LF230 Manual de Operaciones y Servicios (2016) - 1

GLOBAL DRILLING PRODUCTS
Copyright © 2016 Boart Longyear. All rights reserved.
LF230 DIAMOND CORE DRILL

OPERATIONS AND SERVICE MANUAL
P/N: 5006655
DECEMBER 2016
Table of Contents
Chapter 1: Safety
1.1 Important Safety Information..................................................................... 3
1.1.1 Hazard Signal Indicators................................................................. 3
1.1.2 Safety Guidelines............................................................................ 4
1.1.3 Safety Labels................................................................................... 5
1.1.3.1 Personal Protective Equipment (PPE).................................. 11
1.1.4 Inspect Safety Decals/Labels........................................................ 12
1.2 Personal Protective Equipment............................................................... 12
1.3 Emergency Stops...................................................................................... 14
1.3.1 Position of Emergency Stops........................................................ 14
1.3.2 Operation of the Emergency Stops............................................... 16
1.3.3 In the Event of an Emergency Stop............................................... 17
1.3.4 Restarting after an Emergency Stop............................................. 17
1.4 Battery Isolator.......................................................................................... 17
1.5 Rotation Barrier......................................................................................... 18
1.6 Safety Requirements................................................................................ 19
1.6.1 Safety Precautions........................................................................ 19
1.6.2 Safety Precautions for a Truck-Mounted Drill................................ 21
1.6.3 Safety Precautions for a Track-Mounted Drill................................ 21
1.6.4 Specific Safety Instructions for Drilling.......................................... 22
1.6.5 Hazards......................................................................................... 23
1.6.5.1 Hydraulics............................................................................. 23
1.6.5.2 Replacement of Worn Parts.................................................. 23
1.6.5.3 Safety Devices...................................................................... 24
1.6.5.4 Welding................................................................................. 24
1.6.5.5 Operation.............................................................................. 24
1.6.5.6 Operating Instructions........................................................... 24
1.6.5.7 Danger Zone: 2.5 Meters Around the Rig............................. 24
1.6.5.8 Safety Distance..................................................................... 25
1.6.5.9 Noise and Vibration Levels................................................... 25
iii
Copyright © 2007, 2011, 2016 Boart Longyear. All rights reserved. P/N 5006655
Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Table of Contents
1.6.5.10 Transport of Persons............................................................ 25

1.6.5.11 Stability................................................................................. 25
1.6.5.12 Conduct in Case of Fire........................................................ 26
1.6.5.13 Fire Extinguisher Instructions................................................ 26
1.6.5.14 Operation of LF230 Drill Rigs................................................ 26
1.6.5.15 Securing Against Fall............................................................ 27
1.6.5.16 Signalling.............................................................................. 27
1.6.5.17 Utility Lines............................................................................ 27
1.6.5.18 Working Near Overhead Lines.............................................. 28
1.6.5.19 Operational Intervals............................................................. 28
1.6.5.20 Mixing Drilling Mud or Drilling Additives................................ 28
1.7 Extreme Environmental/Job Site Conditions......................................... 29
1.7.1 Extremely Dusty Working Conditions............................................ 29
1.7.2 Warm to Hot Ambient Air Temperature......................................... 29
1.7.3 Extremely Cold Ambient Temperature.......................................... 29
1.7.4 Working in Salty Atmosphere........................................................ 30
Chapter 2: Introduction
2.1 Using this Manual..................................................................................... 33
2.2 Abbreviations Used in This Document................................................... 34
2.3 Prior to First Use....................................................................................... 34
2.4 Ordering and Returning Parts.................................................................. 34
2.4.1 Ordering Parts............................................................................... 34
2.4.2 Returning Parts............................................................................. 35
2.5 Limited Warranty....................................................................................... 35
Chapter 3: Component Description

3.1 General Description/Statement of Use.................................................... 41
3.2 General Drill Arrangement....................................................................... 41
3.3 Decals Used on the Rig............................................................................ 44
3.4 Drill Mast Component Description.......................................................... 52
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Table of Contents
3.4.1 Drill Head....................................................................................... 52

3.4.2 Rotation Barrier............................................................................. 55
3.4.3 Mainline Hoist................................................................................ 56
3.4.3.1 Wire Rope (Mainline)............................................................ 57
3.4.4 Crown Block Assembly.................................................................. 58
3.4.5 Foot Clamp.................................................................................... 59
3.4.6 Rod Tray........................................................................................ 60
3.4.7 Wireline Winch.............................................................................. 60
3.5 Mast Pivot.................................................................................................. 62
3.6 Mast Dump Feature................................................................................... 62
3.7 Fluid Circulation Pump............................................................................. 63
3.8 Controls..................................................................................................... 63
3.8.1 Operator Control Panel (OCP)...................................................... 63
3.8.1.1 Description of Controls.......................................................... 64
3.8.2 Drill Rig Set-Up Controls V40........................................................ 70
3.9 Track Package (Optional)......................................................................... 70
3.10 Rod Racking Platform (Optional)............................................................. 71
3.11 Power Unit - Cummins QSC 8.3L TIER III Engine................................... 73
3.11.1 Engine Control Panel (ECP) Tier III Model.................................... 75
3.11.2 Engine Control Monitor (Canvu Tier III Engine Only).................... 77
3.11.2.1 Preferred Screen Store......................................................... 78
3.11.2.2 Keys 1 to 4 Operation........................................................... 78
3.11.2.3 Adjust Lighting and Contrast................................................. 79
3.11.2.4 Language Support................................................................ 79
3.11.2.5 Quad Analog View (Screen 1).............................................. 79
3.11.2.6 Quad Digital View (Screen 2)................................................ 81
3.11.2.7 Single Analog View (Screen 3)............................................. 81
3.11.2.8 Alarm Screen 4..................................................................... 82
3.11.2.9 Top Level Menu.................................................................... 84
3.11.2.10 Settings Menu and Sub Menu............................................... 85
3.11.2.11 System Menu and Sub-Menus.............................................. 86
3.11.2.12 Database Viewer/Display Mapping....................................... 87
3.12 Power Unit - Cummins QSL 9.0L Tier 4i Engine..................................... 87
v
Table of Contents
3.12.1 Engine Control Panel (ECP) Tier 4i Model.................................... 90

3.12.2 Engine Control Monitor (Murphy Tier 4i Engine Only)................... 92
3.12.2.1 Engine and Transmission Parameters.................................. 93
3.12.2.2 Navigation and Keypad Functions........................................ 94
3.12.2.3 First Time Startup................................................................. 96
3.12.2.4 Gauge Displays..................................................................... 96
3.12.2.5 Adjusting the Menu Selections.............................................. 99
3.12.2.6 Acknowledging Faults......................................................... 104
Chapter 4: Operation
4.1 Introduction............................................................................................. 109
4.1.1 Safeguards.................................................................................. 109
4.1.2 Routine Checks........................................................................... 109
4.1.2.1 Wire Rope Care.................................................................. 110
4.2 Visual Inspection of Masts..................................................................... 110
4.3 Transporting the Drill Site to Site.......................................................... 113
4.3.1 Lifting the Drill.............................................................................. 113
4.3.2 Truck Transport (Shipping).......................................................... 114
4.3.3 Driving a Truck Mounted Drill...................................................... 114
4.3.4 Driving a Track Mounted Drill...................................................... 115
4.3.4.1 Operating the Track Drive Control...................................... 118
4.3.4.2 Activating the Transmitter................................................... 118
4.4 Configuring the Drill Based on Rod Type............................................. 119
4.4.1 Chuck Jaws................................................................................. 119
4.4.2 Upper Chuck Guide Bushing....................................................... 119
4.4.3 Lower Spindle Guide Bushing..................................................... 120
4.4.4 Foot Clamp Slip Sets................................................................... 120
4.4.5 Hoist Plug Bullnose Sub.............................................................. 121
4.4.6 Water Swivel Adapter Sub.......................................................... 121
4.4.7 Overshot...................................................................................... 121
4.5 Pre-start Checklist.................................................................................. 121
4.6 Starting the Drill...................................................................................... 123
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Table of Contents
4.7 Raising The Mast..................................................................................... 124

4.8 Casing/Rod Guide Bushing.................................................................... 127
4.9 Opening the Drill Head........................................................................... 127
4.10 Making Head Float Adjustments............................................................ 128
4.10.1 Head Float Up Adjustment.......................................................... 129
4.10.2 Head Float Down Adjustment...................................................... 130
4.11 Mud Mixer Control................................................................................... 131
4.12 Shifting the Head Gear Range............................................................... 132
4.13 Rod Make-up Torque.............................................................................. 133
4.14 Drilling...................................................................................................... 134
4.14.1 Fluid Circulation........................................................................... 134
4.14.2 Fine Feed Drilling Control............................................................ 135
4.14.3 Fine Feed Rate Valve V26.......................................................... 136
4.14.4 Fine Feed Pressure Control V25................................................. 137
4.15 Calculating the Weight on Bit................................................................ 138
4.16 Inserting the Core Barrel........................................................................ 140
4.17 Rod Making.............................................................................................. 141
4.17.1 Rod Lowering (Rod Making)........................................................ 142
4.18 Rod Breaking........................................................................................... 143
4.18.1 Rod Pulling (Rod Breaking)......................................................... 143
4.18.2 Breaking Casing Under the Mast................................................ 144
4.19 Retrieving the Inner Tube....................................................................... 145
4.20 Hoisting.................................................................................................... 146
4.20.1 Stacking Drill Rods...................................................................... 147
4.21 Shutting Down the Drill.......................................................................... 147
4.22 Lowering the Mast................................................................................... 148
4.23 Refueling the Rig: Safety Precautions.................................................. 148
4.23.1 Fueling Safety............................................................................. 149
4.23.2 Emergency Equipment................................................................ 149
4.23.3 Filling a Container....................................................................... 149
4.23.4 Fueling Facts............................................................................... 150
4.23.5 Emergency Procedures............................................................... 150
4.23.5.1 Fuel Spill............................................................................. 150
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Table of Contents
4.23.5.2 Fire...................................................................................... 151
Chapter 5: Hydraulic System

5.1 Hydraulic Reservoir................................................................................ 157
5.1.1 Hydraulic Reservoir Oil Filling Procedure.................................... 157
5.2 Hydraulic Valves..................................................................................... 158
5.2.1 D05 Manifold............................................................................... 159
5.2.2 V7 Fluid Circulation Pump Flow Control...................................... 161
5.2.3 V9 Fine Feed - Control Valve (Drilling)........................................ 162
5.2.4 V10 Mud Mixer - Control Valve................................................... 162
5.2.5 V11 Head Opener - Control Valve............................................... 162
5.2.6 V12 Rod Slide - Control Valve..................................................... 162
5.2.7 V13 Foot Clamp - Control Valve.................................................. 162
5.2.8 V14 Chuck - Control Valve.......................................................... 162
5.2.9 V15 Pressure Reducing Valve - Chuck....................................... 163
5.2.10 V16 Mainline Hoist Manual Brake Release Valve....................... 163
5.2.11 V18 Pressure Reducing Valve - Foot Clamp............................... 164
5.2.12 V19 Pressure Reducing Valve - Rod Slide.................................. 165
5.2.13 V20 Counterbalance Valve - Rod Slide....................................... 166
5.2.14 V21 Pressure Reducing Valve - Head Opener............................ 166
5.2.15 V22 Counter Balance Valve - Head Opener............................... 166
5.2.16 V23 Mud Mixer - Speed Control Valve D05 Manifold.................. 167
5.2.17 V24 Mud Mixer - Sequence Valve............................................... 167
5.2.18 V25 Fine Feed Pressure Control - D05 Manifold........................ 167
5.2.19 V26 Fine Feed Rate Control - D05 Manifold............................... 168
5.2.20 V28 Float (Thread Making/Breaking).......................................... 168
5.2.20.1 Rod Making/Breaking Adjustment....................................... 169
5.2.20.2 Rod Making Adjustment (V28)............................................ 170
5.2.20.3 Rod Breaking Adjustment (V28)......................................... 170
5.2.21 V29 Solenoid Valve - Rod Making/Breaking............................... 170
5.2.22 V31 Wireline Hoist Counterbalance Valve.................................. 171
5.2.23 V32 Pressure Reducing Valve, Hoist Brake Release.................. 171
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Table of Contents
5.2.24 V33 Main Line Cable Tension (Pressure Relief Valve)............... 171
5.2.25 V34 Mainline Hoist Displacement Control................................... 171
5.2.26 V35 Rotation Torque Limiting Valve-Thread Making................... 171
5.2.27 V36 Mainline Hoist Counterbalance Valve.................................. 173
5.2.28 V37 Main Relief - Fluid Circulation Pump.................................... 173
5.2.29 V40 Auxiliary Control Valve - Drill Setup..................................... 174
5.2.30 V41 Counterbalance Valves - Mast Raising Cylinder.................. 174
5.2.31 V43 Diverter Valve...................................................................... 174
5.2.32 Main Valve Bank V44.................................................................. 175
5.2.33 Main Hoist (V44-01/V44-02)........................................................ 175
5.2.33.1 Setting Flow Rate................................................................ 175
5.2.34 Wireline Hoist (V44-03)............................................................... 176
5.2.35 Fast Feed (V44-04)..................................................................... 177
5.2.36 Rotation Circuit (V44-05)............................................................. 178
5.2.37 V44-06 Auxiliary - Main Control Valve......................................... 180
5.2.38 V46 Main Relief P1 Circuit.......................................................... 180
5.2.39 V47 Auxiliary Relief Valve Adjustment - P3 Circuit..................... 181
5.2.40 V48 Primary Cooler Fan Circuit Relief Valve.............................. 182
5.2.41 V54 Traction Control Valve (Optional)......................................... 182
5.3 Counterbalance Valves........................................................................... 182
5.3.1 Setting Counterbalance Valves................................................... 182
5.4 Hydraulic Pumps..................................................................................... 183
5.4.1 Primary Pump (P1)...................................................................... 183
5.4.2 Secondary Pump (P2)................................................................. 184
5.4.3 Auxiliary Pump (P3)..................................................................... 185
5.4.4 PTO Pump (P4)........................................................................... 186
5.4.5 Optional Pump (P5)..................................................................... 187
5.4.6 Head Lubrication Pump (P6)....................................................... 187
5.4.7 Hydraulic Filler Pump (P7).......................................................... 187
5.5 Fluid Conditioners and Filters............................................................... 187
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Table of Contents
5.5.1 C1 Main Hydraulic Cooler........................................................... 188

5.5.2 C2 Primary Pressure Filter.......................................................... 188
5.5.2.1 Filter Element Change Procedure....................................... 188
5.5.3 C3 Main Return Filter.................................................................. 190
5.5.3.1 Filter Element Change Procedure ...................................... 190
5.5.4 C4 Hydraulic Tank Filler Filter..................................................... 192
5.5.5 C5 Hydraulic Reservoir Breather................................................. 192
5.5.5.1 Filter Change Procedure .................................................... 192
5.5.6 C6 Drill Head Lubrication Oil Filter.............................................. 192
5.5.7 C7 Head Cooler Hydraulic........................................................... 192
5.6 Motors...................................................................................................... 193
5.6.1 M1 Main Rotation Motor ............................................................. 193
5.6.1.1 Minimum Displacement Adjustment Procedure ................. 193
5.6.1.2 Maximum Displacement Adjustment Procedure ................ 194
5.6.1.3 Rotation Speed Control Range Adjustment........................ 194
5.6.2 M2 Mainline Hoist Motor ............................................................. 195
5.6.3 M3 Wireline Winch Motor ........................................................... 195
5.6.4 M4 Water Pump Motor................................................................ 195
5.6.5 M5 C1 Cooler Fan Motor ............................................................ 195
5.6.6 M6 Mud Mixer Motor (Optional)................................................... 196
5.7 Actuators................................................................................................. 196
5.7.1 A1 Feed Cylinders....................................................................... 196
5.7.2 A2 Hydraulic Chuck..................................................................... 197
5.7.3 A3 Foot Clamp Cylinders............................................................ 197
5.7.4 A4 Head Opener Cylinder........................................................... 197
5.7.5 A5 Rod Slide Cylinder................................................................. 197
5.7.6 A6 Mast Raising Cylinders.......................................................... 198
5.7.7 A7 Mast Dump Cylinders............................................................. 198
5.7.8 A8 Mast Extension Cylinder........................................................ 198
5.7.9 A9 Jack Cylinders (Optional)....................................................... 199
5.7.10 A10 Outrigger Cylinders (Optional)............................................. 199
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Table of Contents
Chapter 6: Electrical System

6.1 Electrical Control System....................................................................... 203
6.2 Fast/Slow Selector Switch...................................................................... 204
6.3 Winch Joystick Switch........................................................................... 206
6.4 Wireline/Mainline (Small) Joystick Switch............................................ 207
6.5 Fast Feed Joystick.................................................................................. 209
6.6 Auxiliary Pot............................................................................................ 210
6.7 Rod Make/Break Function (Make/Break Cube)..................................... 212
6.7.1 Rod Breaking............................................................................... 212
6.7.1.1 Head Float Up V29 Activation............................................. 213
6.7.2 Rod Making................................................................................. 214
6.7.2.1 Head Float Down V29 Activation........................................ 214
6.8 Safety Devices......................................................................................... 214
Chapter 7: Maintenance
7.1 Introduction............................................................................................. 219
7.1.1 Operational Requirements.......................................................... 219
7.1.2 Safety Requirements................................................................... 219
7.2 Tools and Equipment.............................................................................. 220
7.2.1 Suggested Assembly Torque Values for SAE Grade 8 Fasteners....
.................................................................................................... 222
7.3 Preventive Maintenance......................................................................... 223
7.3.1 Preventive Maintenance Schedule.............................................. 224
7.3.2 Lubrication Chart......................................................................... 225
7.3.3 Rig Pressure Setting Summary................................................... 226
7.3.4 Rig Component Weights............................................................. 226
7.4 Head Lubrication..................................................................................... 227
7.4.1 Head Oil Change......................................................................... 227
7.4.2 C6 Head Lubrication Oil Filter..................................................... 229
7.4.2.1 Filter Change Procedure..................................................... 229
7.5 Mainline Hoist.......................................................................................... 230
7.6 Wireline Hoist Assembly........................................................................ 230
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Table of Contents
7.6.1 Wireline Rope Installation............................................................ 238

7.6.2 Wireline Splicing.......................................................................... 240
7.7 PQ Head Disassembly Procedures....................................................... 240
7.8 PQ Head Reassembly Procedures........................................................ 257
7.8.1 Intermediate Gear Assembly....................................................... 262
7.8.2 Intermediate Shaft and Gear Assembly...................................... 268
7.8.3 Input Pinion and Shaft Assembly................................................ 274
7.8.4 Output Shaft Assembly (Spindle)................................................ 285
7.8.5 Output Carrier and Pump Mounting............................................ 295
7.8.6 Transmission Assembly.............................................................. 311
7.9 PQ Nitro Chuck ™.................................................................................. 312
7.9.1 PQ Chuck Cross Section............................................................. 313
7.10 PQ Nitro Gas Chuck................................................................................ 314
7.10.1 PQ Nitro Gas Chuck Disassembly Procedure............................. 314
7.10.2 Chuck Assembly Procedures...................................................... 334
7.10.3 Installation of New Jaws.............................................................. 348
7.10.4 Chuck Lubrication........................................................................ 348
7.10.5 Maintenance................................................................................ 349
7.10.6 Nitrogen Gas Springs.................................................................. 349
Chapter 8: Troubleshooting
8.1 Fault Finding Tables............................................................................... 353
8.1.1 Fine Feed.................................................................................... 353
8.1.1.1 Symptom: Low Fine Feed Force - Lack of Force on Drill Bit
While Drilling......................................................................................... 353
8.1.1.2 Symptom: Poor Fine Feed Control While Drilling............... 354
8.1.2 Main Line Winch.......................................................................... 355
8.1.2.1 Symptom: Main Line Winch Brake Not Releasing While
Drilling ............................................................................................ 355
8.1.2.2 Symptom: Erratic Operation of the Main Line Winch While
Lowering Rods...................................................................................... 356
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Table of Contents
8.1.2.3 Symptom: Main Line Winch Slipping and not Holding the Rod
Weight when the Main Line Hoist Lever is Returned to Neutral Position...
............................................................................................ 356
8.1.3 Wireline Winch............................................................................ 357
8.1.3.1 Symptom: Erratic Operation of the Wireline Winch While
Lowering Overshot............................................................................... 357
8.1.3.2 Symptom: Wireline Winch will not Hold the Load with the
Control in the Neutral Position.............................................................. 357
8.1.4 D03 Auxiliary Manifold................................................................. 357
8.1.4.1 Symptom: None of the Functions Work on the D03 Auxiliary
Manifold ............................................................................................ 357
8.1.5 PQ Chuck.................................................................................... 358
8.1.5.1 Symptom: PQ Chuck Does not Open or Close................... 358
8.1.5.2 Symptom: PQ Chuck Slipping on Rods.............................. 358
8.1.5.3 Symptom: PQ Chuck Body Tipping to one Side when
Opening Chuck..................................................................................... 358
8.1.5.4 Symptom: PQ Chuck Noisy when Rotated Slowly in the Open
Position ............................................................................................ 359
8.1.5.5 Symptom: Rotation Speed Control V45 does not Function.359
8.1.6 Rod Clamp.................................................................................. 359
8.1.6.1 Symptom: Rod Clamp does not Open or Close Properly... 359
8.1.6.2 Symptom: Rod Clamp Slipping while Making or Breaking Rod
Joints ............................................................................................ 360
8.1.6.3 Symptom: Head Opener Not Working................................ 360
8.1.6.4 Symptom: Mud Mixer Not Working Properly....................... 360
8.1.6.5 Symptom: Rod Make/Break Head Float Not Working Properly.
............................................................................................ 361
8.1.6.6 Symptom: Rod Make Up Torque Problems........................ 361
8.1.6.7 Symptom: PQ Head Rotation Problems............................. 361
8.1.6.8 Symptom: Mud Pump Problems......................................... 364
8.1.6.9 Symptom: Auxiliary Set Up Valve V40 Problems................ 364
8.1.6.10 Symptom: Tramming Problems (Optional Track Mounted
Drill) ............................................................................................ 365
8.1.7 Engine......................................................................................... 366
8.1.7.1 Symptom: Engine Will Not Start From OCP....................... 366
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Table of Contents
8.1.8 Hydraulic Oil................................................................................ 368

