Jaws for wear.
Look for any looseness or seizure in the Breakout bracket pivot, look for
slack causing rocking. Examine the Cylinder Rods for pitting or damage
and look for oil leaks.
98
ie. if severely ‘sloppy’ or totally seized, strip out the joint and re-new the
Pin, Bushes and fixings. Leaks in hydraulic cylinders can lead to unsafe
conditions (ie. sinking under load and oil contamination), prevent this by
resealing the affected cylinder.
Observance of the Preventive Maintenance in this area should avoid

normal operational damage, however parts may be subjected to
damage as a result of the drilling process, ie. abrasion from drillings,
blows from drill rods and flushing medium corrosion etc. The operator
must monitor and initiate repair of any damage from these causes as
necessary.
To ensure a constant pressure on the jaws while loosening rods, the

hydraulic circuit utilizes a hydraulic accumulator. The accumulators
provide stored energy to compensate for leakage or failure of the
hydraulic components.
The standard pre-charge pressure of the accumulators is 75 > 82 bar

(1100>1200psi). Check from the Hydraulic diagrams in the Parts list
book.
The accumulators should only be serviced by Boartlongyear technicians.
• Prior to servicing an accumulator, all stored energy (both hydraulic and

gas) must be relieved from the accumulator and circuit.
• Prior to working on the clamp hydraulic circuit, any stored hydraulic

energy must be relieved from the circuit. This should be done by moving
the clamp valve levers back and forth with the engine off. When the
lever is moved and the clamp cylinders no longer move, the stored
energy is relieved.
99
Centralising Drill head float shafts and Air Flushing Swivel
Guide Rollers cushion shock absorbers
Mast Trappings Side Tip Out Side Shift cylinder

cylinder clevises Clevises
Daily - Thoroughly clean off any drilling debris, check the motors and
lubrication pump for leaks. Check the Flushing Swivel connecting
thread; if loose, clean and fix in position with Loctite thread lock.
Weekly - Check the centralising Guide rollers on the inside of the

Feeder Connection Flange fasteners and torque-up if required. Clean
and lubricate the Float Shafts and the Shift and Tip-out cylinder
clevises. .
During operation observe the motion of the Drillhead down the mast,
this should be smooth with out wobble, also observe the Mast Frame
and Slide ways for distortion, and trappings for looseness or binding.
Adjust or re-new as required. Look for oil leaks from the front of the
drillhead and also from the drive motors. The Flushing medium should
not leak in the area of the Flushing Swivel. Examine the Cylinder Rods
for pitting or damage and look for oil leaks
Any misalignment in the feeding of the Drill head needs to be corrected

by replacing the Trappings and adjusting the Guide Rollers (see section
3). Excess oil in the area of the outlet shaft of the drilhead could mean
that the shaft seal is worn. Any oil leak in the area of the flanges of the
drive motors could mean motor shaft seal damage, possibly by high
return line pressure, check it out. Leakage from the Flushing Swivel
100
could mean a loose connection or worn seals, check it out. Leaks in
hydraulic cylinders can lead to unsafe conditions (ie. sinking under load
and oil contamination), prevent this by re-sealing the affected cylinder
Other than negligence of the Preventive Maintenance, this area should