8.1.8.1 Symptom: Hydraulic Oil Overheating.................................. 368
8.2 Engine - Monitor Fault Codes (J1939)................................................... 368
Appendix A: Hydraulic Schematic
Appendix B: Electrical Schematics
Appendix C: Technical Specifications

C.3 Technical Specifications........................................................................ C-3
Appendix D: Braden RW300

Installation, Maintenance and Service Manual
xiv
Chapter 1: Safety
Contents
1.1 Important Safety Information..................................................................... 3
1.1.1 Hazard Signal Indicators................................................................. 3
1.1.2 Safety Guidelines............................................................................ 4
1.1.3 Safety Labels................................................................................... 5
1.1.3.1 Personal Protective Equipment (PPE).................................. 11
1.1.4 Inspect Safety Decals/Labels........................................................ 12
1.2 Personal Protective Equipment............................................................... 12
1.3 Emergency Stops...................................................................................... 14
1.3.1 Position of Emergency Stops........................................................ 14
1.3.2 Operation of the Emergency Stops............................................... 16
1.3.3 In the Event of an Emergency Stop............................................... 17
1.3.4 Restarting after an Emergency Stop............................................. 17
1.4 Battery Isolator.......................................................................................... 17
1.5 Rotation Barrier......................................................................................... 18
1.6 Safety Requirements................................................................................ 19
1.6.1 Safety Precautions........................................................................ 19
1.6.2 Safety Precautions for a Truck-Mounted Drill................................ 21
1.6.3 Safety Precautions for a Track-Mounted Drill................................ 21
1.6.4 Specific Safety Instructions for Drilling.......................................... 22
1.6.5 Hazards......................................................................................... 23
1.6.5.1 Hydraulics............................................................................. 23
1.6.5.2 Replacement of Worn Parts.................................................. 23
1.6.5.3 Safety Devices...................................................................... 24
1.6.5.4 Welding................................................................................. 24
1.6.5.5 Operation.............................................................................. 24
1.6.5.6 Operating Instructions........................................................... 24
1.6.5.7 Danger Zone: 2.5 Meters Around the Rig............................. 24
1.6.5.8 Safety Distance..................................................................... 25
1.6.5.9 Noise and Vibration Levels................................................... 25
1
Chapter 1: Safety
1.6.5.10 Transport of Persons............................................................ 25

1.6.5.11 Stability................................................................................. 25
1.6.5.12 Conduct in Case of Fire........................................................ 26
1.6.5.13 Fire Extinguisher Instructions................................................ 26
1.6.5.14 Operation of LF230 Drill Rigs................................................ 26
1.6.5.15 Securing Against Fall............................................................ 27
1.6.5.16 Signalling.............................................................................. 27
1.6.5.17 Utility Lines............................................................................ 27
1.6.5.18 Working Near Overhead Lines.............................................. 28
1.6.5.19 Operational Intervals............................................................. 28
1.6.5.20 Mixing Drilling Mud or Drilling Additives................................ 28
1.7 Extreme Environmental/Job Site Conditions......................................... 29
1.7.1 Extremely Dusty Working Conditions............................................ 29
1.7.2 Warm to Hot Ambient Air Temperature......................................... 29
1.7.3 Extremely Cold Ambient Temperature.......................................... 29
1.7.4 Working in Salty Atmosphere........................................................ 30
2
Chapter 1: Safety
1.1 Important Safety Information
1.1.1 Hazard Signal Indicators

Warning and Caution indicators are located throughout the manual at
specific points of interest, and are intended to alert the reader to the
existence and relative degree of a hazard. These notices are given to
prevent personal injury, death and/or equipment damage. These
indictors must be followed to reduce the possibility of personal injury,
damage to the equipment, or improper service. Always heed these
notices, and practice common sense when performing any maintenance
or repair procedure.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury and death.
“Danger” indicates an imminently hazardous situation which, if not

avoided, could result in death.
“Warning” indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury or property damage.
“Caution” indicates a potentially hazardous situation which, if not

avoided, MAY result in minor or moderate injury and property damage. It
may also be used to alert against unsafe practices.
“Notice” is used to draw attention to detailed instructions. These notes

are intended to give further important information regarding the machine
and/or a step in a procedure.
3
Chapter 1: Safety
1.1.2 Safety Guidelines

Read and understand all safety instructions carefully before operating
this machine. Failing to follow these instructions may result in serious
personal injury or death.
Familiarity and proper training are required for safe operation of this
equipment. Failing to follow these instructions may result in serious
injury or death. Read the operating instructions and familiarize yourself
with the location and proper use of all controls.
Safety is the most important element of any procedure. Preparation is

essential to complete a procedure in a safe and efficient manner.
●● Keep clear of rotating equipment. Wear proper clothing. Loose or

baggy clothing could become tangled in moving parts.
●● Be aware that sliding parts can create pinch points, and tilting parts
that create crush points.
●● Keep guards installed and maintained in good working order.
●● Always keep the work area clean.
●● Avoid dangerous working environments.
●● Do not operate equipment while under the influence of drugs,
alcohol, or medication.
●● Be aware of the operating zones and recommended areas for safe
operation. Keep visitors a safe distance away from the work area.
●● Wear personal protective equipment such as a hard hat, safety
glasses, and steel-toed work boots.
●● Prepare needed parts and materials. Gather the needed parts and
materials before beginning the procedure.
●● Prepare proper tools and equipment. Always use the correct tool for
the job. Improper or homemade tools can cause injury or machine
damage.
●● Use only Boart Longyear replacement parts. Failure to do so could
cause severe damage to the machine or the operator, and may
void your warranty.
●● ISOLATE all energy sources before servicing equipment.
●● Allow machine to cool. Many components can get hot during
operation. Be sure to allow enough time for components to cool
before beginning service. Use only qualified service technicians.
Failure to do so could cause severe damage to the machine or the
operator, and may void your warranty.
●● Never climb on top of the machine.
●● Ensure that the drill and accessories fully comply with applicable
local safety and health regulations.
●● Do not exceed rated capacity of any piece of equipment.
4
Chapter 1: Safety
●● Do not adjust the hydraulic system before consulting a Boart

Longyear Technician.
●● Ensure that all commissioning checks and adjustments have been
thoroughly carried out before operating the machine.
●● Do not change or alter the drill, its components, optional equipment,
or accessories without prior approval from Boart Longyear.
●● Follow procedures and safety warnings. Service procedures are
written to be as safe and efficient as possible. Never take shortcuts.
Operate this machine when any person including the operator
is under or in the operational envelope of the loading/unloading
process.
●● Be prepared for emergencies. Accidents can happen, even under
the best conditions. Fire extinguishers and first aid kits should be
well maintained and easily accessible.
●● Read and understand the operations manual and labels affixed to
the machine.
●● Unauthorized alterations may void the warranty, render the
equipment unsafe, or result in decreased performance.
●● Before operating any controls, be certain you know what function
they control and the ramifications of that function.
●● Before operating any hoist, ensure that the rope is free and clear to
travel.
●● When hoisting/lowering rods, make sure the hoisting cable is in
complete tension before releasing the chuck.
●● Do not use multiple part lines on the main hoist.
●● Ensure that all commissioning checks and adjustments have been
thoroughly carried out before operating the machine.
●● Never attempt to loosen or remove any high-pressure hydraulic line
without relieving pressure beforehand.
●● Always be sure the machine is on a firm, level surface and will not
tip, roll, slide, or fall while operating.
●● Never start a unit in need of repair.
1.1.3 Safety Labels

Become familiar with machine safety labels and locations. The following
illustrations show safety label locations on the machine.
A name plate is included that lists 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.
5
Chapter 1: Safety
When ordering parts or requesting information, you will always be asked

to specify the model number and serial number.
Figure 1–1: Machine Name Plate
Figure 1–2: Warning Decal: Interference with Draw Works
6
Chapter 1: Safety
DO NOT operate this machine without reading and understanding the

operations and service manual.
Figure 1–3: Danger Decal: Read the Manual
DO NOT position mast within 100m of power transmission lines.
Contact with overhead electrical power lines will cause serious injury or
death.
Figure 1–4: Danger Decal: Electrical Shock
7
Chapter 1: Safety
ONLY use this outlet for a 12 VDC 40 AMP circuit.
Figure 1–5: Caution Decal: Electrical Circuit Outlet
Use main winch cable in a single line pull only. DO NOT double line pull.
Figure 1–6: Warning Decal: Winch Cable
DO NOT operate this machine without rotation barrier in place. Operator

may be drawn into rotating parts.
Figure 1–7: Warning Decal: Rotating Parts
8
Chapter 1: Safety
The continuous sound pressure level, during normal coring operations,

at the operator’s workstations, projected over 8 hours is less than 93
dBA.
Figure 1–8: Warning Decal: Sound Levels
Moving parts of the machine have the potential to crush or pinch.

Always use extreme caution when near these areas.
Figure 1–9: Warning Decal: Crush/Pinch Point
ALWAYS use extreme caution when opening the head. NEVER allow
head to travel when head is in the open position.
Figure 1–10: Warning Decal: Opening the Head
9
Chapter 1: Safety
ALWAYS ensure head lock-down bolts are in place before operating.
Figure 1–11: Warning Decal: Head Lock-Down
DO NOT adjust the manifold without consulting field service first.
Figure 1–12: Warning Decal: Manifold Setting
ALWAYS place the mast in the storage position before moving the drill.
Figure 1–13: Warning Decal: Moving the Drill
10
Chapter 1: Safety
ALWAYS use an appropriate lifting device at the designated lifting

points.
Figure 1–14: Decal: Lift Point
1.1.3.1 Personal Protective Equipment (PPE)

●● Read and understand manuals
●● Wear approved safety glasses
●● Wear gloves
●● Wear safety boots
●● Wear hard hat
●● Wear fall arrester when working at heights
●● Wear fall arrester when working at heights
●● Wear hearing protection
Figure 1–15: Decal: Personal Protective Equipment
11
Chapter 1: Safety
Always use Lockout/Tagout procedures before working on or near any

high-risk areas on the rig, i.e. head, engine, electric controls, before
service.
Figure 1–16: Decal: Lockout/Tagout
Always wear fall protection when working on elevated areas of the

machine.
Figure 1–17: Decal: Safety Harness
1.1.4 Inspect Safety Decals/Labels

Safety decals are critical to the safe operation of this machine. Inspect
all equipment for any damaged, missing, or unreadable decals. Replace
decals as needed before placing the machine back in service.
1.2 Personal Protective Equipment

The following safety decals are used to show possible hazards and
safety requirements. This list must be amended to meet your onsite
requirements.
12
Chapter 1: Safety
Figure 1–18: Approved Hard Hat Required
Figure 1–19: Safety Boots Required
Figure 1–20: Working Gloves Required
Figure 1–21: Hearing Protecting Required
Figure 1–22: Respiratory Protection Required
13
Chapter 1: Safety
Respiratory protection is recommended for applications that create dust

or when using compressed air for flushing.
Figure 1–23: Safety Glasses Required
Safety glasses are recommended for applications that create dust or

when using compressed air for flushing.
Figure 1–24: Safety Harness Required
This list must be amended to meet YOUR on site requirements.
1.3 Emergency Stops
This LF230 rig is fitted with four Emergency Stop switches.
Familiarize yourself with the position and operation of all the Emergency
Stop switches. Check the operation of the stop switches daily.
Do not bypass or disconnect any emergency shutdown device.
1.3.1 Position of Emergency Stops

Emergency Stop switches are located as follows:
14
Chapter 1: Safety
1. On the operator’s control panel.
Emergency
Stop
Figure 1–25: OCP Emergency Stop
2. At the setup control.
Figure 1–26: Setup Control Emergency Stop
3. One remote magnetic mounted on with 7.5m (25’) of cable allowing

it to be attached to any metallic surface. This is usually stored
inside the operator’s console for shipping purposes.
15
Chapter 1: Safety
4. A mast lanyard safety switch that runs along the operator’s side of
the mast.
Figure 1–27: Mast Lanyard Emergency Stop
1.3.2 Operation of the Emergency Stops

Depress to shut the engine off. (Twist and pull to reset the circuit and
allow re-start of the engine.)
To operate the lanyard emergency stop, pull on the red cable to shut
the engine off. (Pull the reset button on the lanyard switch to reset the
circuit.)
Under normal operating circumstances, return the diesel engine to an

idle for about five minutes and use the key switch on the control console
to shut down the drill.
Use of the emergency stops to shut the engine off during normal
operation is not recommended as it is very important to allow the
turbocharge to cool down. After an engine shutdown, allow roughly 30
seconds before isolating power at master disconnect to provide time for
the engine ECU to properly shut down, otherwise fault code 627 may
appear on the engine monitor the next time the engine is started. If this
fault code does show up at start up, turn the ignition key switch off and
restart engine to reset.
16
Chapter 1: Safety
1.3.3 In the Event of an Emergency Stop

1. Immediately investigate the cause of the Emergency Stop.
2. In the event of personal injury, assist if you feel able to do so,

otherwise seek medical assistance or contact the emergency
services.
3. If the stop was initiated to prevent mechanical damage, assess the

situation before continuing. If in doubt, seek advice from the Site
Supervisor.
4. If the cause of the stop was unknown, walk around the drill rig and
check for any unsafe conditions before continuing.
1.3.4 Restarting after an Emergency Stop

1. Ensure all controls are in neutral.
2. Turn the ignition switch to the OFF position.
3. Re-set the activated stop buttons by pulling or twisting and pulling.
4. Check the operation of all lights and warning devices.
5. Report all defects to the Site Supervisor.
6. Visually inspect and assess the work area for potential hazards.
7. Re-start the engine. (See the Operation section.)
1.4 Battery Isolator

The battery isolator is located in a small compartment on the side of the
engine housing. It is a 12VDC manually operated battery disconnect
switch with an integral lockout bracket. It is recommended practice to
use a small padlock to lock out power to the drill rig prior to doing any
repairs where inadvertent start up could put the service technician at
risk.
17
Chapter 1: Safety
ALWAYS place the battery Isolator in the OFF position, and use lockout/
tagout procedures when working on this equipment. Failure to comply
may result in serious injuries.
Figure 1–28: Battery Isolator
1.5 Rotation Barrier

The rotation barrier is installed on the drill mast to block access to the
drill string and chuck during the drilling operation. It can be hinged open
18
Chapter 1: Safety
to access the drill head and footclamp for maintenance as well as for
adding or removing drill rods and core retrieval.
Figure 1–29: Rotation Barrier
Never attempt to drill without the rotation barrier in place or serious

personal injury or death could occur. Ensure that Rotation Barrier is
always in the closed position during drilling operations.
1.6 Safety Requirements
1.6.1 Safety Precautions
General Drilling operations frequently expose people to imminently

hazardous situations which, if not avoided, could result in death or
serious injury.
The following safety precautions must be observed at all times.
1. 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 death.
2. Always wear an approved helmet, safety shoes or boots, safety

glasses, and hearing protection when near an operating drill rig.
19
Chapter 1: Safety
A Respirator may be necessary in dusty operations, assess each

situation.
3. 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.
4. Do not touch rotary heads, or the engine exhaust. These parts

usually get hot and a severe burn may result. Be sure to wear work
gloves when you are working near any of these components.
5. 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.
6. When pressurized, damaged accumulators could burst, scattering

metal fragments throughout the area, and severely injuring
personnel.
7. Be sure to bleed the accumulator before attempting to disassemble

it, and only replace with accumulators that have been tested and
approved.
8. Always operate the drill rig from the operator’s position.
9. Make sure all other persons are clear of the drill rig before moving
or starting any drilling operation.
10. 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.
11. Use extreme caution when tramming or setting up on uneven

ground.
12. Always ensure that the stability of the rig is not impaired.
13. Drills have many moving components. Keep yourself and all other
persons clear of moving drill heads, feed mechanisms, drill strings,
and moving tools.
14. Know where you are drilling! Make sure you do not drill into any
utilities, such as buried electric cables, gas, or water mains.
15. Use only purpose-made craneage lugs and/or lifting holders when
lifting the rig.
16. Do not remove or disable protective guards and safety devices

under any circumstances.
17. 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.
20
Chapter 1: Safety
18. Exhaust fumes from internal combustion engines are deadly. Be

sure only operate the drill rig in well ventilated areas.
19. 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.
20. Noise and Vibration levels - The A weighted sound power level at
the operating position is 93.7 dBA. Appropriate hearing protection
is required while operating the rig.
1.6.2 Safety Precautions for a Truck-Mounted Drill

1. Obey posted speed limits.
2. Never attempt to move the drill with the mast in the raised position.
3. Post the overall transport height of your drill in the operator’s cab.
4. Ensure all road heights and weights are obeyed.
5. Be aware of any special licenses or permits required to transport

the rig.
6. Always use the outriggers and jacks to stabilize the drill rig for
drilling.
1.6.3 Safety Precautions for a Track-Mounted Drill

1. Maximum ground speed can be adjusted with engine speed. Do not
exceed 2200 rpm.
2. Never attempt to move the drill with the mast in the raised position.
3. Always tram the drill with the crown block pointing down grade for
maximum stability. The maximum safe grade in this orientation is
15 degrees (25% ).
4. Maximum side grade for tramming is limited to 10 degrees (18%)

side slope.
5. Beware of wet ground conditions when tramming, the overburden

can shear off.
6. Always leave your self a escape route when operating a vehicle

with a radio remote control.
7. Stand well back (at least 10 meters) from the rig when tramming.
8. Never stand between the machine and an obstacle when steering.
21
Chapter 1: Safety
9. Never ride on the vehicle.
10. Always position yourself to get a clear view when tramming.
11. Never leave the rig unattended in tram mode with the engine
running.
12. Always use the outriggers and jacks to stabilize the drill rig for
drilling.
1.6.4 Specific Safety Instructions for Drilling

Drilling operations frequently expose workers 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.
1. While moving the rig no person should walk alongside, even for
short distances.
2. Always check that all helpers are well clear of the tramming and
swing radius of the drill rig prior to moving or setting up.
3. When using level or angle indicator to make the final adjustment of

mast angle, only allow helpers to enter the area after the drill mast
has been aligned and inclined to the approximate degree required.
4. Be sure that all hoses (e.g. for flushing - grouting) are cleared from
the path before moving the drill rig.
5. Care must be taken when handling drill string sections. They are
often cumbersome and heavy.
6. Always ensure there are adequate foot holds (mud-sludge).
7. Remember that some cleaning solvents used for removal of oil and
grease develop dangerous fumes when they vaporize. Be sure to
use solvents only in well-ventilated areas.
8. The operator must never leave the control panel while drilling is in
progress.
9. The rig must be secured against inadvertent and unauthorized

movement between each operational interval.
10. To avoid inadvertent or unauthorized start up once the engine is

stopped, ensure the starter key taken out of the ignition lock and
the battery is disconnected, locked and secured.
11. If the drill rig is parked on a slope or incline, the wheels must be
secured using wedges, in addition to engaging the brakes.
22
Chapter 1: Safety
1.6.5 Hazards
Drilling operations frequently expose workers to imminently hazardous
situation which, if not avoided, could result in death or serious injury.
The following safety requirements must be observed at all times.
1.6.5.1 Hydraulics
The hydraulic components of the drill rig must be checked regularly.
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, boom components, drill mast components and
undercarriage components.
NEVER use your hand to find the leak. Hydraulic fluid is hot and can burn
the skin. A pinhole leak, under pressure, can inject fluid under your skin,
causing poisoning, infection, and threaten life and limb. In the event of
a skin puncture or laceration from high pressure hydraulic oil, get the
patient to an emergency room for immediate treatment.
Prevent possible injury, NEVER work beneath a suspended load held by

an actuator unless properly supported. Failure to properly support the
component may result in death or serious injury.
Settings for pressure limiting valves in the hydraulic circuits of the

crawler drill rig must only be changed by Boart Longyear approved
personnel.
1.6.5.2 Replacement of Worn Parts

Repairs and replacement of worn parts can 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 center.
23
Chapter 1: Safety
1.6.5.3 Safety Devices

The safety devices on the drill rig must only be changed by or with the
permission of Boart Longyear approved personnel.
Safety devices and protective equipment incorporated within moving

machine components must only be opened, removed, or disabled
with the rig’s engine stopped and secured against inadvertent or
unauthorized 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.
1.6.5.4 Welding
Welding of static and load bearing components on the drill rig is only
to be carried out by the manufacturer or by Boart Longyear approved
personnel.
1.6.5.5 Operation
The rig functions must be activated only from the control panel.
1.6.5.6 Operating Instructions

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.
1.6.5.7 Danger Zone: 2.5 Meters Around the Rig

Be sure that no one is within the Danger Zone of the drill rig. This is the
area around the drill rig, within which persons may be endangered by
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 horns, 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.
24
Chapter 1: Safety
1.6.5.8 Safety Distance

A safety clearance of 0.5 meters must be kept from buildings,
scaffolding, and other equipment to prevent the danger of being
squashed. At all times keep in mind the rig’s slewing requirements. If the
safety distance can not be complied with the area must be cordoned off.
1.6.5.9 Noise and Vibration Levels

The A weighted sound power level at the operating position is 93.7 dBA.
Appropriate hearing protection is required while operating the rig.
1.6.5.10 Transport of Persons

Using the rig to transport persons is strictly forbidden.
1.6.5.11 Stability
The crawler drill rig must only be operated when it is in a stable position.
The rig’s stability may be impaired by:
●● Excessive load
●● High Winds
●● Unsecured ground
●● Incorrect drill mast position
●● ‘Jerky’ acceleration and stopping during tramming
●● Slewing movements
●● Operating on slopes and inclines.
Do not operate this drill with rods racked in wind velocities in excess of
85 km/h.
25
Chapter 1: Safety
1.6.5.12 Conduct in Case of Fire

The following figure shows proper extinguishing tactics.
Figure 1–30: Fire Extinguishing Tactics
1.6.5.13 Fire Extinguisher Instructions

The figure below explains the different classifications and related
actions.
Figure 1–31: Fire Classifications
1.6.5.14 Operation of LF230 Drill Rigs

Independent and unassisted operation and maintenance of the LF230
drill rig must only be entrusted to persons who:
●● Are at least 18 years
26
Chapter 1: Safety
●● Have been instructed in operating and maintaining the drill rig and
have demonstrated their ability to the contractor
●● Can be expected to perform responsibly and are designated for the
job by the contractor
The operator is responsible at all times for the rig operation and must
modify procedures to allow for any likely instability and ensure a safe
work area.
1.6.5.15 Securing Against Fall

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.
1.6.5.16 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 coordinated and exclusively used between the

operator and the signaller.
The signaller’s attention must not be diverted by any additional tasks.
1.6.5.17 Utility Lines

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.