be free from damage, however if a part is subjected to damage from
external forces, then the assembly will need to be examined thoroughly
and any distorted part replaced or refurbished.
101
The cradle is centralized on the mast by four Cradle Centralizing Rollers
that guide against the inside of the left and right mast slides. These
Rollers need to be adjusted occasionally to maintain a tight fit of the
cradle to the mast. The clearance between the Rollers and the Mast
Slides is to be checked as part of the weekly maintenance. If the rollers
are adjusted the head may need re-aligning (see next chapter). Also
check the Mast Guides for excessive wear.
Push head sideways until one of the rollers at the top (bottom)
contacts the mast. Check by trying to turn the roller. Insert a 1mm feeler
gauge or, if this is not available, a regular hacksaw blade between the
other roller at the top (bottom) and the mast slide. This should just fit, if
too sloppy or tight the rollers need adjusting (as outlined below).
Start with either top or bottom rollers. Try to have the rollers adjusted
roughly symmetrical. Check by comparing the position of the bolts (B in
picture above) and slots of excenters (C). Push the head over sideways
until one roller contacts the mast guide. The other roller can then be
adjusted: loosen nut (A) while holding allen bolt (B) steady with allen
key. Insert feeler gauge / hacksaw blade between roller and mast slide.
Turn excenter (C) by prying with a screwdriver in slots of excenter until
feeler gauge is tight. Tighten nut (A) while holding allen bolt (B) steady.
Re-check and re-adjust if necessary. Proceed with checking roller
guides at top of head.
102
The sideways and depth alignment of the head can be adjusted
separately on the cradle. Check these once a week or when problems
with stabbing rods/casing occur due to misalignment.
Attach core barrel to head and lower head so that bit is approx. at top
clamp. Measure the distance between the side of the core barrel and
the right side of footclamp housing. Lower core barrel into hole and take
same measurement at top of core barrel. If this distance is more than
10mm different then sideways alignment of head should be adjusted.
Note the way the head needs to be tilted to correct.
The sideways alignment of the head can be adjusted at the bottom

mounting of the tip-out cylinder. Loosen bolts (A in picture below) some
turns. By turning nut (B) the alignment of the head is changed. After
making the adjustment tighten bolts (A) back up and re-check the
alignment as described above
103
The spindle is mounted in the head with axial bearings. These
bearings need to be pre-loaded so that the spindle does not “bounce
up and down” in the bearings. A large nut that is screwed onto the
top of the spindle pushes down the top bearings. By tightening this
nut with a specified torque the correct load is set in the bearings. If
this maintenance is not done regularly the bearings will eventually be
damaged, the water swivel spindle may break and oil leakage across
the top oil seal may result.
Preload should be set after the first 10 hours of Vibe.

Preload should be set every month, unless extremely hard drilling
conditions occur….then sooner
The rotation pressure should be tracked daily during warm up, this
will give a good idea of the preload condition.
Remove the water

swivel
Quantity 8 1/4” -
20 x 1 1/4” Socket
Head bolts
104
Remove the Top
Quantity 8 1/4” -
20 x 4” Socket
Head bolts
Loosen half nuts
Loosen nut
tension bolts, and
back off by 12mm
(½”)
Nut tension key, Insert the narrow end of the Nut Tension key into the hole.
Part 8400971 Make sure the key is fully engaged into the slot in the nut.
With the rig at a medium idle and low torque, rotate as for casing
(counter clockwise), to 125bar (1800 PSI). Activate the rotation two or
three times to ensure full pre-load is achieved.
First torque the

nut tension bolts,
to 70 Nm (50 Ft
Lbs) Then torque
the Half Nuts to
55 Nm (40 Ft Lbs)
Note - Tighten evenly
so tension ring is
even.
Use Ultra Blue
Permatex around
water swivel ring
105
Install new seals, if
needed in the Water
Swivel top grooves,
Ensure the Seal Lip is
pointed upward.
Apply grease
Install water swivel top.

Quantity 8 1/4” -
20 x 4” Socket Head bolts
¼” Nordlock Washer
apply Blue Loctite
Torque to 20 Nm (14 ft. Lbs)
Install O-Ring, this aligns

with the outer Zerk greaser.
Examine the Water

Swivel, install new
seals if needed,
Ensure the Seal

Lip is pointed
downwards.
Install Water Swivel
Quantity. 8 1/4 -
20 x 1-1/4” Socket Head bolts
¼” Nordlock
Apply Blue Loctite
Torque to 20 Nm (14 ft. Lbs)
Make sure to align with

the outer zerk greaser for
greasing the outer seals
Remove key
106
Drive Chain Drive Motor Hammer Slide
Shaft
Chain Hammer SPT

Sprocket Assembly
Regular Service -
Daily - Thoroughly clean off any debris from the STP especially
on the slides (jet wash if necessary). Look for any new oil spots
around the motor as an early indication of problems.
Weekly - Check over the Frames and pivots for damage. Clean and
lubricate the slides and pivot pins.
Inspection -
Observe the SPT when in operating mode, look for loose parts,
sloppy pins and rattling joints. Examine slide rods and cylinder
rods for pitting or damage and look for oil leaks around the motor.
Examine the Hammer guide for wear or damage.
107
Preventive Maintenance -
If any pivots or clevises are seized or loose consider the safety

aspect, ie. if severely ‘sloppy’ or totally seized, strip out the joint
and re-new the Pin, Bushes and fixings. Leaks in hydraulic motors
or cylinders can lead to unsafe conditions (ie. sinking under load
and oil contamination), prevent this by re-sealing the affected part.
Ensure that the drive chain is correctly tensioned, remove links and
re-tension worn chain, replace chain that is stretched over 2% .
Worn or damaged connections must always be renewed.
Repairs -
Observance of the Preventive Maintenance in this area should

avoid normal operational damage, however parts may be subjected
to damage as a result of Tramming around the drilling site or
through the drilling process. The operator must monitor and initiate
repair of any damage from these causes as soon as necessary.
The Winch is mounted on the top of the mast to facilitate the handling of
rods and casings and for handling of the SPT Auto Hammer.
Winch and Wire Rope.

The condition of the winch cables must be inspected every day
that it is used. Kinks in the cable must immediately be straightened
out. Frayed cables and cables where kinks have remained
should be replaced or the damaged end of the cable discarded.
Cables should be inspected for signs of corrosion and replaced if
necessary.
Never splice a cable; all the cable on the drum must be one piece.
There should always remain at least 5 wraps of the cable on the
drum at any time.
When spooling new cable:
Tension must be placed on the cable to ensure proper ‘level
wind’ spooling onto the winch drum. The cable must be spooled
in a counterclockwise direction as viewed from the motor input.
Replacement cable should be 8 mm (5/16”)diameter, and the drum
has a capacity of approximately 65 metres(213ft).
108
!
Regular Service -
Weekly - clean and lubricate the Jacks

Inspection - Observe the cylinders in operation, look for any
looseness or seizure in the Pivoting foot. Examine the Cylinder
Rods for pitting or damage and look for oil leaks, observe the
cylinders for excessive sinking which could mean Piston seal
internal bypass leakage (a small amount of sinking overnight is
normal).
If any swivelling foot is seized or loose consider the safety aspect,

ie. if severely sloppy or totally seized, strip out the joint and re-new
the bearing, and fixings. Leaks in hydraulic cylinders can lead to
unsafe conditions (ie. sinking under load and oil contamination),
prevent this by re-sealing the affected cylinder. Load controls may
not seal if the oil is dirty, Thoroughly de-pressurise the cylinder
before removing any load control. Clean and check for damage and
replace or re-new.
Repairs -
Other than negligence of the Preventive Maintenance, this area

should be free from damage, however if a part should be subjected
to damage from external forces, then the assembly will need to be
examined thoroughly and any distorted part replaced or
refurbished.
Lubrication
Points
Rear Levelling Jacks Front Levelling Jack
109
!
Regular Service -
Daily - Thoroughly clean off any debris from the Main Frame and
Tracks ( see Track manual for full instructions on Track servicing,
especially Track tensioning, and Track drive gearbox servicing
pages). Prior to start-up walk round the Rig and check for any
damage or anything out of place. Look for any new oil spills as an
early indication of problems.
Weekly - Check over the Main Frame for damage. Clean and
lubricate the cylinder clevises
If any pivots or clevises are seized or loose consider the safety

aspect, ie. if severely sloppy or totally seized, strip out the joint and
re-new the Pin, Bushes and fixings. Leaks in hydraulic cylinders
can lead to unsafe conditions (ie. sinking under load and oil
contamination), prevent this by re-sealing the affected cylinder. See
separate sections for Engine, Hydraulic Pump, Water/Mud Pump,
and Winch.
Inspection
Observe the Rig when in tramming mode, look for loose parts,
sloppy cylinders and rattling joints. Examine cylinder rods for
pitting or damage and look for oil leaks, observe the cylinders for
excessive sinking which could mean Piston seal internal bypass
leakage or damaged Load Control cartridges (a small amount of
sinking overnight is normal)
Repairs -
Observance of the Preventive Maintenance in this area should