27
Chapter 1: Safety
1.6.5.18 Working Near Overhead Lines

Unless local or national stipulations require otherwise, the following
minimal safety distances must be complied with.
If working near overhead power lines:
Rated Voltage Proximity
Up to 1000V 1 meter
Above 1KV 3 meters
Above 110KV 4 meters
Above 220KV 5 meters
If rated voltage unknown 5 meters
1.6.5.19 Operational Intervals

The operator must park the drill rig on bearing and level ground, stop
the drill rig engine, and secure the equipment against inadvertent or
unauthorized movement prior to leaving the drill rig. The drill mast and
drill string should be resting on the ground.
The operator must set all operating levers in the neutral position prior to
leaving the control panel. Furthermore, the operator must not leave the
site if any drill rig tools are not secured.
If the drill rig must be parked on a slope or incline, the wheels must be
secured with wedges in addition to the brakes.
Drill rigs should be parked only where they do not impede the public
or any site traffic. If necessary the rig must carry a warning triangle,
signalling lines and/or warning lights when visibility and lighting
conditions are poor.
These shutdown procedures must be performed before each operational

break and at the end of each working day.
1.6.5.20 Mixing Drilling Mud or Drilling Additives
When mixing drilling mud or drilling fluid additives, always wear

approvedsafety goggles and gloves to prevent possible chemical burns.
●● Pay attention to wind direction when loading dry mud as this

material will clog engine air filters, radiators and oil coolers.
●● Use a mask to prevent inhalation of dry dust particles.
●● Keep MSDS sheets on site for first aid instructions.
28
Chapter 1: Safety
●● Keep fingers clear of any rotating mud mixer impellers.

●● Some mud mixing plants can operate at a higher noise level than
the drill rig. Always wear approved hearing protection.
●● Read and understand MSDS sheets and the impact of the materials
on the environment.
1.7 Extreme Environmental/Job Site Conditions
1.7.1 Extremely Dusty Working Conditions

In order to extend the service life of the standard air filter for the diesel
engine with extreme dusty conditions, we recommend the use of a
cyclone.
Thus air is pre-filtered of the rough dust particles. The cyclone should
be fitted before the air filter. To ensure optimum maintenance; the
performance of the cyclone must be monitored during the normal daily
drilling schedule. Please contact Boart Longyear.
1.7.2 Warm to Hot Ambient Air Temperature

If the drill rig is required to operate for extended periods in an ambient
temperature of more than 40 degrees C, we recommend changing the
hydraulic, head and engine oils, as outlined in Chapter 5.
1.7.3 Extremely Cold Ambient Temperature

If the drill rig is required to operate for extended periods in an ambient
temperature below 0 degrees C, with cold starts under 10 degrees C,
then we recommend the cold start option.
The diesel engine is equipped with a pre-heating unit, in order to work

however at extremely low temperatures, an additional block heater
can be fitted. Furthermore the hydraulic oil can be warmed up by an oil
heater integrated into the tank. (Included in the cold start option.)
The hydraulic, head and engine oils should be reviewed as well, as

outlined in Chapter 5.
29
Chapter 1: Safety
1.7.4 Working in Salty Atmosphere

When working in a salty atmosphere the hydraulic cylinder rods in
particular must be protected. Furthermore the machine, especially the
chassis must be coated with a defensive lacquer against corrosion. The
hydraulic oil radiator must also be provided with a protective lacquer
finish, and in extremely salty environments (offshore for instance) the
radiator must be replaced with a stainless steel model.
30
Contents
2.1 Using this Manual..................................................................................... 33
2.2 Abbreviations Used in This Document................................................... 34
2.3 Prior to First Use....................................................................................... 34
2.4 Ordering and Returning Parts.................................................................. 34
2.4.1 Ordering Parts............................................................................... 34
2.4.2 Returning Parts............................................................................. 35
2.5 Limited Warranty....................................................................................... 35
31
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32
2.1 Using this Manual

This manual describes the Boart Longyear LF230 drill and outlines its
operational and maintenance procedures. It also includes a number of
procedural hints.
The purpose of this manual is to furnish the operator with detailed

information which will enable him to achieve the maximum operating
performance from his drill. It will also give information necessary
to perform preventative maintenance and make minor repairs and
adjustments.
Read this manual carefully before attempting to operate the drill and
keep this book handy at all times for reference when any question
arises.
To obtain the utmost in performance and life of the equipment, it should

be given regular care and operated in accordance with the instructions.
Note the following:
●● Pictures, descriptions, and technical data may not match your drill
rig in every aspect.
●● 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 are the one who is responsible for your personal safety
when operating this equipment.
○○ You must comply with all safe working procedures and
instructions relevant to your drill site at all times!
●● The Manual set includes a spare parts catalogue depicting and
describing the individual components of the rig.
In the interests of its technical development, Boart Longyear reserves
the right to modify the drill rig and the data in this manual without prior
notification.
Boart Longyear is backed by over 100 years of experience in the

design, manufacture and operation of core drilling equipment. Many of
the accepted practices in use today were pioneered by Boart Longyear.
33
2.2 Abbreviations Used in This Document

Abbreviations used throughout this document, and their definitions are
outlined below:
Abbreviation Definition
HMI Human Machine Interface
CAN J1939 CANbus communications protocol for
interrogation of data from Cummins
Diesel Engine control system
PWM Pulse Width Modulation – A form of
analog control
OCP Operator Control Panel
MCP Main Control Panel
LH Left Hand
RH Right Hand
2.3 Prior to First Use

Upon arrival of your new Boart Longyear LF230, a quick inspection
should be done.
●● Visually inspect the drill for any loose hoses, fittings, bolts or any
damage that may have occurred during shipping.
●● Take caution when a loose hose or fitting has allowed oil to leak as
this will create a hazard.
●● Make sure that any oil leak has not drained the tank too low for
proper operation.
●● Refer to chapters in this manual for proper and safe movement of
this drill.
●● Visually inspect all electrical connections.
●● Check oil levels and fill with recommended lubricants.
2.4 Ordering and Returning Parts
2.4.1 Ordering Parts

The following procedure will expedite the filling of your parts order,
eliminate delays and assure correct replacement parts:
1. List the model and serial number of the drill.
34
2. State exact quantity required.
3. Specify description and part number as shown in the Parts Manual.
4. Specify method of shipment, ie: Parcel Post, Express, Freight; for

Overseas shipment, Air Freight, Air Parcel Post, or Ocean Freight.
All parts are priced F.O.B., our factory and a separate charge will be
made for transportation and export packing.
2.4.2 Returning Parts

If you wish to return parts whether for repairs, replacement, or warranty,
you should communicate the details of the return request in writing with
your local Boart Longyear Representative.
In Canada the request can be sent

via email to: orderdeskrga@boartlongyear.com
faxed to: 705-474-2373
The request should reference the model and serial number of the
product as well as:
-part number and quantity
-reason for return
Once the return is approved you will be issued an RGA (Return Goods
Authorization) number to track your claim.
DO NOT attempt to ship parts until you receive an RGA number and
shipping instructions otherwise we have no way to track your claim for
returned goods. Boart Longyear will not be held responsible for any
parts shipped without a return good authorization number.
●● All parts for return are subject to incoming inspection and minimum
re-stocking charge of 20% will apply.
●● Special, “made to order”, or obsolete, parts will not be accepted this
includes small items such as nuts, bolts and O-rings.
●● All parts must be returned prepaid.
2.5 Limited Warranty

a. Consumables. Boart Longyear warrants for a period of one (1)
year after the date of shipment of the consumable products
manufactured by it, or the performance of related services,
under the Contract, that such consumable products are free
from defects in materials and workmanship and such services
are performed in a professional and workmanlike manner;
provided, however, with respect to consumable products
purchased through an authorized Boart Longyear distributor,
35
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
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
36
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
37
38
Contents
3.1 General Description/Statement of Use.................................................... 41
3.2 General Drill Arrangement....................................................................... 41
3.3 Decals Used on the Rig............................................................................ 44
3.4 Drill Mast Component Description.......................................................... 52
3.4.1 Drill Head....................................................................................... 52
3.4.2 Rotation Barrier............................................................................. 55
3.4.3 Mainline Hoist................................................................................ 56
3.4.3.1 Wire Rope (Mainline)............................................................ 57
3.4.4 Crown Block Assembly.................................................................. 58
3.4.5 Foot Clamp.................................................................................... 59
3.4.6 Rod Tray........................................................................................ 60
3.4.7 Wireline Winch.............................................................................. 60
3.5 Mast Pivot.................................................................................................. 62
3.6 Mast Dump Feature................................................................................... 62
3.7 Fluid Circulation Pump............................................................................. 63
3.8 Controls..................................................................................................... 63
3.8.1 Operator Control Panel (OCP)...................................................... 63
3.8.1.1 Description of Controls.......................................................... 64
3.8.2 Drill Rig Set-Up Controls V40........................................................ 70
3.9 Track Package (Optional)......................................................................... 70
3.10 Rod Racking Platform (Optional)............................................................. 71
3.11 Power Unit - Cummins QSC 8.3L TIER III Engine................................... 73
3.11.1 Engine Control Panel (ECP) Tier III Model.................................... 75
3.11.2 Engine Control Monitor (Canvu Tier III Engine Only).................... 77
3.11.2.1 Preferred Screen Store......................................................... 78
3.11.2.2 Keys 1 to 4 Operation........................................................... 78
3.11.2.3 Adjust Lighting and Contrast................................................. 79
3.11.2.4 Language Support................................................................ 79
3.11.2.5 Quad Analog View (Screen 1).............................................. 79
39
3.11.2.6 Quad Digital View (Screen 2)................................................ 81

3.11.2.7 Single Analog View (Screen 3)............................................. 81
3.11.2.8 Alarm Screen 4..................................................................... 82
3.11.2.9 Top Level Menu.................................................................... 84
3.11.2.10 Settings Menu and Sub Menu............................................... 85
3.11.2.11 System Menu and Sub-Menus.............................................. 86
3.11.2.12 Database Viewer/Display Mapping....................................... 87
3.12 Power Unit - Cummins QSL 9.0L Tier 4i Engine..................................... 87
3.12.1 Engine Control Panel (ECP) Tier 4i Model.................................... 90
3.12.2 Engine Control Monitor (Murphy Tier 4i Engine Only)................... 92
3.12.2.1 Engine and Transmission Parameters.................................. 93
3.12.2.2 Navigation and Keypad Functions........................................ 94
3.12.2.3 First Time Startup................................................................. 96
3.12.2.4 Gauge Displays..................................................................... 96
3.12.2.5 Adjusting the Menu Selections.............................................. 99
3.12.2.6 Acknowledging Faults......................................................... 104
40
3.1 General Description/Statement of Use

The LF drill is a high production diesel driven surface core drill. It is
capable of drilling holes from 45 to 90 degrees off horizontal. (Hole
diameters and depths are detailed in the appendix.)
The LF230 depth rating is based on its 40,000 lb hydraulic mainline

hoist for pulling drill rods. A wireline hoist is also installed for wireline
core tube retrieval.
The drill system utilizes a spindle drive drill head with a nitrogen charged
chuck to grip the drill rods for rotation directly coupled to a single feed
cylinder to provide thrust and pullback for drilling and breaking core.
The drill bit requires a continuous supply of drilling fluid to operate and
in the hole drilling conditions may also dictate the use of rod grease and
or drilling muds or polymers to flush cuttings, maintain circulation, and
reduce friction in the hole.
The LF230 is available in three basic configurations for transport:
1. Track mounted for slow speed off road hole to hole transport.
2. Truck mounted for country of end use specific, on and off road
applications.
3. Base frame version for on-site installation, truck mounting, skid or

shack mounting.
The drill can be configured from the factory for cold or hot weather
applications with an overall operating temperature range of –40 to +50
degrees C.
The drill can operate up to an altitude of 1676 MASL before the engine
automatically starts to de-rate.
The drill is not designed for fly applications and is not intended to
be used in an area with a risk of explosive atmosphere or off shore
applications with extended exposure to salt water spray.
3.2 General Drill Arrangement

The photos on the following pages show the components of the LF230
drill rig.
41
Figure 3-1 shows the rig in a truck-mounted configuration.
Crown Block Assembly
Telescopic Mast Assembly
OPTIONAL Rod
Racking Platform
Mast Slide
Mast Support Legs

Lower Mast Assembly
Hydraulic Reservoir
Mast Raising Cylinders

Diesel Engine
Main Line Hoist
PQ Rotation Unit Fuel Tank

c/w Nitro Chuck
Mast Pivot Wireline Hoist Drill Base Frame
Figure 3–1: LF230, Truck-Mounted
42
Figure 3-2 shows the rig in a crawler-mounted configuration.
Crown Block Assembly
Telescopic Mast
Assembly
Lower Mast Assembly
Mast Slide
Mast Support Legs

Mast Raising Cylinders
Diesel Engine
Hydraulic Reservoir
Main Line Hoist Fuel Tank
PQ Rotation Unit
c/w Nitro Chuck
Drill Base Frame
Mast Pivot Wireline Hoist

Fluid Circulation Pump
Figure 3–2: LF230, Crawler-Mounted

43
3.3 Decals Used on the Rig

The following decals are used on the LF230 drill rig.
Figure 3–3: Decals Used on the Rig
44

45

46
47
48
49
50
51
3.4 Drill Mast Component Description

The following sections describe the parts of the mast.
Figure 3–11: Drill Mast
3.4.1 Drill Head

The drill head is inside the lower section of the mast on a pivoting head
opener.
52
Never attempt to operate the chuck with any of the spring retainer bolts
loose or missing. Severe injury or death could result. Carefully inspect
the threads on the bolts and spindle and replace the spindle and or bolts
if the threads show any sign of damage or wear.
Monitor head oil level on the lower reservoir sight gauge provided while
drilling. Never attempt to drill with low head oil level. Permanent damage
to bearings and gears will occur.
Never rotate the drill head with the chuck open; damage to the floating
bearing and retaining ring can occur.
The drill head is powered by a variable displacement bent axis hydraulic

motor with a proportional displacement control coupled to a four speed
mechanical transmission coupled to the drive spindle through a 2:1 ratio
gearbox.
Boart Longyear’s patented PQ Nitrochuck™ is used to transmit the

rotary power from the drill head spindle to the drill string. The chuck
opens to allow oversize reaming shells and bits to pass through the
spindle. The bolt on chuck design allows for reverse rotation to break
53
drill rod joints. The chuck has seven retractable jaws which are applied
using nitrogen gas springs for superior axial holding force.
Figure 3–12: PQ Head Assembly
Head speed can be controlled by a combination of gear selection,

rotation motor displacement setting and engine speed. Engine speed is
normally set to 2200 RPM while drilling.
54
3.4.2 Rotation Barrier

The Rotation Barrier is a safeguard device that prohibits access to the
rods during operation. This rotation barrier can be equipped with an
interlock switch (optional) to limit rotation rpm to make break speed
when the barrier is open.
Figure 3–13: Rotation Barrier
Avoid serious Injury, always operate this equipment with the Rotation
Barrier in the closed position when running the machine. If not avoided,
COULD result in death or serious injury.
55
3.4.3 Mainline Hoist

The Mainline Hoist with its 40,000 lb (18 144 kg) capacity is the drill’s
mainline winch. It is fitted to the rear of the lower mast assembly, under
the mast slide. It pivots with the mast section and is used ONLY IN A
SINGLE LINE configuration to lower and raise drill rods and casing.
Figure 3–14: Main Line Hoist
Note: May not be exactly as shown.
The main line winch is powered by a variable (2-speed) displacement

axial piston, hydraulic motor. In addition, the main line winch features an
internal Sprag bearing mechanism, which ensures the main line winch
drum must be hydraulically powered to unlock the drum (i.e. the load
cannot drive the drum ahead of the hydraulic motor).
The Mainline Hoist is installed on the dump frame on the LF230. It

utilizes a dual brake system comprised of a spring applied hydraulically
released park brake as well as a 3 port counterbalance valve. The park
brake (friction brake) is released automatically as the main control is
shifted to lower the load.
The 3 port counterbalance valve with “pilot to open assist” is installed in

the hoist control manifold to prevent overrunning loads and block flow
(hold the load) until pilot pressure is applied.
The counterbalance valve pilot pressure signal is normally generated

in the hoist control circuit whenever the main hoist control valve is
shifted by the operator to lower the load. The counterbalance valve will
remain closed until sufficient pilot pressure is applied to the spool to
open the valve. It is not negatively affected by system back pressure.
Once the counterbalance valve cracks open, pilot pressure becomes
flow dependant and modulates the valve spool opening thus controlling
the speed of the descending load. The park brake (friction brake) is a
load holding brake only and has nothing to do with dynamic braking or
controlling the rate of load descent.
56
Winch tension control is designed only to be used to tension (create

drag) on the hoist cable through the counterbalance valve when the
control is manually set for drilling (not while hoisting).
The counterbalance valve is preset to 5000 psi. DO NOT TAMPER

WITH THIS SETTING. Any setting below this will limit the maximum
load the hoist can suspend.
A hydraulic press is preferred for putting together many of the high

tolerance parts found in the planetary winches.
If the winch is operating incorrectly contact Boart Longyear at info@

boartlongyear.com before proceeding with disassembly. The winch
should only be disassembled if it is not feasible to return it to the factory
for proper disassembly and inspection. During disassembly, all parts
should be inspected for wear and damage. Any abnormal wear should
be reported to Boart Longyear.
Always use Boart Longyear original equipment. See Chapter 7 for care
and inspection.
1—Winch, Planetary 40,000 lb 2—Tensioner Asm, 40K Winch 3—Guard, 40K Winch
4—Manifold ASM, C/B 5—Stop Plate, Winch Cable 6—Stop Plate, Winch Cable
Cartridge
Figure 3–15: Mainline Hoist
3.4.3.1 Wire Rope (Mainline)

The wire rope is designed to provide superior flexibility and strength.
Wire ropes are certified as part of the hoisting system for a specific
breaking strength to meet accepted industry standards. Always use
Boart Longyear original equipment.
57
3.4.4 Crown Block Assembly

The Crown Block Assembly is located on the top of the mast. It carries
the sheave wheels for the mainline and wireline wire ropes. The
mainline sheave has a lube for life bearing and the twin wireline sheaves
have grease fitting installed requiring regular lubrication.
A certified fall arrest system and regular review of safe working

procedures at height is strongly recommended for all workers.
Figure 3–16: Crown Block Assembly
58
3.4.5 Foot Clamp

The footclamp is a hydraulic operated rod clamp located at the base of
the drill mast. The footclamp is used to hold the drill string in position
when adding or removing drill rods. It also functions as a rod wrench for
making or breaking drill rod joints or casing below the head.
Figure 3–17: Foot Clamp
The footclamp jaws (slip sets) must be changed according to the drill
pipe diameter being used. The jaws have two rows of carbide set in
place to bite into the outside of the drill pipe. The raised carbide profile
must be cleaned regularly with a wire brush to remove any build-up
of dirt and grease; at the same time, the inserts must be inspected
regularly for any signs of damage. Slip sets should be immediately
replaced if damage has occurred.
Never attempt to remove or shift footclamp slipsets with drill rotation

engaged. Operator could be drawn into the rotating drill string resulting in
severe personal injury or death.
There is always a risk that the drill string could be hung up off bottom
with the footclamp open. Use caution when servicing slip sets that the
drill string could shift resulting in a crush hazard.
59
Drill engine must be shut down while this work is in process.
3.4.6 Rod Tray