avoid normal operational damage, however parts may be subjected
to damage as a result of Tramming around the drilling site or
through the drilling process. The operator must monitor and initiate
repair of any damage from these causes as soon as necessary.
110
Lift engine bay top cover for easy access. Top up with water / antifreeze
mix if required.
Top up if required (see recommended oils for type).
Look around and underneath the Engine.
Check for water and contaminant presence. Clean if required.
Check after operating the rig for some hours. Temp should be below 60
degrees C. at all times.
Replace the filter when the indicator on top of the filter is red. Mark
engine hrs on filter. Notify Supervisor.
Ensure no debris is present between tracks, tread is more than 10mm,

no cuts in tracks, no oil leakages, no loose or excessively worn parts.
Prime with water/antifreeze mix as necessary.
Check tank, tank cover, hoses, valves, fittings for damage, leakages
and loose parts.
Check frame, hoses, pivots, cylinders, motors for damage, excessive

wear and loose parts. Check for oil leakage as an early indication
of problems.
Check frame, hoses, hoisting cable and hook assembly for damage,
excessive wear and loose parts. Check for oil spots around motor
and gearbox.
Check mast frame, hoses, cylinders, water swivel, pivots for damage,
excessive wear and loose parts and bolts. Check for oil spots around
motors, cylinders and seals. Check if all flange bolts are tight. Centralise
Sonic head and torque the Head spindle nut if required. See section
previous instructions.
Lift tracks of the ground with stabilizers and check for excessive sagging
(more than approx. 30mm) of bottom track half. To adjust: Remove
cover plate from side of track frame. Connect grease gun to nipple and
pump to 250 bar or until grease runs out of release valve. See Operator
manual Tracks section.
111
Check frame, hoses, water swivel, pivots for damage, excessive wear
and loose parts. Check for oil spots around cylinders.
Tension chain if it is slack when travelling head down (without load).

2 large adjustment nuts are on top plate of mast (note 3 % maximum
stretch.
With one roller touching mast slide, clearance of other roller should be
1mm. If not adjust.
Adjustment eccentric is located at
the lower pin of the tip-out cylinder. Loosen bolts that secure eccentric
and turn this via the large hexagonal at the back. Re-tighten the
securing bolts.
Adjust by loosening top allen bolts that hold the head float shafts. Turn
the adjustment bolts in/out as required. Ensure both head float shafts
are aligned symmetrically by counting exposed threads on adjustment
bolts before tightening large allen bolts.
See chapter 5.4.6.1
Check case, hoses and fittings for damage, excessive wear and loose
parts. Check for oil spots around motor and gearbox. Check FMC Pump
Crankcase Oil Level Level plug. Also check for contamination with
water.
Check cases, hoses and fittings for damage, excessive wear and loose
parts. Check for oil spots around motor and gearbox. Check Bredel
Pump Glycerin Level through Window
Check frame, hoses, pivots for damage,
excessive wear and loose parts. Check for oil spots around motors,
cylinders and seals. Lubricate Feed Chain With mast upright raise head
to top. Apply motor oil with brush on chain at bottom pulley while slowly
lowering head. Put mast in horizontal position and apply oil with brush
on top chain. Lubricate SPT Chain. Lower the mast into the horizontal
position and move weight to the top position. Apply motor oil onto chain
with brush. DO NOT DO THIS WITH MAST UPRIGHT AS WEIGHT
DROPPING ONTO UNSUPPORTED ANVIL WILL CAUSE DAMAGE.
In the interests of safe operation of the rig and

traceability of completed maintenance tasks it
is suggested that a Pre-Shift Inspection Form is
compiled as part of the work schedule of the drilling crew. The following
format would give a continuous monitoring procedure for the care and
maintenance of the drill rig. Note this is a suggested format and the
instructions given in the manuals for proprietary items such as engine,
tracks and pumps must take precedence.
112
A pre-shift inspection must be performed at the start of each shift or day. Turn it in with the job file or fax to
office weekly.
Pre-Shift Carried out by Rig No.