The rod tray is installed on the lower mast to provide a guide for the
hoist plug and tools in the drilling process, especially when operating
on angle holes. It can be extended hydraulically by the operator when
required.
Power is provided for this function from the P2 pump. The rod tray is
extended by the driller (via the hydraulic control in the D05 Manifold) to
position the tray to aid in rod handling.
1—Mast Assembly, Lower 2—Mast Assembly, Telescopic
Figure 3–18: Rod Tray
3.4.7 Wireline Winch

The Wireline Winch is a hydraulically operated model with an integrated
level winder. The unit is located on the drill deck.
60
The wireline winch is only intended to be used as a device for inner tube
retrieval. It must never be used as a winch for servicing the rig or lifting
people.
Figure 3–19: Wireline Winch
The winch is controlled by the driller from the OCP. There is a 3 position
winch mode selector switch on the OCP which must be set to the
wireline winch position for the winch joystck to be active.
The hoist control is a proportional lift to shift joystick. A maximum engine

speed of 1500 RPM is more than sufficient to reach maximum hoisting
speed. Any more is a waste of fuel.
The level winder should be repositioned as part of the mast setup

procedure to optimize the wireline rope angle to the crown block
sheaves. The level winder is driven by a chain as the hoist rotates to
control wireline placement on the drum.
The traverse speed of the spooling device is controlled through a

mechanical sprocket and chain arrangement. The spooler rate of travel
relative to the drum speed is controlled by the number of teeth on the
61
drive pinion sprocket. This system utilizes a compound drive pinion

sprocket to set the ratio for travel speed. Refer to Chapter 7 for detailed
rope installation and set up instructions.
Ensure that the helper does not become entangled in the wire rope. Never
wrap the wire rope around fingers or hands as this could result in severe
personal injury.
3.5 Mast Pivot

The mast dump frame holds the mast and is attached to the mast pivot.
The mast raising cylinders tilt the mast via the dump frame on this pivot.
Figure 3–20: Mast Pivot
3.6 Mast Dump Feature

Mast dump cylinders move the mast assembly up and down relative
to the mast dump frame. They are provided to allow the mast to make
contact with the ground prior to drilling. This action is required whenever
the rig is set up and will have to be checked regularly depending on the
condition of the soil under the rig as it gets washed out.
62
The dump cylinder control is located on the drill rig setup valve bank.
The operator must select set up mode using diverter valve V43 to
activate the set up controls.
3.7 Fluid Circulation Pump

The Fluid Circulation Pump is used to circulate fluid through the rod
string to flush and cool the bit and can deliver both high pressure and
flow suitable for normal drilling conditions. The circulation of drilling fluid
can serve several purposes including cooling the bit, flushing cuttings
from the hole as well as reducing friction in the hole. It also can provide
indication of bit condition, landing indication, core blockage or full tube
indication.
Figure 3–21: Fluid Circulation Pump
Maximum output of the standard fluid circulation pump is limited to 35

GPM @ 1000 psi (70 Bar).
An optional liner kit is available to improve pump operation at lower flow

rates. Maximum pump output is limited to 20 GPM @1000 psi (70 Bar)
with that kit installed.
3.8 Controls
3.8.1 Operator Control Panel (OCP)

This section describes the Operator Control Panel (OCP). The OCP is
situated beside the mast pivot and is secured to the drill’s base frame.
All drilling functions are controlled from this panel. All electronic controls
are sealed in the Operator’s Console in water resistant compartments.
Various gauges used to monitor the power unit and the drill’s hydraulic
system are located here.
63
3.8.1.1 Description of Controls

The main drilling controls are equipped with a lift-to-shift or pull-to-shift
device to reduce the possibility of inadvertent operation. These safety
devices must be maintained and should never be bypassed,
defeated or removed by the operator. Brief descriptions of the
controls of the drill are as follows.
18 19
16 17
23 21 20
22
10 11
9
12 14
24 13
26
27
2 15
1 25
3 5
7 8
4 6
Figure 3–22: Operator Control Panel (OCP)
The controls shown in the figure perform the following functions:
1. Emergency Stop Push Button
Push in to shut down the engine. Pull to reset.
After activating the emergency stop switch, it must be reset by lifting

it up to the top position before the engine can be restarted.
64
2. Spare
This selector switch is installed as an option. It is not installed as

standard equipment on this rig.
3. Rotation Control Lever
This controls the forward rotation of the chuck. Move the lever
forward for forward (clockwise) rotation; reverse (counterclockwise)
rotation is controlled by the make/break rotation lever. Maximum
rotation speed is controlled by the rotation control lever, engine
rpm, and the motor displacement control knob. The rotation control
lever has a friction held detent to maintain the rotation speed
setting and features a mechanical lift to shift device to lock it in the
off position.
Note: The rotation control lever has an internal neutral engine

start switch. This feature ensures that the lever is in neutral before
allowing the engine to start.
4. Make/Break Rotation/Feed Control
The make break control provides slow speed rotation and slow
feed for making and breaking drill rod joints. It is a 3 position spring
centered switch. (See head float section for more details.)
5. Fast Feed Control Lever
This spring centered lever controls the “up” and “down” traverse
of the drill head. It is not used when fine feeding during drilling
operations (it remains in the neutral position). Forward movement
of the lever raises the drill head; backward movement of the lever
will lower the drill head. This lever also features a mechanical lock-
out to prevent accidental operation.
When hoisting and lowering rods, make sure the hoisting cable is in
complete tension before opening the chuck.
6. Mainline Hoist Speed Selector Switch
Used to switch the mainline winch to low speed/high torque mode

as the hole depth increases. The driller can shift from low speed for
hoisting to high speed to lower the hoist plug.
Always ensure that the winch control is in neutral before shifting

speeds, otherwise damage will occur to the mainline winch motor.
65
7. Hoist Control Joystick
This joystick controls the direction of the main line or wireline hoist.
Moving the joystick forward raises the hoist selected, pulling back
lowers the hoist. This joystick is a lift to shift spring centered type
and will return to the neutral position when released.
8. Main Line Hoist /Wireline Hoist Selector Switch
This switch is used to configure the hoist control joystick for

the main line hoist or wireline hoist modes. Turning the switch
counterclockwise from the neutral position selects the main line
hoist function, turning the switch clockwise selects the wireline hoist
function. Use the hoist control joystick beside this switch on your
panel to activate the selected function.
9. Fine Feed Control Lever (V9)
This detented, three-position lever controls the movement of the

drill head when in fine feed (drilling) mode. The center position
blocks the fine feed circuit and allows the direction of the drill head
to be controlled by the fast feed lever.
Moving the lever forward will convert the system to fine feed in the
downward direction (drilling mode). Rearward movement of this
lever will convert the system to fine feed in the upward direction
(back reaming or getting weight off the bit).
Never close the rod clamp while the rods are rotating.
10. Hydraulic Mud Mixer Lever (V10)
This two position, detented lever activates the mud mixer. Forward
movement of the lever will switch the mud mixer circuit off, while
rearward movement of the lever initiates the circuit.
11. Head Opener (V11)
This lever controls the opening and closing of the head assembly.
To open the head pull towards you, when closing push away.
Note: The head is locked in place with locking bolts which must be
unbolted prior to activation.
12. Rod Slide (V12)
This lever controls the position of the rod slide located along the
front of the lower mast section during drilling. The slide may be
used for aiding in lowering the inner tube or rod pulling. To raise the
slide pull the lever toward you, when retracting push away.
66
13. Hydraulic Rod Clamp Lever
This two position, detented lever will “open” or “close” the rod
clamp. Moving the lever forward closes the rod clamp; rearward
movement of the lever opens the rod clamp. There is a mechanical
lockout device on this lever to prevent accidental operation.
14. Chuck Open/Close Lever
This two position, detented lever will “open” or “close” the chuck.
Moving the lever forward closes the chuck; rearward movement of
the lever opens the chuck. There is a mechanical lockout device on
this lever to prevent accidental operation.
Never activate this lever while in drilling mode.
15. Brake Release, Mainline Hoist (V16)
This control is used to manually release the mainline hoist when

drilling. The hoist cable is attached to the top of the water swivel
and keeps tension on the swivel while drilling.
16. Multi-Port Hydraulic Gauge
This gauge allows for pressure readings of multiple diagnostic

ports. For more on this feature refer to the hydraulic section.
17. Mainline Hoist Tension Control (V33)
The mainline hoist tension control allows the operator to increase

or decrease mainline rope tension on the water swivel while drilling.
It is only active when the manual brake release control V16 is
activated.
The hoist tension/brake release circuit V16/V33 is only to be used

while drilling with the hoist cable attached to the water swivel. Never
attempt to release the mainline hoist brake when hoisting or lowering
rods as the load could inadvertently drop.
18. Bit Flushing Control Lever
This lever is used to control water to the bit.

19. Fluid Re-circulation Control Lever
This lever is used to send drilling fluid back to the mud tank for re-
circulation.
67
20. Rod Torque Pressure Gauge
This gauge registers the system pressure of the main valve bank
functions, i.e., rotation, fast feed, mainline hoist, and wireline
hoist. The maximum pressure is limited by the individual port relief
cartridges in the main valve bank.
21. Fluid (Water) Pressure Gauge
This gauge shows the drilling fluid (water/mud) pressure.

22. Feed Pressure Gauge
This gauge registers the system pressure of the circuit.

23. Bit Weight Pressure Gauge
This gauge shows the bleed off pressures in the hydraulic feed
cylinder. As weight on the bit is increased, the value of the needle
will fall, i.e., it registers the bleed off pressure in the feed cylinder.
24. Feed Rate Control Valve
This valve controls the feed rate or penetration of the drill string.
Turn clockwise to slow the penetration rate or counterclockwise to
increase the penetration rate.
25. Feed Pressure Reducing Control
This valve controls the desired sensitivity of Feed Rate Control as

required when rod weight contributes to the force on bit.
26. Mud Mixer Speed Control
This valve controls the rotation speed of the mud mixer motor.
Clockwise rotation of the valve knob will decrease rpm, while
counterclockwise rotation will increase rpm to maximum.
27. Motor Displacement Control (V45)
Adjusts the speed and torque of the rotation motor by changing the
motor displacement setting. Rotate the adjustment knob clockwise
to increase motor speed and counter clockwise to decrease motor
speed.
Note: Since the method of changing speed is by adjusting motor

displacement, an increase in speed will result in a decrease in
68
motor output torque. All adjustments are made during drilling to

adjust for in hole conditions.
28 29 30 31 32 33
Figure 3–23: Manual Override Valves
28. Manual Override (Main Line Hoist) (V44-01/V44-02)
Manual override for Main Line Hoist Control.

29. Manual Override (Wireline Hoist) (V44-03)
Manual override for Wireline Hoist.

30. Manual Override (Fast Feed) (V44-04)
Manual override for Fast Feed Directional Control Joystick #5.

31. Manual Override (Rotation) (V44-05)
Manual override for Rotation Control #3.

32. Manual Override (Auxiliary) (V44-06)
Optional Equipment
33. Fluid Pump Speed Control (V7)
This dial controls the speed of the hydraulic motor on the water
pump. Rotating the knob counterclockwise increases the speed of
the water pump motor. Rotating the knob clockwise will decrease
the speed. To ensure that the water pump motor is off, rotate all the
way clockwise.
69
3.8.2 Drill Rig Set-Up Controls V40

The set-up control valve bank is hydraulically isolated while drilling to
prevent inadvertent operation. In a track drive version, the mode
selector switch on the track drive electrical enclosure automatically
controls a solenoid valve V43 for this function. For more details refer to
Chapter 4. On a non-track drive version a manually controlled two
position diverter valve V43 is supplied. The diverter valve either supplies
oil to the set up controls or the D05 manifold for drilling.
Figure 3–24: Hydraulic Valve Bank
3.9 Track Package (Optional)

The optional track package will allow the drill rig to be relocated by
transferring the machines weight to the ground through several contact
points. The drill rigs weight is evenly distributed throughout the tracks.
Figure 3–25: Optional Track Package
For track drive operation details, please refer to Chapter 4, Operation.

For details on track maintenance, refer to Chapter 7, Maintenance.
70
3.10 Rod Racking Platform (Optional)

The rod pulling process can normally be managed at ground level using
a rod sloop located in front of the drill rig to reduce the chance of injury
while working at heights.
An optional rod racking platform is available for applications where site

conditions may dictate that rods be stacked vertically against the mast.
This option requires that a driller helper be located on the upper platform
to handle the hoist plug and guide rods during the rod pulling/lowering
process.
Workers working on raised platforms must always must always be tied

off, wear certified fall protection equipment, and be trained in its use.
Workers should not be left unattended while working on the platform.
Work platform must be kept clear of loose tools that could fall and injure
workers below. If a pipe wrench is required for the hoisting plug, it should
be secured with a lanyard.
Work platform must be kept clear of ice and snow during winter
conditions.
Allowable rod stacking load can vary depending on mast angle.
Do not operate the drill with rods racked against the platform in wind
velocities in excess of 85 kph.
71
Note: For vertical hole setup ONLY..
Figure 3–26: Rod Racking Platform
72
3.11 Power Unit - Cummins QSC 8.3L TIER III Engine
Read and understand the Cummins Operations and Maintenance Manual

before operating this equipment.
The power unit module is located at the rear of the drill. It encloses the
prime mover (engine), hydraulic reservoir, hydraulic pump group,
coolers and main electrical control panel, filters (air, fuel, engine, and
hydraulic). It consists of a six cylinder, turbocharged, water cooled,
charge air cooled engine rated at 194 kW (260 hp) (intermittent) with a
displacement of 8.3 L (506 in).
Figure 3–27: Cummins QSC 8.3L Tier III Power Unit
Basic engine spares are covered in your LF parts manual. For more
detailed replacement parts, record your engine serial number and
contact your local Cummins distributor.
A detailed Cummins Parts and Operations/Service Manuals is supplied

with your drill, refer to that for more detailed service and repair
information.
The oil and fuel filters on this power unit are a spin on design and are
situated for easy servicing. Inspection of these components should
73
be done at regular intervals. Use only Cummins replacement filters

when servicing.
A 12-volt alternator is standard equipment on this unit and is used to

charge the main battery and power the electrical system of the drill. The
main hydraulic pumps P1, P2, and P3 are directly coupled to the engine
flywheel by a composite toothed adapter plate, the fourth pump, P4, for
the hydraulic oil cooler fan(s) is PTO mounted.
An engine management system is configured to automatically cut back

on fuel in the event of high coolant temperature, low oil pressure, or high
intake manifold temperature.
The Cummins engine is equipped with a pre-programmed throttle

control that controls low idle and full engine speed. This ensures that
the hydraulic pumps are at full rotation speed when delivering flow and/
or pressure on demand. A manually controlled throttle is also installed to
allow the operator to reduce engine speed (reducing noise and saving
fuel) for specific lower flow demand tasks (ie wireline operation).
Engine instrumentation is mounted in the Engine control panel assembly

(ECP). An engine monitor is provided by Cummins to monitor the
following engine parameters:
●● Engine rpm
●● Engine coolant temperature
●● Charging or battery voltage.
●● Engine oil pressure
●● Engine hours
●● % engine load at current rpm
●● Fuel economy/current fuel consumption
●● Engine manifold air temperature
The engine control monitor can be re-configured by the operator for

different languages and display preferences.
The power unit exhaust system will become very hot during operation.
Care must be taken when working in area.
74
3.11.1 Engine Control Panel (ECP) Tier III Model

The ECP Tier III control functionality is as follows:
4
1 5
7
2
Figure 3–28: ECP Tier III Model
1. Engine Control Module
Monitors engine performance and is used for diagnostic purposes.

Refer to the Engine Control Monitor section that follows for more
information on the operation of this unit.
2. Engine Idle/Run Toggle
This toggle switch allows the operator to toggle between normal

drill operating rpm of 2200 rpm and then return to the last engine
speed set by the rotating throttle control. For example, if the engine
rpm has been set to 1200 rpm with the rotating throttle control when
the switch is toggled to the Run setting the engine will increase rpm
until it reaches 2200 rpm. Then when the switch is toggled back to
the idle setting the engine rpm will return to 1200 rpm.
3. Ignition Key
This controls the engine start-up and shut down. There are three
positions: OFF, ACC/RUN and START. There is a mechanical
interlock in the switch which prevents the operator from re-
engaging the starter without first resetting the key to the off position
4. Engine Stop Light (Red)
This light indicates an engine condition has occurred that could

cause permanent engine damage. It flashes when an engine
shutdown is about to occur and remains illuminated when an
engine shutdown has occurred.
75
5. Engine Warning Light (Amber)
This light illuminates when an engine fault has occurred. Further

investigation should be done by the operator using the engine
control monitor to determine the nature of the fault.
6. Engine Preheat Light (Blue)
This light illuminates during the engine preheat cycle indicating wait
to start.
7. Engine Electronic Throttle Control
The ETC Multi-Turn knob varies in direction of rotation for engine

speed increases. Rotating the knob clockwise increasing rpm and
counter-clockwise decreases rpm. Pushing the control knob in will
instantly return the rpm back to idle. The ETC Multi-Turn provides
the operator with adjustments for lower and upper engine rpm limits
to ensure the equipment is operated safely and efficiently.
Low RPM Settings: (850 RPM)
a. With the control knob facing you, turn the control knob
counterclockwise until the desired low rpm is reached. If
necessary, back out the set screw “A” to reach the desired rpm.
b. Lock the control knob in place by tightening the tension nut. The
low rpm limit stop is set by turning set screw “A” in until contact
is made.
c. Release the tension nut and rotate the control knob clockwise.
d. Rotate control knob counterclockwise and check adjustment.

Fine adjust if necessary.
High RPM Settings: (2200 RPM)
a. With the control knob facing you, turn the control knob
clockwise until the desired high rpm is reached. If necessary,
back out the set screw “B” to reach the desired rpm.
b. Lock the control knob in place by tightening the tension nut. The
high rpm limit stop is set by turning set screw “B” in until contact
is made.
c. Release the tension nut and rotate the control knob

counterclockwise.
d. Rotate control knob clockwise and check adjustment. Fine

adjust if necessary.
Once the adjustments have been made, the limit stops will provide
a high and low rpm limit for engine operation and the engine may
be operated at any throttle setting necessary for the job within the
confines set by the stops.
76
Note: Check to ensure that the tension nut is working properly by

attempting to turn the control knob with the tension nut engaged in
the holding position. Failure to check the locking of the tension nut
may result in a decrease on engine rpm over a period of time.
3.11.2 Engine Control Monitor (Canvu Tier III Engine

Only)
The Veethree Engine Monitor (VEM) user-configurable application
software creates graphical instrument clusters to display parameters
and alarms - providing users with a timesaving solution for introducing
equipment incorporating higher degrees of electronic display and
control.
These pages provide operating instructions for the Veethree Engine

Monitor which displays J1939-compatible engine/ transmission data.
Please read through the guide before use.
The VEM software runs on a CANvu display with five soft keys,
providing a flexible and intuitive Human-Machine Interface (HMI). The
5 soft keys access a graphical menu structure that uses standard and
easily-understood icons to indicate the key’s current function. This
enables the operator to select the required engine/transmission data
and display it in the following formats:
●● Analog gauges
●● Digital values
●● Current alarm messages (Alarm Fault Codes are listed in
Chapter 8: Troubleshooting)
Additionally, various diagnostic screens are available, allowing detailed

investigation of the engine and transmission data stream. The
underlying structure of the VEM and its interaction with the soft keys are
further explained in the following section. By accessing the
Configuration menu, users can customize some of the displayed data to
77
show, for example, metric or imperial units, and various parameters

such as the full-scale reading of gauges.
Figure 3–29: Veethree Engine Monitor (VEM)
For fault codes, please refer to Chapter 8, Troubleshooting.
3.11.2.1 Preferred Screen Store

The VEM automatically stores the current screen as the user’s preferred
page, after a delay of approximately 15 seconds (if no buttons are
pushed). On the next power-up the display will start with the splash
screen, and then go to the last stored screen.
Note: Selecting Restore Defaults on the Systems sub-menu of

Configuration will set the screen 1 as the default display.
3.11.2.2 Keys 1 to 4 Operation

There are 4 main user screens accessed via the first four keys The keys
have icons to represent the screen view types, as follows.
Key 1 is a quad gauge view, Key 2 is a quad digital data view and key 3
is a single analog gauge view. Key 4 is used to access the alarm
screen.
Figure 3–30: Keys 1 to 4
78
3.11.2.3 Adjust Lighting and Contrast

Pressing Key 5 (the right-hand key) when the menu icons are not being
displayed brings up the lighting menu. The LCD has a number of back-
lighting levels that allow the display brightness and keypad brightness
to be adjusted. The appropriate level is selected by pressing keys 1
or 2 to decrease or increase the illumination level of the LCD. The
keypad brightness is adjusted in the same manner, using Keys 3 and 4.
Adjusting the brightness plus or minus will activate the day/night feature.
White background for better visibility in daylight and black background
for better visibility at night.
3.11.2.4 Language Support