Date Engine Hours
Job No. Next Service Due (every 100h)
Site Name/Client
Coolant Level Hydraulic Hose Condition OK

Engine Oil Level Tracks OK - No Debris / Dirt on Inside Track
Fuel Pre-Filter OK Fuel Level
Engine Hoses OK - Water/Fuel/Air/Exh. Guards & Rotation Barrier in Place
Hydraulic Pressure Filter Indicator Green Hydraulic Stabilizer Pads Used
Hydraulic Components - No Leaks Winch Cable & Safety Hook OK
Emergency Shutdown Switches Checked

Hydraulic Oil Temperature below 80 Degree C
Fire Extinguishers (incl. current inspections) Site Clean & Orderly - No Trip Hazards
First Aid, CPR, Bloodborne Pathogens Kits Proper PPE Available / Worn By Crew
Eye Wash Utilities Located - Safe Distance / Clearance
Hospital Route Exclusion Zone Delineated
Safety Meeting Held Proper Fuel Storage
JSA Reviewed (nrs)
Support Vehicle No. Truck No.

Mileage / km m Mileage / km m
Next service due (3500m) m Next service due (3500m) m
Daily Inspection Carried Out Daily Inspection Carried Out
Operators Manual and Inspection Book in Cab Operators Manual and Inspection Book in Cab
113
Replace Hydraulic Pressure and Return Oil Filter
Mark engine hrs on filter.
Check Undercarriage Bolt Torques
Check all bolts on undercarriage with torque wrench.
Torques shown in rig manual section Tracks
Check Oil Level in Track Gear Units Take out centre plug of gear unit;
oil level should just reach hole. Top up with Statoil 80W90 - (SAE90) if
required.
Check Bredel Pump Gearbox Oil Level Take out level plug at side of
gearbox; oil level should just reach hole. Top up if required.
Check SPT Chain Tension Position chain so that drop weight is not
lifted up. Check chain tension by prying the chain off back in the
centre with screwdriver. If sloppy tighten chain at bottom pulley; do not
overtighten and re-check.
Replace Engine Oil and Oil Filter see Cummins Manual. Oil: Statoil
MaxWay E6 5W-30 15L
Replace FMC Pump Crankcase Oil Also clean magnetic drain plug.
Check for larger steel parts. Oil: Statoil 10W40 - (SAE30)
Check Battery Acid Level

Check Air Filter Check filter cartridge for damage and empty rubber
outlet at bottom filter cover.
Check Undercarriage Bolt Torques
Check all bolts on undercarriage with torque wrench. Torques shown in
rig manual Track section
Check Winch Gearbox Lubricant Level See Winch Ops. Manual Top up
if required.
Replace Hydraulic Oil and Filters

Replace Oil in Track Gear Unit Oil: Statoil 80W90 - (SAE90).
Replace Bredel Pump Gearbox Oil Oil: Statoil 80W90 - (SAE90).
114
Oil: Chevron Ursa Ultra 10W-40, 12-14L. Fill new filter with new clean oil
before mounting it. Mark engine hrs on filter. Cummins Manual.
Fill new filter with clean diesel before mounting it. Mark engine hrs on
filter.
Replace outer filter cartridge only. Mark engine hours on filter.
Clean block and fins with pressure washer. Take care not to damage
fan.
Also clean magnetic drain plug; check for larger steel parts.
Ventilating filter is inside breather on top of the tank.
Contact Supervisor.
Oil: Statoil 80W90 - (SAE90). Rig manual Tracks
With mast in vertical position and head down measure and replace if
required as shown in section 3.
Chevron Meropa 150. Rig manual
Lube: Bredel Genuine Lubricant (5L). Rig manual
Contact Supervisor.
115
Clean tank on the inside with lint-free cloths. Be
sure to remove all sludge and debris, report metal particles. Fill with new
oil via filter and pump.
Cleaning the Oil Tank
Required at every oil change.

Use only lint-free cleaning rags.
Thoroughly check cleanliness.
Filling the Oil Tank
Be sure to fill only through filter.