There are 9 languages supported by CANvu: English, Swedish,
German, Spanish, Italian, Portuguese, and Russian. Use the following
steps to adjust to your preferred language.
1. Turn the unit on.
2. Push and hold Key 5 until the config screen comes up.
3. Click Settings.
4. Click on Language and then choose your preferred language.
5. Press Key 5 three times and the language choice will be locked in.
3.11.2.5 Quad Analog View (Screen 1)

This screen is a configurable quad analog gauge view.
There is an option to have up to 4 quad analog views (so a total of

16 gauges can be selected). The number of quad views is adjustable
between 1 and 4 (default).
79
The data that can be chosen shall also be configurable (an option in the
DBViewer screen).
Figure 3–31: Quad Analog View
Note: If a parameter is not available from the engine/ transmission, it will

not be possible to select it. If the parameter becomes unavailable while
in view, ‘- - -’ is displayed.
To adjust the contents of the quad screens - first press any of the first
four keys to raise the button bar and then press key 5 to enable the
cycling through of all the display parameters.
Data.Available.for.Quad.Screens.(both.analog.and.digital.views)
db_0190_ENGINE_RPM db_0084_0517_NAV_WHEEL_
BASED_ VEHICLE_SPEED
db_0110_ENGINE_COOLANT_ db_0168_0158_ELEC_BAT_
TEMP POTENTIAL
db_0167_ALTERNATOR_ db_0115_ALTERNATOR_CURRENT
POTENTIAL
db_0114_NET_BATTERY_ db_0102_BOOST_PRESSURE
CURRENT
db_0109_COOLANT_PRESSURE db_0094_FUEL_DELIVERY_
PRESSURE
db_0100_ENGINE_OIL_PRESSURE db_0247_TOTAL_ENGINE_HOURS
db_0127_TRANS_OIL_PRESSURE db_0177_TRANS_OIL_TEMP
db_0173_EXHAUST_GAS_TEMP db_0175_ENG_OIL_TEMP_1
db_0105_INTAKE_MANIFOLD_1_ db_0092_TORQUE_USE_AT_RPM
TEMP
db_0091_ACCELERATOR_ db_0524_SELECTED_GEAR
POSITION
db_0523_CURRENT_GEAR db_0441_AUXILIARY_TEMP_1
db_1387_AUXILIARY_ db_0975_EST_PERCENT_FAN_
PRESSURE_1 SPEED
db_0174_FUEL_TEMP db_0176_TURBO_OIL_TEMP
80
db_0052_ENGINE_INTERCOOLER_ db_0098_ENGINE_OIL_LEVEL
TEMP
db_0111_COOLANT_LEVEL db_0108_BARO_PRESSURE
db_0172_AIR_INLET_TEMP db_0106_AIR_INLET_PRESSURE
db_0107_AIR_FILTER_1_DIFF_ db_0183_FUEL_RATE
PRESS
db_0513_ACTUAL_ENGINE_ db_1029_TRIP_AVERAGE_FUEL_
PERCENT_TORQUE RATE
db_1036_TRIP_ENGINE_ db_0096_FUEL_LEVE
RUNNING_TIM
3.11.2.6 Quad Digital View (Screen 2)

This screen is a configurable quad digital view. There is an option to
have up to 4 quad views (so a total of 16 items can be selected). The
number of quad views are adjustable between 1 and 4 (default). The
data that can be selected is also configurable (an option in the
DBViewer screen).
Figure 3–32: Quad Digital View

3.11.2.7 Single Analog View (Screen 3)

This screen is a single analog gauge view. The data selected is also
configurable (an option in the DBViewer screen).
81

Figure 3–33: Single Analog View
Note: Data Available for Single Screen
db_0190_ENGINE_RPM db_0110_ENGINE_COOLANT_
TEMP
db_0100_ENGINE_OIL_PRESSURE db_0183_FUEL_RATE
db_0102_BOOST_PRESSURE db_0168_0158_ELEC_BAT_
POTENTIAL
db_0167_ALTERNATOR_ db_0115_ALTERNATOR_CURRENT
POTENTIAL
db_0114_NET_BATTERY_ db_0109_COOLANT_PRESSURE
CURRENT
db_0094_FUEL_DELIVERY_ db_0127_TRANS_OIL_PRESSURE
PRESSURE
db_0177_TRANS_OIL_TEMP db_0173_EXHAUST_GAS_TEMP
db_0175_ENG_OIL_TEMP_1 db_0105_INTAKE_MANIFOLD_1_
TEMP
3.11.2.8 Alarm Screen 4

The VEM supports active faults received from DM1 messages.
When an active/current alarm is received, a flashing pop-up window

appears overlaid on the active screen, showing details of the current
alarm. When an active alarm is received, the VEM activates its internal
sounder.
The alarm list is accessed by pressing any key while an alarm pop-up is
displayed, or by pressing any of the first 4 keys to show the button bar,
and then key 4. This screen displays all current active alarms. Alarms
not yet acknowledged are shown in black text on a red background.
Alarms already acknowledged are shown in white text on black. If the
82
engine hours data is available, the list indicates when the alarm was
initiated.
Figure 3–34: Alarm Pop-up Screen
When first entering the alarm screen, the list automatically displays the
most recent alarm. The list can be scrolled using keys 1 and 2. This
screen cannot be exited until all alarms have been acknowledged by
pressing key 3. Alarm messages are automatically cleared from the list
when no longer received by the VEM.
ENGINE SERVICE WARNING In the Configuration menu, users can set

the engine service interval in hours. When the VEM determines an
engine service is due, it will display SERVICE REQUIRED on the splash
screen that appears at power-up.
Figure 3–35: Alarm Screen Before Alarm Acknowledgement
DATA COMMUNICATIONS FAILURE If the VEM cannot detect engine/

transmission data broadcasts, a pop-up window with a data
communications failure warning icon will appear and flash. Once engine/
83
transmission data is detected the warning disappears and normal data

display resumes.
Figure 3–36: Typical Alarm Screen After Alarm Acknowledge
If any active alarms still exist after acknowledging the icon shown below
will continue to flash to indicate this.
Figure 3–37: Active Alarm Still Exists
3.11.2.9 Top Level Menu
Figure 3–38: Config Menu
84
3.11.2.10 Settings Menu and Sub Menu
Figure 3–39: Settings
Figure 3–40: Units
Figure 3–41: Display
Figure 3–42: Service
85
3.11.2.11 System Menu and Sub-Menus
Figure 3–43: System
Figure 3–44: Com Viewer
Figure 3–45: J1939 Settings
Figure 3–46: Pin Settings
86
3.11.2.12 Database Viewer/Display Mapping

This screen can be adapted to allow the data mapping/filter for each of
the three data views. The operator can check boxes for each item they
want to appear on each of the standard views (Quad and Single). Key 1
and Key 2 are page up/down respectively. Key 3 moves down the list
one item and Key 4 is to edit the settings of the view filters.
Figure 3–47: Database Display
This shows the screen in “edit” mode where the highlighted item (in
RED) can be chosen to be viewed in the quad or the single view or in
both or in neither.
Figure 3–48: Database Display in Edit Mode
3.12 Power Unit - Cummins QSL 9.0L Tier 4i Engine
Read and understand the Cummins Operations and Maintenance Manual

before operating this equipment.
87
The power unit consists of a six cylinder, turbocharged, water cooled,

charge air cooled engine rated at 205 kW (275 hp) (intermittent) with a
displacement of 9.0 L (549 in3).
Figure 3–49: Cummins QSL 9.0L Tier 4i Power Unit
Basic engine spares are covered in your LF parts manual. For more
detailed replacement parts, record your engine serial number and
contact your local Cummins distributor.
A detailed Cummins Parts and Operations/Service Manual is supplied

with your drill; refer to that for more detailed service and repair
information.
The oil, coolant and fuel filters on this power unit are a spin on design
and are situated for easy servicing. Inspection of these components
should be done at regular intervals. Use only Cummins replacement
filters when servicing.
A 12-volt alternator is standard equipment on this unit and is used to

charge the main batteries and power the electrical system of the drill.
The main hydraulic pumps P1, P2, and P3 are directly coupled to the
engine flywheel by a composite toothed adapter plate. The fourth pump,
P4, for the hydraulic oil cooler fan(s) is PTO mounted.
An engine management system is configured to automatically cut back

on fuel in the event of high coolant temperature, low oil pressure, or high
intake manifold temperature.
A manual 5 position throttle control is installed to allow the operator to

reduce engine speed (reducing noise and saving fuel) for specific lower
flow demand tasks.
88
Engine instrumentation is mounted in the Engine control panel assembly

(ECP). An engine monitor is provided by Cummins to monitor the
following engine parameters:
●● Engine rpm
●● Engine coolant temperature
●● Charging or battery voltage
●● Engine oil pressure
●● Engine hours
●● % engine load at current rpm
●● Fuel economy/current fuel consumption
●● Engine manifold air temperature
The engine control monitor can be re-configured by the operator for

different languages and display preferences.
The power unit exhaust system will become very hot during operation.
Care must be taken when working in area.
89
3.12.1 Engine Control Panel (ECP) Tier 4i Model

The ECP Tier 4i control functionality is as follows:
4
3
7 8
Figure 3–50: Engine Control Panel
1. Engine Control Module
Monitors engine performance and is used for diagnostic purposes.

Refer to the Engine Control Monitor section that follows for more
information on the operation of this unit.
2. Ignition Key
This controls the engine start-up and shut down. There are three
positions: OFF, ACC/RUN and START. There is a mechanical
interlock in the switch which prevents the operator from re-
engaging the starter without first resetting the key to the off
position.
3. Engine Regeneration Switch
This is a 3 position switch used to manually inhibit or initiate the

engine regeneration cycle.
○○ Position 1 (left hand side) - Is used to force the engine to initiate
a regeneration cycle.
○○ Position 2 (center position) - For normal rig operation, the switch
should be set to this position.
90
○○ Position 3 (right hand side) - Has a momentary contact, with

spring return to center (position 2). It is used to cancel an active
regeneration command.
4. Horn
Depress the button to sound the horn.

5. Drill Lighting Switch
This switch is used to turn on and off work area lighting.

6. Fault Light
When any emergency stop is activated this light will illuminate, and
stay on until the fault is corrected.
7. Engine Idle/Run Toggle
This is a two position switch allowing the operator to toggle

between an engine idle speed of 750 rpm and a function specific
engine operating speed selected by switch 8.
○○ Position 1 (left hand side) is Idle speed.
○○ Position 2 (right hand side) signals the engine to maintain a pre-
set engine speed per the position of switch 8.
8. Engine Multi Speed Control
This is a four position switch which allows the operator to increase

engine speed as it is rotated in a clockwise direction. Each position
is a pre-programmed speed for specific rig functions. Those speed
settings are configured to provide optimal function performance
while minimizing fuel consumption and noise.
○○ Position 1 – 1000 RPM for flushing the hole
○○ Position 2 – 1500 RPM for Wireline function
○○ Position 3 – 1800 RPM for Drilling
○○ Position 4 – 2200 RPM for Hoisting
9. Engine Speed Increment / Decrement
This switch is used to manually increase or decrease engine speed

in increments of 25 RPM. This switch is only active when switch 7
is in position 2 and switch 8 is in position 4.
91
3.12.2 Engine Control Monitor (Murphy Tier 4i Engine

Only)
There are two pre-programmed six panel screens for the operator as
shown below in screens 2 and 3. The function of the screen is covered
in more detail in the Murphy Powerview Section that follows. Alarm
Fault Codes are listed in Chapter 8: Troubleshooting.
Figure 3–51: Screen 1
Screen 1 identifies the program version.
Screen 2 contains the following information:
●● Engine RPM
●● Spindle (Drilling) RPM
●● Fuel Level
●● Fuel Consumption
92
●● Coolant Temperature
●● Engine Oil Pressure
Screen 3 contains the following information:
●● Soot % (Diesel Particulate Filter)

●● System Voltage
●● Engine exhaust filter inlet temp
●● Engine Load %
●● Engine Exhaust filter outlet temp
●● Engine Hours
3.12.2.1 Engine and Transmission Parameters

The following are some of the engine and transmission parameters
that can be displayed in standard or metric units as well as in English,
Spanish, French, Italian, or German languages.
●● Engine Speed
●● Total Engine Hours of Operation
●● Machine Hours
●● Battery Voltage
●● Coolant Temperature
●● Engine Oil Pressure
●● Engine Fuel Level
●● Engine Fuel Rate
●● Instantaneous Fuel Economy
●● Average Fuel Economy
93
●● Exhaust Filter Inlet Temperature

●● Exhaust Filter Outlet Temperature
●● Engine Total Vehicle Distance
●● Diesel Exhaust Fluid (DEF) Level
●● Percent Soot Level
●● Transmission Oil Pressure
●● Transmission Oil Temperature
●● Hydraulic Oil Pressure
●● Hydraulic Oil Temperature
●● % Load @ Current RPM
●● Active Fault Codes
●● Stored Fault Codes
3.12.2.2 Navigation and Keypad Functions

The keys on the keypad are as follows:
Figure 3–54: Keypad Keys
From any 4- or 6-up display screen, pressing any of these Soft Keys will
display the following menu on the screen:
Figure 3–55: Soft Keys Menu
94
The Soft Keys below each symbol will produce the following when
pressed:
Key Function
Soft Key 1 Displays the menu items of:
Brightness
Contrast
Units
Language
ECU Address
In addition, it becomes a down arrow

when in the menu selection to move
to the next selection.
Soft Key 2 Displays the Emissions menu:
Request DPF Regen

Current Regen mode (Auto or Inhibit)
Method of changing the Regen Mode
In addition, it becomes an up arrow

when in the menu selection to move
to the previous selection.
Soft Key 3 Displays the Diagnostics menu:
Active Faults – ECU

Stored Faults – ECU
Clear Fault Codes
Soft Key 4 Displays the Service Reminders

menu:
Engine Oil
Fuel Filter
Engine Air Filter
Hydraulic Oil
Service Engine
Service Machine
Soft Key 5 Scrolls through the four available
gauge screens.
Table 3–1: Soft Keys Symbols
After displaying the context menu, if no pushbutton is pressed within 5

seconds, the pop-up menu shall disappear from view.
95
3.12.2.3 First Time Startup

When power is applied to the PowerView 350/380, the Warning and
Shutdown lights illuminate and the Boart Longyear logo displays. If a
preheat message is being actively broadcast from the Engine Control
Unit (ECU), a Wait to Start symbol will be displayed below the Boart
Longyear logo.
Figure 3–56: First Time Startup Screen
Once the engine has started, the 4-up parameter view displays with
Engine RPM, Oil Pressure, Voltage, and Coolant Temperature. To reach
the various gauge displays, press any button to enable the menu to
appear, then press the Right Arrow repeatedly.
3.12.2.4 Gauge Displays

There are four (4) gauge displays on the PV350/PV380. They can be
displayed when the right arrow is pressed repeatedly from the menu
display. The displays are described in detail below:
Engine 4-Up
Figure 3–57: Engine 4-Up Screen
The Engine 4-Up Screen shall consist of the follow parameters.
96
1. Engine Speed
○○ Gauge: 0-3,000 rpm

2. Engine Oil Pressure
○○ Gauge: 0-100 psi

○○ Gauge: 0-700 kPa
○○ Gauge: 0-7 bar
3. Coolant Temperature
○○ Gauge: 150-250°F
○○ Gauge: 65-120°C
4. Battery Voltage
○○ Gauge: 8-32V
Emissions 4-Up Screen
Figure 3–58: Emissions 4-Up Screen
The Emissions 4-Up Screen shall consist of the following parameters.
1. DEF Level
○○ Gauge: 0-100%
2. Percent Soot level
○○ Gauge: 0-250%
3. Exhaust filter inlet temperature
○○ Gauge: 450-750°F
○○ Gauge: 250-400°C
4. Exhaust filter outlet temperature
97
○○ Gauge: 550-1050°F
○○ Gauge: 300-550°C
6-Up #1 Screen
Figure 3–59: 6-Up #1 Screen
The first 6-Up Screen shall consist of the following parameters.
1. Percent Engine Load at current RPM
2. Transmission Oil Pressure
3. Transmission Oil Temperature
4. Engine Fuel Rate
5. Instantaneous Fuel Economy
6. Average Fuel Economy
6-Up #2 Screen
Figure 3–60: 6-Up #2 Screen
The second 6-Up Screen shall consist of the following parameters.

98
1. Hydraulic Oil Pressure
2. Hydraulic Oil Temperature
3. Engine Total Vehicle Distance
4. Engine Fuel Level
5. Engine Total Hours of Operation
6. Machine Hours
3.12.2.5 Adjusting the Menu Selections

Brightness
Follow these steps to adjust the Brightness:
1. Press any Soft Key to display the Menu.
2. Press the Soft Key 1 (Menu), and if Brightness does not have the
arrow beside it, press Soft Key 2 (up arrow) to place the arrow
beside Brightness.
3. Press Soft Keys 3 (+) and 4 (-) to adjust the Brightness.
4. Press Soft Key 5 (return arrow) to exit the menu.
Contrast
Follow these steps to adjust the Contrast:
2. Press the Soft Key 1 (Menu), and if Contrast does not have the
arrow beside it, press Soft Key 1 (down arrow) or Soft Key 2 (up
arrow) to place the arrow beside Contrast.
3. Press Soft Keys 3 (+) and 4 (-) to adjust the Contrast.
Units
Follow these steps to adjust the Units:
2. Press the Soft Key 1 (Menu), and if Units does not have the arrow
beside it, press Soft Keys 1 or 2 (up and down arrows) to place the
arrow beside Units.
3. Press Soft Keys 3 (+) and 4 (-) to cycle through the choices of:
99
a. USA Standard
b. Metric kPa
c. Metric Bar
Language
Follow these steps to adjust the Language:
2. Press the Soft Key 1 (Menu), and if Language does not have the
arrow beside it, press Soft Keys 1 or 2 (up and down arrows) to
place the arrow beside Language.
3. Press Soft Keys 3 (+) and 4 (-) to cycle through the choices of:
a. English
b. French
c. German
d. Spanish
e. Italian
ECU Address
Follow these steps to adjust the ECU Address:
2. Press the Soft Key 1 (Menu), and if ECU Address does not have
the arrow beside it, press Soft Keys 1 or 2 (up and down arrows) to
place the arrow beside ECU Address.
3. Press Soft Keys 3 (+) and 4 (-) to adjust to the appropriate ECU
Address.
DPF Regen
Follow these steps to adjust the Regen Mode:
2. Press the Soft Key 2 (Emissions Menu).
100
3. If Regen Mode does not have the arrow beside it, press Soft Keys
1 or 2 to place the arrow beside Regen Mode.
Figure 3–61: Regen Mode
4. Press the Soft Key 3 to change the Regen Mode(“INHIBIT” when in

AUTO mode, “AUTO” when in INHIBIT mode.
Follow these steps to request the ECU to start a DPF Regen:
2. Press the Soft Key 2 (Emissions Menu).
3. If “Request DPF Regen” does not have an arrow beside it, press
Soft Keys 1 or 2 to place the arrow beside Request DPF Regen.
4. Press Soft Key 3 (OK). A confirmation screen will be displayed:
Figure 3–62: Confirmation Screen
5. Pressing the Soft Key 2 (Yes) will request the ECU to begin a DPF
Regen. Pressing Soft Key 4 (Cancel) will return to the previous
menu.
Diagnostics Menu
Follow these steps to display the Diagnostics Menu:
101
2. Press the Soft Key 3 (Diagnostics Mode).
3. To view the:
a. Active Faults, press the Soft Key 3 (OK).
■■ The Diagnostic Message screen # of # will appear. Press

the Soft Keys 1 and 2 to scroll through additional messages
if present. Each saved code shows the SPN (Suspect
Parameter Number), FMI (Failure Mode Identifier), and OC
(Occurrence Count). The OC indicates if the same fault
occurred more than once. If available, a text explanation of
the Warning or Shutdown also displays.
■■ Press the Soft Key 5 (return arrow) to return to the Faults
screen.
b. Stored Faults, press the Soft Key 1 (down arrow) once, then the
Soft Key 3 (OK).
■■ Stored faults are requested from the ECU. While the data is
being requested, “Requesting Data” and “Receiving Data” will
be displayed. If data is not received from the ECU, “Timeout/
Failure” will be displayed. Pressing Get Faults will request
data from the ECU again. If data is received, the Diagnostic
Message screen # of # will appear. Press the Soft Keys 1
and 2 to scroll through additional messages if present. Each
saved code shows the SPN (Suspect Parameter Number),
FMI (Failure Mode Identifier), and OC (Occurrence Count).
The OC indicates if the same fault occurred more than once.
If available, a text explanation of the Warning or Shutdown
also displays. Press the Soft Key 3 (Get Faults) to receive
additional Stored Faults. Press the Soft Key 5 (return arrow)
to return to the Faults screen.
c. Ability to Clear Fault Codes, press the Soft Key 1 (down arrow)
twice, then the Soft Key 3 (OK).
■■ Press the Soft Key 3 (OK) to Clear Fault Codes. A message

will be sent to clear the stored faults to the ECU. Press the
Soft Key 5 to return to the Faults screen.
Service Reminders Menu
Follow these steps to display the Service Reminders Menu:
2. Press the Soft Key 4 (Service Reminders).
3. To view the:
a. Engine Oil reminders, press the Soft Key 1 (down arrow).
■■ The arrow moves down one slot to Interval. Use the Soft Keys
3 (+) and 4 (-) to adjust the number of hours.
102
■■ Press the Soft Key 1 (down arrow) to move the right arrow
to Hour Type. Choose the appropriate setting of Engine
Hours or Machine Hours. The Remaining hours will adjust
accordingly.
■■ To reset the hours, Press the Soft Key 1 (down arrow) to
move the right arrow to Reset. Press the Soft Key 3 (OK) and
the hours will be reset.
b. Fuel Filter reminders, ensure the right arrow is beside the first
item in the list, and press the Soft Key 3 (+) until Fuel Filter
appears. Press the Soft Key 1 (down arrow).
accordingly.
c. Engine Air Filter reminders, ensure the right arrow is beside the
first item in the list, and press the Soft Key 3 (+) until Engine Air
Filter appears. Press the Soft Key 1 (down arrow).
accordingly.
d. Hydraulic oil reminders, ensure the right arrow is beside the first
item in the list, and press the Soft Key 3 (+) until Hydraulic Oil
appears. Press the Soft Key 1 (down arrow).
accordingly.
e. Service Engine reminders, ensure the right arrow is beside the
first item in the list, and press the Soft Key 3 (+) until Service
Engine appears. Press the Soft Key 1 (down arrow).
103
accordingly.
Note: If the type is set to Engine Hours, the unit must be connected
to an ECU and be receiving data to reset the service reminder. If
Engine Hours data is not being received, the service reminder will
not reset.