New oil is always contaminated!
Condensation
High humidity and extreme fluctuations in oil temperature often create

condensation.
Water present in the oil leads to saponification and frothing, and
subsequent cavitation and damage of pumps.
Check the condition of the oil visually at the filling level indicator.
Park drill rig on incline and let oil in tank settle.
Drain the oil/water mixture and dispose of according to environmental

stipulations.
116
Please refer to the following list when
selecting hydraulic fluids from leading manufacturers. Other non-
listed hydraulic fluids may also be used, providing they meet the
quality standard of the oils indicated below. Boart Longyear strongly
recommends using hydraulic oils of class (ISO 4406)-17/15/13.
STATOIL HYDRAWAY BIO SE 32-68 *
AGIP OSO 32
ARAL VITAM HF 32, VITAM GF 32, VITAM DE 32
BP ENERGOLHLP 32, ENERGOL HLP-D32,BARTRAN HV 32
CHEVRON EP OIL 32, EP OIL 32HV
ESSO NUTO H32, UNIVIOS N32
MOBIL DTE 13, DTE 24
SHELL TELLUS OIL 32, HYDROL DO32
TEXACO RANDO OIL HD A-32
AGIP OSO 46, ANICA 46

ARAL VITAM HF 46, VITAM GF 46, VITAM DE 46
BP ENERGOLHLP 46, ENERGOL HLP-D46,BARTRANHV 46
SHELL TELLUS OIL 46, HYDROL DO 46
STATOIL HYDRAULIC SUPER 46*
STATOIL HYDRAWAY HVX-46
AGIP OSO 68
ARAL VITAM GF 68, VITAM DE 68
BP ENERGOLHLP 68, ENERGOL HLP-D68,BARTRAN HV 68
SHELL TELLUS OIL 68, HYDROL DO 68
STATOIL HYDRAULIC SUPER 68
Rigs are Factory filled with Lubricants marked’*’
Please refer to the following list when selecting Gear oil or Grease.
Other non-listed lubricants may be used, providing they meet the quality
standards indicated below. Boart Longyear strongly recommends using
Gearbox Oils of class SAE 80W-90 conforming to DIN 51517 Part 3
CLP,and Muti-purpose Lithium based Grease for general lubrication
and protection.
BP ENERGEAR HT80W-90 ENERGREASE LS3

CHEVRON DELO ESI 80W-90 DELO EP NLG1
ESSO GX 80W-90 RONEX EXTRA DUTY
MOBIL GX 80W-90 XHP 220
SHELL MALLEUS ALVANTA
STATOIL GEAR EP5 80W-90* MOLYWAY LI 752
117
Note - This table gives a typical list of the general lubrication
requirements for the BL series of Drill rig, please refer to the relevant
section of this Operator Manual for specific instructions on ancillary Drill
rig components such as Winches, Hoists and Water/Mud Pumps.
Diesel Engine See engine manual
Levelling Jacks - -
Cylinder Rods Coat with grease Thin film
Clevises Grease gun Fill
Pivots Grease gun Fill
Slideways Coat with grease Thin film
Rollers Coat with grease Thin film

Tramming gear See Track manual
- -
Mast slides Coat with grease Thin film
Support slides Coat with grease Thin film
Feed chain Coat with oil Thin film
Rope pulleys Coat with grease Thin film
See separate manual
Grease gun Fill
- -
Jaw slides Coat with grease Thin film
Breaker bearing Coat with grease Thin film
- -
Jaw slides Coat with grease Thin film
- -
Slides Coat with grease Thin film
Chains Coat with oil Thin film
118
Component Part Number Designation Quantity
Engine 6005053 Statoil MaxWay E6 5W-30 15 litres
Hydraulic Oil 4200778 Hydraway HVX68
Hydraulic Oil 9014127 Hydraway HVX46 373 litres
Hydraulic Oil 9013666 Hydraway SE32-68
Deisel Oil 56311001 190 litres
Crawler Gear Box 56311028 Statoil 80W90 - (SAE90)

Refer to Crawler Ops Manual
Winch, P9 Grease Refer to Winch Ops Manual
Mud Pump FMC E04 9016145 Statoil 10W40 - (SAE30) 0.95 litres
Mud Pump FMC L09 9016145 Statoil 10W40 - (SAE30) 2.1 litres
119
120
6.1.1 No Pressure .................................................................................. 123
6.1.2 Flow low or Pressure fluctuating ................................................... 124
6.1.3 Valves not operating correctly ...................................................... 124
6.1.4 Hydraulic oil temperature too high ................................................ 124
6.1.5 Leakage from drillhead ................................................................. 125
6.1.6 Noises from pumps, no oil supply ................................................. 125
6.1.7 Engine stalling .............................................................................. 126
Table 6–1: Troubleshooting “No Pressure” Situations ....................................... 123

Table 6–2: Troubleshooting “Fluctuating Pressure” .......................................... 124
Table 6–3: Troubleshooting Valve Operation .................................................... 124
Table 6–4: Troubleshooting High Oil Temperature ........................................... 124
Table 6–5: Troubleshooting Drillhead Leakage ................................................. 125
Table 6–6: Troubleshooting Pump Noises ........................................................ 125
Table 6–7: Troubleshooting Engine Stalling ...................................................... 126
121
Copyright © 2015 Boart Longyear. All rights reserved. 20150301
Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
122
Do not attempt to repair everything yourself. If you are not fully familiar
with the item or do not have the right tools, you may cause greater
damage. It is no disgrace not to be familiar with every machine. If in
doubt, contact the Boart Longyear Service Section.
Insufficient pump Air entering suction line Seal suction line

capacity
Too high pump Pump damaged Replace / repair
temperature Viscosity of fluid too low Change hydraulic oil
Pump rpm too low Pump gear box or Replace / repair
or insufficient engine engine damaged
capacity
Leakage from pressure Wrong pressure Apply correct
to return lines setting pressure
Valve not closing Clean valve
Blocked by dirt or Assess damage / repair
particles
Damaged cylinder bore Replace damaged
piston rod or piston components
seals
123
Valve sticking Contaminated hydraulic Drain hydraulic oil
oil Clean tank and
components, fill with
new oil
Air enclosure in System not properly Bleed system
system causing jerky
movements
ventilated
Valves knocking Valve seat(s) damaged Replace / Repair
Valve spool wedging Contamination Remove piston and

clean the valve
Hydraulic oil Cool oil to 50° c
temperature too high
No pilot pressure Check pilot pressure
(or insufficient pilot
pressure)
Insufficient cooling Cooler motor damaged Replace / Repair

Cooler fins are dirty and Clean cooler fins
closed
Hydraulic fluid Fluid level in tank too Replenish hydraulic oil
circulating too fast low to required level
Fluid is dumped to Malfunction of valve Clean and repair or
tank via valves under caused by dirt or replace damaged
pressure damaged components components
Pressure setting too low Adjust to right pressure
setting
124
Leakage from spindle Seal rings worn Replace upper and
lower rings
Leakage from space Case drain too small Check limits 0.7 to 1.5 l/
hydraulic motor min
Shaft seal worn Replace hydraulic motor
Leakage from water Damaged packing Replace packing
flushing head
Blocked up flushing Damaged bearings Replace bearings
head
Pump rotation in wrong Suction and pressure Change connections

direction line exchanged
Hydraulic fluid frothing Fluid level too low Replenish with correct
hydraulic oil
Wrong hydraulic fluid Replace with correct
hydraulic oil
Air entering suction line Check and
or suction line Porous tightenconnections
Repair or replace
Engine defective Damaged or worn out Repair or replace
Mechanical vibrations Couplings damaged or Repair or align as
misaligned required
Vibrations caused by Tighten connection or
swinging replace hydraulic hoses
or lines
Cavitation of pump Restriction in suction Open stop- cock fully
line i.e. partially closed
stop- cock
Hydraulic fluid too cold Pre-heat oil to be
required
Damaged tubes or Replace tubes/hoses
hoses
Pump defective Damaged or worn out Repair or replace
125
Engine stalls shortly Operating too soon after After engine has started
after start-up start-up raise to 1200 until
the red ignition light
extinguishes
126
127
128
129
Portal Riesco
Av. El Salto 4001, Floor 8
Huechuraba, Santiago
info@boartlongyear.com
Tel: +56 2 595 3300
12 Avenue des Morgines
CH1213 Petit-Lancy, Geneva
Switzerland
infoEU@boartlongyear.com
Tel: +31 077 850 58 50
Fax: +31 077 850 58 51
Cycad House, Constantia Office Park
Cnr 14th Avenue and Hendrik Potgieter