f. Service Machine reminders, ensure the right arrow is beside the
first item in the list, and press the Soft Key 3 (+) until Service
Machine appears. Press the Soft Key 1 (down arrow).
accordingly.
■■ Press the Soft Key 5 (return arrow) to return to the gauge
screen.
Note: The interval remaining time may be negative when the

service reminder is “expired”.
3.12.2.6 Acknowledging Faults

LED Indicators
The PV350/PV380 features amber (Warning) and red (Shutdown)

colored LEDs on the front keypad. These are illuminated according the
J1939 error definition for alarms and shut-down conditions.
Figure 3–63: LED Indicators
104
Indicator Lamps
On each gauge screen and menu (where space allows) the following
indicator lamps shall be shown:
Icon PGN SPN Description

DM1 Stop Diagnotic lamp: indicates
an active DM1 stop fault.
DM1 Warning Diagnotic lamp:

indicates an active DM1 fault.
64892 3714 High Exhaust Temperature

(HEST) lamp: indicates
regeneration in process.
64892 3697 DPF Particulate Filter Restricted

lamp: indicates a Regen is
needed.
64892 3703 DPF Inhibit lamp: indicates an

inhibited Regen status.
65110 1761 Diesel Exhaust Fluid (DEF)

lamp: displays when the fluid
level drops below 12%.
Table 3–2: Indicator Lamps
Supported Parameters
The following table of parameters shall be available for selections based

on being actively broadcast on the CAN bus:
Description Short PGN

Description
1 PERCENT LOAD AT CURRENT RPM LOAD@RPM 61443
2 ENGINE SPEED ENG RPM 61444
3 TOTAL VEHICLE DISTANCE VEH DIST 65248
4 TOTAL ENGINE HOURS ENG HRS 65253
5 ENGINE COOLANT TEMPERATURE COOL TEMP 65262
6 ENGINE OIL PRESSURE OIL PRES 65263
7 FUEL RATE FUEL RATE 65266
105
Description Short PGN

Description
8 INSTANTANEOUS FUEL ECONOMY FUEL ECON 65266
9 AVERAGE FUEL ECONOMY AVG ECON 65266
10 AIR INLET TEMPERATURE AIR IN TP 65269
11 BATTERY POTENTIAL VOLTAGE BAT VOLT 65271
12 TRANSMISSION OIL PRESSURE TRAN PRES 65272
13 TRANSMISSION OIL TEMPERATURE TRAN TEMP 65272
14 FUEL LEVEL FUEL LEVEL 65276
15 HYDRAULIC PRESSURE HYD PRES 61448
16 HYDRAULIC TEMPERATURE HYD TEMP 65128
17 MACHINE HOURS MACH HRS 61444
18 DIESEL EXHAUST FLUID LEVEL DEF LVL 65110
19 % SOOT % SOOT 64891
20 EXHAUST FILTER OUTLET TEMP EF OUT T 64947
21 EXHAUST FILTER INLET TEMP EF IN T 64948
Table 3–3: Supported Parameters
106
Contents
4.1 Introduction............................................................................................. 109
4.1.1 Safeguards.................................................................................. 109
4.1.2 Routine Checks........................................................................... 109
4.1.2.1 Wire Rope Care.................................................................. 110
4.2 Visual Inspection of Masts..................................................................... 110
4.3 Transporting the Drill Site to Site.......................................................... 113
4.3.1 Lifting the Drill.............................................................................. 113
4.3.2 Truck Transport (Shipping).......................................................... 114
4.3.3 Driving a Truck Mounted Drill...................................................... 114
4.3.4 Driving a Track Mounted Drill...................................................... 115
4.3.4.1 Operating the Track Drive Control...................................... 118
4.3.4.2 Activating the Transmitter................................................... 118
4.4 Configuring the Drill Based on Rod Type............................................. 119
4.4.1 Chuck Jaws................................................................................. 119
4.4.2 Upper Chuck Guide Bushing....................................................... 119
4.4.3 Lower Spindle Guide Bushing..................................................... 120
4.4.4 Foot Clamp Slip Sets................................................................... 120
4.4.5 Hoist Plug Bullnose Sub.............................................................. 121
4.4.6 Water Swivel Adapter Sub.......................................................... 121
4.4.7 Overshot...................................................................................... 121
4.5 Pre-start Checklist.................................................................................. 121
4.6 Starting the Drill...................................................................................... 123
4.7 Raising The Mast..................................................................................... 124
4.8 Casing/Rod Guide Bushing.................................................................... 127
4.9 Opening the Drill Head........................................................................... 127
4.10 Making Head Float Adjustments............................................................ 128
4.10.1 Head Float Up Adjustment.......................................................... 129
4.10.2 Head Float Down Adjustment...................................................... 130
4.11 Mud Mixer Control................................................................................... 131
107
4.12 Shifting the Head Gear Range............................................................... 132

4.13 Rod Make-up Torque.............................................................................. 133
4.14 Drilling...................................................................................................... 134
4.14.1 Fluid Circulation........................................................................... 134
4.14.2 Fine Feed Drilling Control............................................................ 135
4.14.3 Fine Feed Rate Valve V26.......................................................... 136
4.14.4 Fine Feed Pressure Control V25................................................. 137
4.15 Calculating the Weight on Bit................................................................ 138
4.16 Inserting the Core Barrel........................................................................ 140
4.17 Rod Making.............................................................................................. 141
4.17.1 Rod Lowering (Rod Making)........................................................ 142
4.18 Rod Breaking........................................................................................... 143
4.18.1 Rod Pulling (Rod Breaking)......................................................... 143
4.18.2 Breaking Casing Under the Mast................................................ 144
4.19 Retrieving the Inner Tube....................................................................... 145
4.20 Hoisting.................................................................................................... 146
4.20.1 Stacking Drill Rods...................................................................... 147
4.21 Shutting Down the Drill.......................................................................... 147
4.22 Lowering the Mast................................................................................... 148
4.23 Refueling the Rig: Safety Precautions.................................................. 148
4.23.1 Fueling Safety............................................................................. 149
4.23.2 Emergency Equipment................................................................ 149
4.23.3 Filling a Container....................................................................... 149
4.23.4 Fueling Facts............................................................................... 150
4.23.5 Emergency Procedures............................................................... 150
4.23.5.1 Fuel Spill............................................................................. 150
4.23.5.2 Fire...................................................................................... 151
Tables
Table 4–1: Mast Inspection Checklist............................................................ 113
108
4.1 Introduction
The following are recommended guidelines and practices to help
prolong the life of your newly obtained Boart Longyear mast.
Enclosed is a checklist for a visual inspection which should be done

every 1000 hrs of operation. (Inspections may have to be done more
often when operating in extreme environmental conditions.) Make
copies of the checklist for each inspection. The checklist should be
signed and filed for future reference.
4.1.1 Safeguards
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.
During mast raising and lowering operations it is essential that the drill is
securely anchored first. A slow practical operating speed must be used
during this function at all times.
The strength of rusty wire rope cannot be accurately established,

therefore, rusty rope lines must be replaced immediately. Areas
adjacent to cable end connections must be examined closely for any
evidence of corrosion.
Design modifications or welding to the mast is prohibited. These

modifications could result in weakening of the mast members and lead
to structural failure later.
Should the drill need to be set up in a situation that places the operator
platform higher off the ground than permitted by local regulations, a
properly constructed platform addition should be made.
The LF230 drill is equipped with a rod make/break system. At no time

should a pipe wrench or stillson be used to break rod joints.
4.1.2 Routine Checks

●● Inspection of welds in erecting mechanism for cracks and other
signs of deformity.
●● Check unit for level and correct placement before erecting
operation.
109
●● During drilling operations, it is advisable to make scheduled

inspections of all bolted connections to ensure that they are tight.
48 hours after the initial erection of the mast, check the bolts for
correct torque.
●● Ensure that the Load Rating and Warning decals are installed on
the mast and are in good shape.
●● Steel becomes brittle when operating in low temperature
conditions. Extreme caution must be exercised when operating at
or below -25°C (-13°F) as the mast may no longer hold the rated
load. Frequent visual inspection of mast members and welds is
even more critical at these temperatures, see inspection list.
●● Ensure support legs are located on a solid footing and tied back to
a solid anchoring point.
●● Inspection of wire rope, including operating lines, raising lines, and
guy lines, for kinks, broken wires, or other damage.
4.1.2.1 Wire Rope Care
Never exceed the Rated Hook Load, which is indicated on the Load Rating
decal. When calculating hook load, always include load handling devices
(travelling blocks, etc.).
Rope life varies depending on water ph. Duty cycle and weather
conditions will determine rules for replacement. Wire ropes should be
inspected daily and replaced if damaged. Internal corrosion and broken
external strands are the biggest concern.
Wire hoist ropes should be inspected daily during use, looking for
signs broken strands or corrosion. Inspected clevis and hoist pin daily.
Sheaves should be inspected for damage every 6 months of operation
or when hoist ropes are changed. Replace damaged components.
Wire ropes may be lubricated with LPS Wire Rope Lubricant or

equivalent to repel water and extend rope life. Keep in mind, too much
lubrication will attract dirt further reducing rope life.
4.2 Visual Inspection of Masts

The following is a checklist for a visual inspection of the mast. Ensure
that the inspection is performed by an individual with knowledge of all
mast operational procedures during erection or relocation of mast. Each
section has a pass or fail choice. If there is a problem, it should be noted
and corrected immediately. Make copies of this checklist and file this
check list for future reference.
110
Mast Visual Inspection Checklist

Crown Assembly
Condition: OK
Sheaves Warped OK
Grooves Worn OK
Spacers or Seals Bad OK
Crown Frame Bent Flanges Bent Webs OK
Cracked Welds
Comments: Rusty Bent Webs
Needs Painting Other:
Vertical Members
A. Front Leg, Driller’s Side
Condition
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
Safety Pins Missing OK
B. Front Leg, Off Driller’s Side
Condition: OK
Bow Slight Bad OK
Safety Pins Missing
C. Rear Leg, Off Driller’s Side
Condition: OK
Bow Slight Bad OK
Safety Pins Missing
D. Rear Leg, Driller’s Side (Not applicable for “T” style mast)
Condition: OK
Bow Slight Bad OK
Safety Pins Missing
Comments: Needs Repair Other
Bracing
Condition: Slight Damage Badly Damaged
OK Needs Repair
Adjustable Support Legs and Feet
Condition: Damaged Cracked Welds OK
111
Worn Pins/Hole Needs Repair Corroded

Working Platform
Condition:
Racking Platform
Frame: Damaged Cracked Welds OK
Pin Connections Worn OK
Safety Pins Missing Worn OK
Fingers Damaged Needs Repair OK
Working Platform Damaged Cracked Welds OK
Handrails Damaged Needs Repair OK
Guyline Anchorage
Condition:
Guyline Damaged Needs Adjusting
Needs Replacing OK
Cable Clamps Loose Needs Repairing OK
Turnbuckles Damaged Needs Replacing OK
Anchor and Deadman Replace OK
Bolt Connections
All bolted connections are to be inspected, tightened, and missing parts replaced or visibly marked as
missing or damaged and in need of repair.
All connections found to be satisfactory as checked and loose bolts tightened. OK
All connections visually inspected and spot checked for tightness and no further OK
bolt tightening or repairs necessary.
Substructures for Mast

Damages: Minor Major OK
Corrosion: Minor Major OK
Condition:
Connections Worn Cracked Welds OK
Safety Pins Missing OK
Mast Raising and Angling Cylinders

Condition: Oil Leaks Hose/Tubing OK
Damage
Summary of Inspection
Appearance: Good Fair Poor
Repairs Needed: None Minor Major
Number of Missing Parts:
List of Work to be Completed
112
Signature: Date:
Ref No:
Table 4–1: Mast Inspection Checklist
4.3 Transporting the Drill Site to Site

Note: Refer to Boart Longyear for recommended truck and mounting
group.
This drill is capable of supporting itself on the outrigger/jack group but is

not designed to drill in that configuration.
The outrigger/jack group is also capable of supporting the weight of a

truck, but it is recommended that an additional support under the front
of the truck be used. The set up valve that runs the outrigger/jack group
has provisions to run the extra jack.
Please consult your parts book or Boart Longyear sales representative

for jack part number.
When moving the drill, always follow the safety precautions below.
4.3.1 Lifting the Drill

Only trained and qualified personnel are to perform rigging, crane
operations, and lift communications. All other personnel are to be
stationed safely away from the lift.
We recommend a ‘critical lift plan’ approved by a certified engineer

when lifts are performed under the following circumstances:
●● A lift exceeding 80% of the rate load of the crane or lifting device
●● A tandem lift where two cranes or lifting devices are used
●● Any time the lifted load is to be completed over structures,
buildings, vehicles etc
●● Lifting within 15’ of any overhead power or communications lines.
The crane operator has three main responsibilities.
1. Verify the condition of all slings prior to rigging and replace them if
worn, frayed, cut, or if heavily soiled with oils or chemicals.
113
2. Verify the condition of shackles that are to be used during the lift.
Shackles are to be replace if deformed, show cracks or sharp nicks
in the metal.
3. Verify the satisfactory condition of all anchorage points. Anchorage

points are not to be used if deformed, excessively corroded, or
welding is cracked. Anchorage points are to be designed and
certified by an engineer.
Where anchorage is to be performed by wrapping or undercarriage

slinging, we recommend that the lift plan be approved by a qualified
person or performed under the design of a certified engineer.
We further recommend that all lifts above waist height are to be

controlled by the use of tag lines by qualified personnel to ensure all
personnel are stationed safely away from the lifted load.
Always have a planned escape route during the loading and unloading
process, never stand under a suspended load.
Shipping weight of the rig is listed on the drill master serial number
decal.
4.3.2 Truck Transport (Shipping)

The transport operator is to verify the truck is rated for the load, and that
the load is properly secured using the tie downs provided and all covers
are secured in place and loose parts or tools have been properly stowed
prior to transport.
4.3.3 Driving a Truck Mounted Drill

●● Obey posted speed limits.
●● Never attempt to move the drill with the mast in the raised position.
●● Post the overall transport height of your drill in the operator’s cab.
●● Ensure all road heights and weights are obeyed.
●● Be aware of any special licences and or permits required to
transport the rig.
114
●● Always use the outriggers and jacks to stabilize the drill rig for
drilling.
Figure 4–1: Truck Mounted Drill
4.3.4 Driving a Track Mounted Drill

●● Maximum ground speed can be adjusted with engine speed. Do not
exceed 2200 rpm.
●● Never attempt to move the drill with the mast in the raised position.
●● Always tram the drill with the crown block pointing down grade for
maximum stability. The maximum safe grade in this orientation
is 15 degrees (25% ). The maximum side grade for tramming is
limited to 10 degrees (18%) side slope.
●● Beware of wet ground conditions when tramming, the overburden
can shear off.
●● Always leave your self a escape route when operating a vehicle
with a radio remote control.
●● Stand well back (at least 10 meters) from the rig when tramming.
●● Never stand between the machine and an obstacle when steering.
●● Never ride on the vehicle.
●● Always position yourself to get a clear view when tramming.
●● Never leave the rig unattended in tram mode with the engine
running.
●● Always use the outriggers and jacks to stabilize the drill rig for
drilling.
115
The radio remote control transmitter operating frequency is matched to

the radio receiver mounted on the drill rig (parent) it was supplied for.
Never attempt to operate one drill rig using the radio from another.
These radios have a significant operating range and under certain

conditions the user can inadvertently move the parent drill rig, which
could result in rig damage or serious personal injury.
Radio frequencies are matched to the purchaser’s original country of end

use. Radios for use in North America are marked with “FCC,” and radios
for use in European as well as many other countries are marked with
“CE.”
The rig owner is responsible to confirm if the operating frequency of the

radio meets local regulations before attempting to move and operate a
drill rig in another country.
The Track Drive control is a 3 position tram/drill switch located on the

small electrical panel located above the set up controls.
Figure 4–2: Track Drive Control
The Track Drive control has 3 positions:
1. Drill Mode
Position 1 is “Drill Mode.” Radio remote for the track drive is

not powered, the D05 manifold controls are active, the head
lubrication circuit is active, the set up controls are disabled, and
the local e-stop on the track drive transmitter is disabled.
116
2. Setup Mode
Position 2 is “Setup Mode.” Radio remote for track drive is not

powered, D05 manifold controls are disabled, the head lubrication
circuit is disabled, the set up controls are active, and the local
e-stop on the track drive transmitter is disabled.
3. Tram Mode
Position 3 is “Tram Mode.” Radio remote for track drive is active,

D05 manifold controls are disabled, the head lubrication circuit is
disabled, and the set up controls are active.
Note: The key switch on the OCP must be in the accessory position and
all e-stops reset before the engine will start from the radio.
Note: Switching the tram drill switch from drill mode to tram mode
without the radio active will cause the engine to shut down because of
the inactive e-stop in the transmitter.
Radio receiver and transmitter serial numbers may be required for

service. They are located as shown in the following photo:
Figure 4–3: Radio Receiver and Transmitter Serial Numbers
117
4.3.4.1 Operating the Track Drive Control

The radio transmitter uses an ion key, as shown below, to match the
transmitter to the receiver. The system will not function if this key is
loose or missing.
Figure 4–4: Ion Key
4.3.4.2 Activating the Transmitter

The track drive transmitter allows you to control the track drive remotely.
Figure 4–5: Transmitter and E-stop
To activate the transmitter, do the following:
1. Ensure master disconnect is switched on.
2. Set the tram drill switch to Tram.
3. Verify that all e-stops are released.
118
4. Set the engine key switch to position 1.
5. Twist and pull the e-stop button on the transmitter.
6. Shortly actuate the start button and then release. The transmitter
will switch off if the button is pressed for longer than half a second!
7. Actuate the start button again until the status LED flashes green.
Then release the button. The transmitter is now ready for operation.
Note: Steps 6 & 7 need to be carried out within 4 seconds.
8. Depending on the application, you must actuate the start button

again before movement commands can be carried out.
Note: A battery charger for the transmitter is located inside the

Tramming control panel. In addition, a back up control cable is supplied
with the transmitter for direct connection to the receiver to allow
operation in the event of battery failure.
4.4 Configuring the Drill Based on Rod Type

The following components are affected by rod type (diameter) and must
be changed prior to starting a new hole with a different rod diameter.
Note: Part numbers are identified in your parts book and or Global
Product Catalog for in the hole tools.
4.4.1 Chuck Jaws

The procedure for changing chuck jaws is outlined in the maintenance
section of this manual. Care must be taken not to drop any foreign
object down the open hole when working in this area of the drill.
4.4.2 Upper Chuck Guide Bushing

The procedure for changing the chuck guide bushing is outlined in the
maintenance section of this manual. Care must be taken not to drop any
foreign object down the open hole when working in this area of the drill.
119
4.4.3 Lower Spindle Guide Bushing

The procedure for changing the lower spindle guide bushing is outlined
in the maintenance section of this manual. Care must be taken not to
drop any foreign object down the open hole when working in this area of
the drill.
4.4.4 Foot Clamp Slip Sets

Drill rods must be on bottom or removed before proceeding. The foot
clamp must be in the fully opened position. Foot clamp slip sets are
designed for removal by removing the retaining pin located at the top of
the slip. The pin is retained by a hair pin type cotter pin. Care must be
taken not to drop any foreign object down the open hole when working
in this area of the drill.
Never attempt to remove or shift footclamp slipsets with drill rotation

engaged. Operator could be drawn into the rotating drill string resulting in
severe personal injury or death.
There is always a risk that the drill string could be hung up off bottom
with the footclamp open. Use caution when servicing slip sets that the
drill string could shift resulting in a crush hazard.
120
4.4.5 Hoist Plug Bullnose Sub

Install the proper bull nose sub to match the drill rod thread in use.
Always insure that the sub is changed when any signs of thread wear
or galling is present. Failure to do so could result in dropped rods and
or damage to the entire drill string. Rod thread types (Q vs RQ) are not
interchangeable.
4.4.6 Water Swivel Adapter Sub