Weltevreden Park, 1709
Gauteng, South Africa
infosa@boartlongyear.com
Tel: +27 11 767 9300
Fax: +27 11 767 9301
130
131
132
133

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THIS PAGE INTENTIONALLY LEFT BLANK

Non-authorised personnel MUST NOT under any circumstances

Safety Precautions listed in the manual are intended to alert the

Safety First must always be the primary consideration of all

Since these Safety Precautions cannot cover every possible

Hazard signal Words and Warnings

The signs DANGER, WARNING, CAUTION and NOTICE are

2.2.1 Cautions and Warnings .................................................................. 28

2.4.1 In the event of an Emergency Stop ................................................ 35

2.6.1 Danger Zone ................................................................................... 40

Figure 2–1: Location of Warning Signage......................................................... 22

3.6.1 General rules for Feed chains: ....................................................... 54

4.4.1 Stabilizer Jacks ............................................................................... 77

4.5.1 Travelling on Slopes ....................................................................... 77

4.6.1 Prior to Start up .............................................................................. 79

4.7.1 Tramming Tracking Hazards ........................................................ 82

4.9.1 Safety Cage – Restricted Operation ............................................... 84

Figure 4–2: General View of Driller Panel ......................................................... 72

5.4.1 Repairs to Hydraulic Components .................................................. 94

5.5.1 Pre-Shift Inspection Form (Example only) .................................... 112

6.1.1 No Pressure .................................................................................. 123

Table 6–1: Troubleshooting “No Pressure” Situations ....................................... 123

b. Capital Equipment. Boart Longyear warrants that the capital

c. General Terms. Boart Longyear further warrants that, to the

(ii) upon receipt of an approved authorization code from Boart Longyear,

(iii) with respect to consumable products purchased through an

(i) normal wear and tear;

(ii) corrosion, abrasion or erosion;

(iii) any goods, components, parts, software or services which, following

(iv) defects resulting from Purchaser’s specifications or designs or those

(v) defects associated with consumable parts or materials, the lifetime of

(vi) defects associated with Purchaser’s specifications or designs or

(vii) defects resulting from the manufacture, distribution, promotion or

(d) Sourced Goods. If the defective parts or components are not

Boart Longyear Global Headquarters,

Minisonic SPT Test Rig Hinged Safety Safety

Drill Mast Crawler Front Stabilisers Driller Panel

The LS250 Minisonic drill rigs are designed to operate fully

Safety Grout Pump Water Pump Engine Compartment

The main power source is an liquid-cooled diesel engine, which drives

The drill rig electrics are:- 24V DC

Maximum Drilling Diameter 305 mm 12 in

Pull Back 66 kN 14838 lbf

Down Force 24 kN 5395 lbf

Maximum Casing Length 3m 10 ft

DIMENSIONS AND WEIGHTS

Dry weight - 11,500 kg (25,300 lbs)

Crawler - Standard Unit - Track One

* Dimensions and weights may vary depending on options and should

Standard Unit - Cummins QSB liquid cooled, turbo charged, charge

2 X 75 cc (/rev = 150 l/min @ 2000 rpm (Crawler + Sonic

HYDRAULIC SYSTEM - Open Loop:

1 Load Sense Pump 75 cc/rev 205 bar (3000 psi)

1 Gear pumps 19+16 cc/rev 205 bar (3000 psi)

DRILL MAST AND FEED SYSTEM WITH FEED CYLINDER

Total Length 7,18 m (23,56 ft)

Line Pull - Bare Drum 11,000 N 2,472 lb

Rod Clamps - 2 (dual cylinders-top and bottom)

Type - SPX40 Hose Pump

Type - Triplex FMC E0413

Voltage - 230 V / 400 V

The Rig may need to be off-loaded either by Lifting or by Driving,

Consult with a specialised lifting company for suitable spreader