Install the proper water swivel adapter sub to match the drill rod thread
in use. Always insure that the sub is changed when any signs of
thread wear or galling is present. Rod thread types (Q vs RQ) are not
interchangeable.
4.4.7 Overshot
Overshots are sized according to the inside diameter of the rods in use.
Refer to the Boart Longyear In the hole tool catalog to select the proper
overshot for the job.
4.5 Pre-start Checklist

1. Prior to starting the machine, ensure the drill is level and firmly
supported.
2. Check the diesel engine coolant level and ensure that it contains
ample antifreeze. The sight glass should be full.
Figure 4–6: Radiator Cap
121
Never attempt to remove radiator cap when engine is hot.
3. Check diesel engine oil level. The oil level should be half way
between the minimum and maximum markings on the dipstick.
Note: Use the correct grade of oil. For more detailed engine
lubrication and servicing requirements, refer to the Cummins
Operations/Maintenance manual that is supplied with your drill.
Dip Stick
Figure 4–7: Oil Cap
4. Check hydraulic oil reservoir level. The oil level should be half way
on the gauge. If oil must be added, use the hand pump located on
the tank stand. Refer to the lubrication chart for lubrication types
and quantities.
5. Check the diesel fuel level. The tank should be full.
6. Check the oil level in the head box when in the vertical position.
See Chapter 3 for the proper location of oil.
7. Before start up, check battery electrolyte level. If low, top up with
distilled water only.
Always wear safety goggles when topping up a battery as splash

back can occur. Always maintain a supply of fresh potable water on
site for emergency use in case of contact with battery acid.
8. Ensure that the water pump and the mud mixer (if necessary) are
connected.
122
9. Visually check the drill for any loose or unserviceable components,

leaks, faulty equipment, etc. Repair these before operating the
machine.
4.6 Starting the Drill

The following procedure shows you how to start up the drill.
Before operating controls, know how each control functions.
1. Complete the pre-start check list.
2. Ensure the control panel levers and gear box selectors are in the
following positions:
Fine Feed Pressure — Fully Clockwise (Max)

Fine Feed Rate — Fully Clockwise (Closed)
Fast Feed Joystick — Center Position (Neutral)
Rotation Control — Fully Counterclockwise (Off)
Wireline Hoist/Main Line Hoist — Center Position (Neutral)
Mud Mixer Speed Control — Fully Clockwise (Off)
Water Pump Speed Control — Fully Clockwise (Off)
Chuck — Center Position (Closed)
Foot Clamp — Open or Closed
Drilling Fine Feed Lever — Center Position (Neutral)
3. Turn the key to start to engage the engine starter; release it once
the engine starts.
○○ Do not continue to crank the engine if it doesn’t start after 30

seconds.
○○ Excessive cranking can damage the electrical starter solenoid or
motor.
○○ Before operating controls, know all of the functions.
○○ Investigate why the engine will not start (i.e., fuel or electrical
problems) before cranking excessively.
4. Allow the diesel engine to warm up for two minutes before gradually
increasing the rpm.
If operating in extremely cold, ambient conditions, allow the engine

at least seven minutes to warm up before increasing the engine
speed or placing any load on the machine.
123
4.7 Raising The Mast

1. Prior to starting the machine, ensure the drill is level, and securely
anchored.
2. Telescopic section of the mast should be retracted.
3. Route the main line hoist and wireline hoist cables through the
sheave wheels of the crown block assembly, making sure to
replace the cable retaining spacers and bolts.
4. Attach the overshot to the wireline cable and insert into the
provided holder on the side of control panel. Attach the hoist plug to
the hoist cable, this will prevent these items from falling during the
raising operation.
5. Run the drill head down to the end of its travel (base end of mast).
Bleed the hydraulic mast raising cylinders to vent any trapped air
before attempting to raise the mast.
Accomplishing these steps prior to raising the mast, will avoid any
unnecessary delays in securing the mast support legs, once the
tower has been raised and put at the desired angle.
Before raising the mast, ensure the drill is properly supported and
anchored, make sure that there are no overhead power lines, trees or
any other structures which could foul the mast during the raising or
lowering operations.
6. Prior to raising the mast, make sure that all hoses, fittings and
cables are free and that they will not get caught on anything during
the raising operation. Make certain there are no loose objects on
the mast which could fall during the raising of the mast.
7. Set selector valve V43 to Activate.
8. Set up valve bank V40.
9. Slowly begin to raise the mast by moving the mast raising lever in
the upward direction until the mast is clear of the mast rest.
Note: Raising the mast should be accomplished in a gentle,

smooth fashion. Avoid jerky and erratic stop and start motions.
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10. Extend the mast telescopic section and install the locking pin and
hardware. Erect and assemble the rod racking platform group if
equipped.
Figure 4–8: Auxiliary Valve V40
Once mast raising has commenced, under NO circumstances should

any person or part thereof, get under or perform any work in that
area until the mast raising operation is complete (as detailed in this
section) and the tower is firmly secured by the mast support legs.
11. Continue to raise the mast by holding the lever in the upward
direction until the tower is in the vertical position.
Note: During the raising operation, double check that no hoses,

fittings or cables are hanging or getting caught.
12. Stop the power unit.
13. Now that the mast is in a vertical position, release the outside
(furthest away from the control panel) mast support leg from its
retaining bracket on the lower mast section (off rod slide), pull the
snap lock hitch pin and allow the inner tube to fall.
14. Position the leg in its respective support bracket located on the drill
base. Adjust the rod end until the leg can be bolted in the support
bracket. Tighten the jam nut. Reinstall the hitch pin into the support
leg.
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It is recommended that the person hold the inner tube while

removing the hitch pin to prevent possible injury, as the tube may
want to fall at a high rate of speed.
Support Leg
Hitch Pin
Figure 4–9: Support Leg and Hitch Pin
15. Do the same by removing the inside mast support leg from its
retaining bracket and position the leg in its respective support
bracket on the drill base. At this time restart the power unit, remove
the hitch pin from the outer support leg again, and move the mast
to the desired angle.
Note: Some adjustment of the rod end will be required to properly

align the nearest holes in the inner and outer support legs so the
snap lock hitch pins can be reinstalled correctly.
16. Reinsert both hitch pins and tighten the jam nut on both rod ends.
Figure 4–10: Support Leg
17. After the mast is in position, reset the diverter valve V43 to activate
the D05 controls for drilling.
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4.8 Casing/Rod Guide Bushing

The bores of these bushings are over sized to the outer diameter of the
particular casing string that is being used to collar the hole (i.e. BW,
HWT, etc.). This is to allow the bit and reaming shell to pass through
without removing the guide bushing.
The casing/rod bushing is designed to stabilize the casing string and

maintain hole alignment. This bushing should be used throughout the
entire casing run. Casing should be firmly seated into the bedrock
before reducing to the coring system that will be used.
Following this procedure will ensure that the LF 230 is securely aligned
onto the casing string which minimizes problems as drilling progresses.
Casing
Guide
Bushing
First
Level
Mast
Assembly
Figure 4–11: Casing/Rod Guide Bushing
4.9 Opening the Drill Head

If it is necessary to get the drill head out of the way to handle large
casing, the head can be hydraulically pivoted out of the mast.
Never allow the head to travel up and down the mast or attempt to raise or
lower the mast with the drill head in the open position. Interference with
other components or hoses can occur.
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4.10 Making Head Float Adjustments

Head float on a spindle drive drill rig is required to allow the head to
move up or down with the threading/unthreading operation taking the
load off the rod thread flanks and reducing the tendency of the rod
threads to gall.
Head float feed is controlled by the rod making breaking switch located
on the OCP. The switch activates the feed and rotation functions
simultaneously.
Do not attempt to make or break drill rods using the main rotation
and fast feed levers. Damage to equipment or personal injury could
occur.
The head float circuit consists of two independent pressure reducing/

relieving cartridges installed in the D05 manifold.
Figure 4–12: Head Float Control (Rod Making)
Head float must be re-adjusted every time the mast position is changed.
The cartridge in the front of the D05 manifold, see Figure 4-9, controls
rod making feed force and the cartridge in the rear, see Figure 4-10,
controls rod breaking feed force. Head float must be set to the point that
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the head is just starting to move when the switch is is activated. The
threading action will push or pull the head the rest of the way.
Figure 4–13: Head Float Control (Rod Breaking)
One cartridge allows the head to float up for breaking rods and one
allows the head to float down when making rods. The head float setting
is sensitive to mast angle so it will have to be adjusted from time to time.
Never attempt to adjust head float until the hydraulic oil temperature
is above 20 degrees C. The procedure for head float adjustment is
detailed in the following sections.
4.10.1 Head Float Up Adjustment

1. Move the head midway up the mast using fast feed and return fast
feed to neutral.
2. Activate head float up function with the rod breaking switch located
on the OCP.
This switch will also activate slow rotation, make sure no one in in
the vicinity of the drill rod when attempting to make this adjustment.
3. Adjust the up float pressure control located behind the control

manifold until the head just starts moving up at a very slow speed.
4. Adjust clockwise to raise pressure, counterclockwise to lower

pressure.
It will be necessary to adjust this pressure based on mast position

and changing drilling conditions.
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4.10.2 Head Float Down Adjustment

1. Center the head midway up the mast using fast feed and return fast
feed to neutral.
2. Activate head float down function with the rod making switch
located on the OCP.
This switch will also activate slow rotation, make sure no one in in
the vicinity of the drill rod when attempting to make this adjustment.
3. Adjust the down float pressure control located on the front of the
control manifold until the head just starts moving down at a very
slow speed.
4. Adjust clockwise to raise pressure, counterclockwise to lower

pressure.
It will be necessary to adjust this pressure based on mast position and

changing drilling conditions.
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4.11 Mud Mixer Control

This is a detented, two position valve which either starts or stops the
optional mud mixer.
V10
V23
Figure 4–14: V10 Mud Mixer Selector Valve/V23 Mud Mixer Flow
Rate Control
The flow control valve V23 located below this selector valve controls the
mud mixer speed. Clockwise adjustment of the flow control valve will
reduce speed while counterclockwise adjustment will increase speed.
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Note: The mud mixer motor must be properly connected to the

D05 manifold (metering oil in with flow control V23) otherwise the
shaft seal in the Mud Mixer Hydraulic Motor could be damaged.
V24
Figure 4–15: V24 Mud Mixer Sequence Valve Adjustment Screw
4.12 Shifting the Head Gear Range

Spindle speed (RPM) is affected by the gear selection in the head
mounted four speed transmission, engine RPM and rotation motor
displacement setting.
There are two manually operated shift levers located on the side of the
head transmission used to select gears 1 through 4. Max spindle speed
of 1250 RPM is achieved in 4th gear by setting the engine speed to
2200 RPM and setting the motor displacement control to minimum.
Figure 4–16: Head Gear Shift Levers

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Shifting the transmission gear range requires the operator to open the
rotation barrier and manually shift the levers on the transmission. The
outside handle shifts between 1st and 4th gear, the inside handle shifts
between 2nd and 3rd gear. The operator may have to rotate the chuck
by hand to get the gear to properly engage.
Always stop the engine before attempting to rotate the chuck by hand.
Never allow a helper to work on or near the chuck with someone on the
controls.
4.13 Rod Make-up Torque

Rod threading and unthreading is a balance between head float,
rotation speed, proper lubrication and torque. If any component is off,
the threading operation will be noisy and rough, and thread damage will
occur.
Rod make-up torque is an important feature on the LF230 that limits the
maximum torque the drill can offer when making-up drill rod joints. This
feature reduces drill rod thread damage and prevents over torqueing of
drill rod joints during the threading process. It extends the life of the drill
string and makes it easier to break drill rod joints when pulling rods.
Figure 4–17: V35 Rotation Torque Limiting Valve
Rod make up torque is preset in the factory to NQ size drill pipe. Keep
drill rod threads clean and properly lubricated; always use first gear
when making up drill rod joints. Details on how to adjust rod make up
torque are covered in Chapter 5, V35 Rotation Torque Limiting Valve
Adjustment.
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4.14 Drilling
This LF230 drill rig has been configured to drill with an engine speed of
2200 rpm for the Cummins Tier III engine version and 1800 RPM for the
Cummins Tier 4i engine version.
The motor displacement settings are pre-set at the factory to 65cc min
and 107 cc max displacement.
Tier 4i engine.....
Never attempt to adjust the motor displacement limit screws; damage can
occur by overspeeding the motor.
Monitor head oil flow and pressure on the gauges provided while drilling.
A lower pressure could indicate, low oil level, low relief valve setting, or
a damaged lubrication pump.
Monitor head oil level on the lower reservoir sight gauge provided while
drilling. Never attempt to drill with low head oil level. Permanent damage
to bearings and gears will occur.
Never rotate the drill head with the chuck open; damage to the floating
bearing and retaining ring can occur.
Never attempt to operate this drill rig without proper training. Read and
understand the operators manual.
4.14.1 Fluid Circulation

The drilling process requires fluid circulation to do the following:
●● Lubricate and cool the bit

●● Reduce friction in the hole
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●● Flush cuttings from the hole

●● Provide core block indication
●● Provide landing indication
●● Indicate bit condition
An optional hydraulic driven fluid circulation pump is provided to

circulate drilling fluid. Fluid circulation pump output is controlled by the
driller using the Flow control valve V7 mounted in the lower section of
the OCP. It is a rotary control providing variable flow control.
Figure 4–18: V7 Flow Control Valve
Fluid circulation pump output is affected by engine speed and the valve
position. The full speed position provides the driller with maximum pump
flow for conditioning the hole and pumping in the tube. The operator
needs to reset the control to the desired pump flow rate for drilling.
4.14.2 Fine Feed Drilling Control

While drilling, the mainline hoisting cable is connected to the water
swivel bail. A slight tension is kept on the cable to prevent rod whip
above the drill head. During drilling operations, with the drill head
feeding down, the mainline hoist brake must be released manually by
the driller using valve V16 to allow the hoisting cable to unspool under
tension.
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Never attempt to drill or rotate the drill string at high speed without the
hoist cable connected to the water swivel.
Always minimize rod stick out above the chuck while drilling or rotating
at high speed to prevent the upper rod and water swivel from vibrating.
Failure to do so could cause the drill rod to fail above the chuck resulting
in severe personal injury or death.
Inspect and grease the water swivel bearing daily to ensure it runs freely,
failure to do so could cause the water swivel to seize during operation
resulting in supply hose damage and possible personal injury.
Never use the manual mainline hoist brake release to lower the rod string.
Uncontrolled lowering of the drill string will result in damage to the hoist
plug, chuck and/or hoist park brake. Always reset the hoist brake control
V16 to the on position before attempting to hoist rods.
When “fine feeding down”, selector valve V9 is in down direction, feed

rate flow control valve V26 is partly open and hoist brake release V16
is released sending a pressure signal to a shuttle valve mounted in
the mainline hoist motor manifold block. This signal moves the shuttle
valve and allows a flow of oil to release the spring applied brake on the
mainline hoist. Oil is also directed through the Hoist Tension control
V33 providing a signal to the mainline hoist brake valve V36. When
this signal is applied, the hoist is free to unspool. Rope tension can be
adjusted by the driller using V36 located on the OCP.
4.14.3 Fine Feed Rate Valve V26

This rotary valve controls the penetration rate (weight on bit) when the
fine feed selector valve V9 is in the “down” mode. Conversely, if the
fine feed selector valve V9 is in the “up” mode, the fine feed flow control
valve V26 will control the rate at which the drill head retracts (ie. back
reaming). Turning the rotary control counterclockwise increases the rate
of penetration (weight on bit). The relationship between the fine feed
flow control valve and the “weight on bit” gauge on the control panel is
evident as this valve is adjusted.
This valve is an adjustable orifice which meters oil from the “T” port of
the fine feed selector valve (piston end when in the down mode) and is
known as the bleed off pressure. If the valve is only cracked slightly (ie.
counterclockwise), the volume of oil escaping from the low pressure side
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is minimal, which translates to a slow rate of penetration and bit weights.

The bit weight gauge is plumbed in between the “T” port of the fine feed
selector valve and the feed flow control valve. In the above scenario,
we are only allowing a small volume of oil to escape from the feed
cylinder. This will create only a slight pressure differential between the
rod (pressure in) and the piston (pressure out) end of the cylinder. This
slight pressure differential will register as a small reduction in the value
displayed on the bit weight gauge.
As the fine feed flow control valve V26 is opened further

(counterclockwise rotation), more oil is allowed to escape from the
(piston side) end of the cylinder. This increased flow translates to a
greater pressure differential which will register as a larger drop in the
value displayed by the bit weight gauge.
4.14.4 Fine Feed Pressure Control V25

Situated below the Fine Feed Flow Control valve and accessible from
the front of the Hydraulic Module, is the Fine Feed Pressure Control
Valve V25. This valve controls the maximum feed pressure (thrust or
force on the bit). Feed pressure affects the sensitivity of the Feed Rate
Control V9.
The Feed cylinder on the LF230 can provide roughly 26600 lbs of thrust
at full system pressure which exceeds the allowable bit weight for most
diamond drill bits.
At the start of the hole, the Pressure Reducing Valve V25 should be
backed off to a maximum feed pressure (depending on bit diameter)
of roughly 400 psi (35 bar) on the feed pressure gauge located on the
OCP. V25 can easily be set to the desired pressure using the fine feed
drilling control V9 to position and stall the drill head at the bottom of the
mast while observing the feed pressure gauge.
The rod weight increases as the hole gets deeper, so the force on the bit
must be decreased to maintain a relatively constant hold back pressure
using valve V25.
When the desired sensitivity of penetration is lost you may adjust the
Pressure Reducing Valve V25 in order to regain the desired sensitivity.
After the hole is completed, always reset the Pressure Reducing Valve
V25 to full open.
1. Select Drill mode (Track Drive Version).
2. Connect the water swivel to the drill rod above the chuck.
3. Close the safety barrier.
4. Ensure control levers are in neutral.
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5. Start the engine.
6. Ensure the drill head is in the desired speed range.
7. Set the Motor Displacement Control knob to Min displacement

(Rabbit) to maximize spindle speed.
8. Set engine speed to 2200 rpm using the engine “fast speed” switch
located on the Engine Control Panel.
9. Position the chuck above the joint so that the chuck is roughly in
the middle of the driving rod to minimize vibration.
10. Close the chuck.
11. Start the fluid circulation pump and flush the hole, making sure the
inner tube is properly seated.
12. When inner tube is seated, stop the fluid circulation pump and blow
off the water pressure to allow the inner tube shut off washers to
relax.
13. Restart fluid circulation pump until water return volume is adequate
for drilling.
14. Apply light tension to the hoist cable attached to the water swivel to
support the rod weight in the hole.
15. Open the footclamp.
16. Slowly start rotation using the Rotation Control lever and increase
rpm to the maximum desired.
17. Finer adjustments to speed can be made using the Motor

Displacement Control knob while drilling to adjust for in the hole
conditions or rod vibration.
18. Use the Fine Feed Control lever to advance the drill head and start
drilling.
19. Pay close attention to water pressure and drilling torque pressure.
4.15 Calculating the Weight on Bit

The force exerted on the diamond bit while drilling is approximately
equal to the weight of the rods plus the down force exerted by the
hydraulic feed cylinder.
Bit weight pressure shown on the Bit Weight Gauge is a measurement

of hydraulic oil pressure being metered out at the cap end of the feed
cylinder.
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The actual “weight on bit” must be calculated from two different pressure
readings taken on that gauge.
The following are the steps to calculate Weight on Bit:
1. Suspend the rods a short distance off bottom with the drill rods
rotating slowly.
2. Close off the fine feed control rate valve and engage the fine feed
directional control valve to the feed down position.
3. Record the pressure indicated on the bit weight gauge. This is

the “Maximum Bit Weight Pressure” that can be exerted on the bit
including the weight of the drill head and drill rods in the hole.
4. Slowly open the fine feed control rate valve. The rods will begin to
move towards bottom and when the bit contacts the bottom of the
hole, Max Bit Weight Pressure will begin to reduce. Record the bit
weight pressure when the pressure stops dropping off.
5. Subtract the Bit Weight Pressure with the bit on bottom, (step 4)
from the “Maximum Bit Weight Pressure” (step 3). This pressure
difference is referred to as the OFF PRESSURE.
For example:
MAXIMUM BIT WEIGHT PRESSURE (WITH RODS OFF
BOTTOM) 1500 PSI (103.4 BAR)
BIT WEIGHT PRESSURE (WITH RODS ON BOTTOM) 1000 PSI
(70 BAR)
OFF PRESSURE = 1500-1000 = 500 PSI (35 BAR)
BIT WEIGHT (FORCE ON BIT) = 25.13 SQ IN x 500 PSI = 12566
lbf
6. The off pressure when multiplied by the effective area of the
hydraulic cylinder ( measured in square inches) will give you the
downward force on the bit or “Bit Weight” measured in lbs. The
following table in Figure 4-9 covers that calculation for you.
7. Refer to the Diamond products Field Manual for the maximum

recommended bit weight and adjust feed pressure accordingly
while drilling to optimize the weight on bit. This procedure should
be performed several times during the drilling process, especially
as the hole gets deeper to maximize bit life.
139
The allowable bit weight operating range for each bit size shown on the
table in Figure 4-17 is only a guideline. Allowable weight on bit may vary
from manufacturer to manufacturer and in different ground conditions to
get the best performance.
A drop in bit weight pressure on the gauge while drilling indicates an

increase in rod weight on the bit.
Figure 4–19: Bit Weight Table
4.16 Inserting the Core Barrel

1. Run the drill head to the base of the mast and open the chuck and
rod clamp.
2. Attach the water swivel or hoisting plug to the core barrel.
3. Attach the main hoist cable to the water swivel or hoisting plug bail.
4. Push the Mainline Hoist Control lever to raise the core barrel (guide
the water swivel or hoisting plug into the rod slide when doing this)
above the drill head.
5. Pull the Mainline Hoist Control lever to lower the core barrel
assembly into the casing.
6. Securely clamp the core barrel in the chuck or rod clamp.
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7. Remove the water swivel or hoisting plug from the core barrel and
attach to drill rod.
8. Using the Mainline Hoist Control lever, raise the rod above the drill
head and attach the rod to the core barrel.
Make sure the hoist cable is in tension, this will prevent the drill
string from falling and damaging the cable when the chuck is
opened.
4.17 Rod Making

1. Follow the instructions outlined in section 4.11 to adjust rod torque
limit value.
2. Keep rod threads dirt free and always apply fresh rod joint grease
to the threaded joint to maximize rod string life.
3. Set engine speed to 1000 rpm min.
4. Shift the head transmission to first gear.
5. Footclamp closed, open chuck and lower head so rod joint is

sticking above the chuck.
6. Add rod above chuck and start threads by hand.
7. Raise chuck above rod joint.
8. Close chuck.
9. Activate the rod making function with the rod making switch located
on the OCP to allow the head to float down.
This switch will also activate slow rotation, make sure no one is in
the vicinity of the drill rod when attempting to operate this control.
Never use the main fast feed lever or rotation joystick to make the
drill rod joint. If the rod making process produces any significant noise
from the threaded rod joint, the head float control is not synchronized
with rotation speed per section 4.8 and will have to be re-set before
attempting to make more rod joints.
141
Pay attention to helper when manually greasing rods while lowering the
drill string, keep a clear line of sight on the job and keep visitors well
back. Don’t get distracted! Possible finger crush injury could result.
4.17.1 Rod Lowering (Rod Making)

1. Place the funk transmission in first gear and rotation speed control
in the low speed mode.
2. Adjust throttle to 1800 rpm.
3. Insert the core barrel as mentioned in the previous section.
4. Prior to opening the chuck ensure that the hoist cable is in tension
to prevent damage to the main hoist sprag bearing.
5. Open the chuck, then open the foot clamp while raising the rod
slightly to assist the foot clamp.
6. Lower the rod until the rod joint is approximately 6” (150 mm) above
the top of the chuck.
7. Close the foot clamp, then unscrew the hoisting plug.
8. Attach the hoisting plug to the next drill rod to be used and tighten
firmly using a pipe wrench.
9. Hoist the rod and suspend over the chuck, the rod slide can be
extended to help with rod positioning on an angle hole, at this point
lower the drill rod and start the rod thread by hand.
10. Lower the rod slide, move the head upwards approximately 12” (300
mm) over the rod joint and close the chuck.
11. Rotate the chuck clockwise to tighten the rod joint while monitoring
the torque gauge and downward float of the head.
The rotation unit has the potential to break or damage rod joints.
Ensure that the torque limiting valve (V35) has been properly
adjusted for the size or rod being used. Check for proper threading.
If threads are galling, readjustment of the rod making/breaking valve
(V28) may be necessary.
12. After the rod is tightened, retention the hoist cable, open the chuck
and run the head back to the bottom of the feed stroke.
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13. Open the foot clamp while raising the rods slightly and lower the
rod string until the rod joint next to the hoisting plug is 6” (150 mm)
above the chuck.
14. Close the foot clamp and repeat the sequence from step number 8.
4.18 Rod Breaking

1. Set engine speed to 1000 rpm min.
2. Shift the head transmission to first gear.
3. Footclamp closed, open chuck and raise head so rod joint is below
the chuck.
4. Close chuck.
5. Activate the rod breaking function with the rod making switch
located on the OCP to allow the head to float up.
This switch will also activate slow rotation, make sure no one is in
the vicinity of the drill rod when attempting to operate this control.
6. Never use the main fast feed lever to break the drill rod joint. If
the rod breaking process produces any significant noise from the
threaded rod joint, the head float control is not synchronized with
rotation speed per section 4.8 and will have to be re-set before
attempting to break more rod joints.
4.18.1 Rod Pulling (Rod Breaking)

1. Run the head to the bottom of the feed stroke (base of the mast).
2. Position the rod joint 6” (150 mm) above the chuck, close the foot
clamp.
3. Remove the water swivel, attach the hoisting plug to the rod string
and tighten firmly using a pipe wrench.
4. Prior to opening the chuck, always ensure that the hoist cable is
in tension to prevent damage to the main hoist sprag bearing or
equipment.
5. Open the chuck.
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6. Place the funk transmission in first gear and rotation speed control
in the low speed mode.
8. Open the foot clamp while raising the rod slightly, using the hoist to
assist the foot clamp jaws in releasing.
It is important to observe the head upward travel and inspect the

rod threads periodically as the joints are broken to ensure proper
adjustment of the rod making/breaking valve (V28).
9. Hoist the rods until the rod joint to be broken is approximately 6” (150
mm) above the top of the chuck.
10. Close the foot clamp, then raise the head so that the chuck jaws
are is positioned, approximately 12” (300 mm) above the rod joint.
11. Close the chuck, rotate the chuck counterclockwise to break the
rod joint while monitoring the torque pressure, observe the head
floating upward.
12. Once the joint has been broken, open the chuck and run the head
back to the bottom of the feed stroke.
13. Position the rod slide close to the rod to assist on an angle hole.
14. Hoist the rod clear of the chuck and lower onto the ground or stack
in the rod racking platform.
15. Reattach the hoist plug to the rod string and tighten firmly with a
pipe wrench.
16. Lower the rod slide so that it will not interfere with the head travel.
17. Tension the hoist cable, open the foot clamp and repeat the
sequence from step number 8.
18. Once the core barrel has been reached, it is advisable to clamp the
core barrel in the foot clamp. Attach the hoist plug securely to the
core barrel, tension the cable, open the foot clamp and remove the
core barrel.
4.18.2 Breaking Casing Under the Mast

When breaking casing under the mast, take note of the following safety
measures.
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• Never use unrestrained wrenches under power to make or break casing

under the mast.
• Never allow a helper to hold or support a wrench while power is applied.
• Always use tools that are properly secured to the frame and rated for the
load.
• Operators must be trained on the best working practice for using a

secured wrench under power including guarding, exclusion zone distance
and Personal Protective equipment. Failure to do so could result in
serious personal injury or death.
4.19 Retrieving the Inner Tube

1. Stop rotation and pull back rods off bottom with the head to break
the core.
2. Blow off any residual water pressure in the drill string to water to
allow inner tube seals to unblock.
3. Reduce engine speed to 1500 RPM.
4. Keep the bit off bottom and continue to flush hole to remove any
sediment that could hinder reseating the next inner tube.
5. Shut off flushing water to the bit and remove the water swivel.
6. Pay attention to the wireline cable as the overshot descends to the

inner tube.
Never jam the Wireline Hoist Control lever and leave the wireline
running unattended.
7. Once the overshot contacts the head of the inner tube, the wireline
rope will slacken, immediately stop the lowering process.
8. Pull back on the wireline rope to hoist the inner tube.
Never jam the Wireline Hoist Control lever and leave the wireline
running unattended.
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9. Pay attention to the wire rope as the overshot nears the surface;
water being bailed from the drill string will normally increase.
Never allow anyone to wipe the wireline rope by hand. Severe injury
could occur.
10. Stop the wireline as soon as the inner tube exits the funnel.
Always lock the overshot before the inner tube is hoisted above the
head to prevent inadvertent release and possible injury to personnel
below.
11. Once the overshot is secure, hoist the inner tube above the funnel
where the helper can assist in guiding it to the ground.
4.20 Hoisting
The mainline hoist is only intended to be used as an aid for lifting drill
rods and casing into the mast or for hoisting the drill string from the hole.
It must never be used as a winch for servicing the rig or lifting people.
●● Ensure that the mainline hoist rope and hoisting tools are inspected
daily for any sign of damage.
●● Use the proper load rated tools for the hoist, including clevis pins,
hoist plug, and water swivel.
●● Replace any hoisting subs with worn or damaged threads.
●● The wire rope is designed to provide superior flexibility and
strength. Wire ropes are certified as part of the hoisting system for
a specific breaking strength to meet accepted industry standards.
Always use Boart Longyear original equipment.
●● Ensure the hoist is kept in good working order and serviced
regularly as detailed in Appendix D.
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When hoisting or lowering rods, make sure the main hoisting cable is
in tension before opening the chuck. Failure to do so could result in the
hoist slipping and the rods dropping uncontrollably. This situation could
cause both equipment damage and personal injury.
The LF230 has a two speed mainline hoist control. The high speed
setting can be used at the top of the hole where maximum pulling force
is not required. As the hole gets deeper, select the slower setting to get
more pulling force. Set Engine speed to 2200 RPM for maximum hoist
speed.
4.20.1 Stacking Drill Rods

Rods can be stacked on a stand in front of the drill, or against the
optional mast-mounted rod rack.
The lower end of rod should be placed on a suitable wooden platform

covered with a heavy rubber mat located beside the drill. Stack the rods
in lengths at an angle slightly steeper than the mast angle to ensure that
they remain secure against the rod rack under their own weight.
4.21 Shutting Down the Drill

1. If the drill string is rotating, ensure that the fine feed is off.
2. Stop rotation by returning the rotation joystick to the off position.
3. Use the fast feed joystick to raise the drill head to break the core
and pull the bit at least 12” (300 mm) off the bottom of the hole.
4. Allow the water pump to flush the hole for about five minutes before
rotating the pump’s speed control completely clockwise.
5. Return the diesel engine to an idle by pushing the engine speed

control button.
6. Allow the unit to idle for about five minutes. This is very important to
allow the turbocharger to cool down.
7. Turn the engine off by rotating the key all the way
counterclockwise.
147
4.22 Lowering the Mast

1. Stop the engine.
2. Loosen the clamping jaw set screw on the inside mast support leg
(i.e., closest to the diesel engine) and detach the sliding section
from the front of the drill base.
3. Push the telescoping inner support leg section into the outer
support leg section and fold the support leg back to its travelling
position on the lower mast section and retain it in the bracket
provided.
4. Repeat step 2 with the outside mast support leg (i.e., furthest from
the diesel engine) and retain it in its travelling position.
5. Start the engine and adjust to 1500 rpm. Pull the diverter valve.
Slowly move the Mast Raising Control lever to begin lowering the
mast.
Mast lowering should be accomplished in a smooth, steady fashion.

Avoid jerky stop/start motions.
6. When lowering the mast, ensure no hydraulic hoses, fittings, or
cables will get caught or snagged during this operation, or that the
hoisting and wireline cables and accessories are firmly secured to
the mast and cannot fall off.
Ensure that no one is in the vicinity of the mast lowering area and
that there are no overhead power lines, trees, or structures that may
foul the mast during the lowering operation.
7. Once the mast has come to rest on its support brackets at the
front of the drill base, remove the spacers and bolts from the cable
retainers on the crown block assembly and remove the mainline
hoist and wireline hoist cables.
8. Remove mast lock pins and return to storage location.
9. Retract the mast.
4.23 Refueling the Rig: Safety Precautions

Product spills are dangerous and environmentally hazardous. Every
time you refuel, follow these safety precautions.
148
4.23.1 Fueling Safety

Pump nozzles should be held open by hand pressure only. Using
objects such as fill caps to hold the nozzle in the open position is
unsafe.
Note the following:
●● No Smoking
●● Cell phones and battery powered equipment switched off
●● Turn off ignition
●● Fill only SCA or ULC
●● Do not overfill . . . allow room for fuel to expand
●● Do not leave vehicle unattended while refueling
●● Remove all ignition sources within 3 meters
Figure 4–20: Fueling Safety Reminders
4.23.2 Emergency Equipment

Understand the use of the following emergency equipment:
●● Fire extinguisher
●● Fuel spill absorbent material
●● Emergency shut-off switch
4.23.3 Filling a Container

It is unsafe to fill metal or plastic containers that do not meet appropriate
safety specifications, for example, ULC or CSA. Plastic containers that
meet these codes will have an appropriate safety code stamped or
molded on them.
Do not fill a container such as a 20-liter metal or plastic lubricant pail

that is not designed for this purpose.
149
Filling of truck-mounted slip tanks and drums is unsafe and not

acceptable unless a proper grounding system is being used to dissapate
the static charges generated during filling of the tank or drum.
4.23.4 Fueling Facts

Diesel fuel can be extremely hazardous unless properly and safely
handled.
What follows are some of the characteristics and hazards of fuel you
should be aware of.
1. Class II combustible liquid
Flash point +37.8 C. Low flammability and volatility. Mist or vapor

can create an explosive mixture with air. Do not use water to
extinguish except as a fog.
2. Fuel vapor is heavier than air—hugs ground—displaces air
May cause asphyxiation. May explode if exposed to a source of

ignition.
3. Diesel fuel flows at ground level and floats on water
Spill can travel through the ground, contaminate drinking water,

and seep into buildings.
4. Ingestion or prolonged exposure
Prolonged exposure can cause headache, nausea, dizziness,

unconsciousness, and even death. Irritating to skin, eyes, and
respiratory passages. Can cause dermatitis. May cause cancer.
4.23.5 Emergency Procedures

If an accident happens, knowing the following safety features and
procedures could save your life and the lives of others.
4.23.5.1 Fuel Spill

Observe the following:
●● Protect human life

●● Stop product flow
●● Do not restart vehicle
●● Eliminate ignition sources
●● Clean up spill using earth or absorbent material
●● Telephone emergency and government officials
150
4.23.5.2 Fire
Observe the following:
●● Protect human life.

●● Extinguish small fires using fire extinguisher only if safe to do so.
Follow instructions on fire extinguisher for proper use. Do not
jeopardize your own safety.
●● Telephone emergency and government officials.
151
152
Contents
5.1 Hydraulic Reservoir................................................................................ 157
5.1.1 Hydraulic Reservoir Oil Filling Procedure.................................... 157
5.2 Hydraulic Valves..................................................................................... 158
5.2.1 D05 Manifold............................................................................... 159
5.2.2 V7 Fluid Circulation Pump Flow Control...................................... 161
5.2.3 V9 Fine Feed - Control Valve (Drilling)........................................ 162
5.2.4 V10 Mud Mixer - Control Valve................................................... 162
5.2.5 V11 Head Opener - Control Valve............................................... 162
5.2.6 V12 Rod Slide - Control Valve..................................................... 162
5.2.7 V13 Foot Clamp - Control Valve.................................................. 162
5.2.8 V14 Chuck - Control Valve.......................................................... 162
5.2.9 V15 Pressure Reducing Valve - Chuck....................................... 163
5.2.10 V16 Mainline Hoist Manual Brake Release Valve....................... 163
5.2.11 V18 Pressure Reducing Valve - Foot Clamp............................... 164
5.2.12 V19 Pressure Reducing Valve - Rod Slide.................................. 165
5.2.13 V20 Counterbalance Valve - Rod Slide....................................... 166
5.2.14 V21 Pressure Reducing Valve - Head Opener............................ 166
5.2.15 V22 Counter Balance Valve - Head Opener............................... 166
5.2.16 V23 Mud Mixer - Speed Control Valve D05 Manifold.................. 167
5.2.17 V24 Mud Mixer - Sequence Valve............................................... 167
5.2.18 V25 Fine Feed Pressure Control - D05 Manifold........................ 167
5.2.19 V26 Fine Feed Rate Control - D05 Manifold............................... 168
5.2.20 V28 Float (Thread Making/Breaking).......................................... 168
5.2.20.1 Rod Making/Breaking Adjustment....................................... 169
5.2.20.2 Rod Making Adjustment (V28)............................................ 170
5.2.20.3 Rod Breaking Adjustment (V28)......................................... 170
5.2.21 V29 Solenoid Valve - Rod Making/Breaking............................... 170
5.2.22 V31 Wireline Hoist Counterbalance Valve.................................. 171
5.2.23 V32 Pressure Reducing Valve, Hoist Brake Release.................. 171
153
5.2.24 V33 Main Line Cable Tension (Pressure Relief Valve)............... 171
5.2.25 V34 Mainline Hoist Displacement Control................................... 171
5.2.26 V35 Rotation Torque Limiting Valve-Thread Making................... 171
5.2.27 V36 Mainline Hoist Counterbalance Valve.................................. 173
5.2.28 V37 Main Relief - Fluid Circulation Pump.................................... 173
5.2.29 V40 Auxiliary Control Valve - Drill Setup..................................... 174
5.2.30 V41 Counterbalance Valves - Mast Raising Cylinder.................. 174
5.2.31 V43 Diverter Valve...................................................................... 174
5.2.32 Main Valve Bank V44.................................................................. 175
5.2.33 Main Hoist (V44-01/V44-02)........................................................ 175
5.2.34 Wireline Hoist (V44-03)............................................................... 176
5.2.35 Fast Feed (V44-04)..................................................................... 177
5.2.36 Rotation Circuit (V44-05)............................................................. 178
5.2.37 V44-06 Auxiliary - Main Control Valve......................................... 180
5.2.38 V46 Main Relief P1 Circuit.......................................................... 180
5.2.39 V47 Auxiliary Relief Valve Adjustment - P3 Circuit..................... 181
5.2.40 V48 Primary Cooler Fan Circuit Relief Valve.............................. 182
5.2.41 V54 Traction Control Valve (Optional)......................................... 182
5.3 Counterbalance Valves........................................................................... 182
5.3.1 Setting Counterbalance Valves................................................... 182
5.4 Hydraulic Pumps..................................................................................... 183
5.4.1 Primary Pump (P1)...................................................................... 183
5.4.2 Secondary Pump (P2)................................................................. 184
5.4.3 Auxiliary Pump (P3)..................................................................... 185
5.4.4 PTO Pump (P4)........................................................................... 186
5.4.5 Optional Pump (P5)..................................................................... 187
5.4.6 Head Lubrication Pump (P6)....................................................... 187
5.4.7 Hydraulic Filler Pump (P7).......................................................... 187
5.5 Fluid Conditioners and Filters............................................................... 187
154
5.5.1 C1 Main Hydraulic Cooler........................................................... 188

5.5.2 C2 Primary Pressure Filter.......................................................... 188
5.5.2.1 Filter Element Change Procedure....................................... 188
5.5.3 C3 Main Return Filter.................................................................. 190
5.5.3.1 Filter Element Change Procedure ...................................... 190
5.5.4 C4 Hydraulic Tank Filler Filter..................................................... 192
5.5.5 C5 Hydraulic Reservoir Breather................................................. 192
5.5.5.1 Filter Change Procedure .................................................... 192
5.5.6 C6 Drill Head Lubrication Oil Filter.............................................. 192
5.5.7 C7 Head Cooler Hydraulic........................................................... 192
5.6 Motors...................................................................................................... 193
5.6.1 M1 Main Rotation Motor ............................................................. 193
5.6.1.1 Minimum Displacement Adjustment Procedure ................. 193
5.6.1.2 Maximum Displacement Adjustment Procedure ................ 194
5.6.1.3 Rotation Speed Control Range Adjustment........................ 194
5.6.2 M2 Mainline Hoist Motor ............................................................. 195
5.6.3 M3 Wireline Winch Motor ........................................................... 195
5.6.4 M4 Water Pump Motor................................................................ 195
5.6.5 M5 C1 Cooler Fan Motor ............................................................ 195
5.6.6 M6 Mud Mixer Motor (Optional)................................................... 196
5.7 Actuators................................................................................................. 196
5.7.1 A1 Feed Cylinders....................................................................... 196
5.7.2 A2 Hydraulic Chuck..................................................................... 197
5.7.3 A3 Foot Clamp Cylinders............................................................ 197
5.7.4 A4 Head Opener Cylinder........................................................... 197
5.7.5 A5 Rod Slide Cylinder................................................................. 197
5.7.6 A6 Mast Raising Cylinders.......................................................... 198
5.7.7 A7 Mast Dump Cylinders............................................................. 198
5.7.8 A8 Mast Extension Cylinder........................................................ 198
5.7.9 A9 Jack Cylinders (Optional)....................................................... 199
5.7.10 A10 Outrigger Cylinders (Optional)............................................. 199
155
Tables
Table 5–1: Valves.......................................................................................... 159
Table 5–2: Pressure Settings for Rod........................................................... 172
Table 5–3: Hydraulic Pumps......................................................................... 183
Table 5–4: Fluid Conditioners....................................................................... 187
Table 5–5: Hydraulic Motors......................................................................... 193
Table 5–6: Actuators..................................................................................... 196
156
5.1 Hydraulic Reservoir

This module contains the hydraulic pumps, valves, reservoir, hydraulic
hoses, function controls, filters and gauges. The reservoir is constructed
from aluminium to prevent internal corrosion.
The tank is constructed of aluminium plate. Access for inside the tank is
through an 18” (450 mm Ø) end cover. Return from the main valve bank
flows through an oil cooler and on through a return filter mounted in
the hydraulic tank. The return filter is outfitted with a return line diffuser
to prevent foaming of the oil. Suction and return oils are separated by
a baffle down the centre of the tank. On top of the tank is the return
line filter from the auxiliary pump. On the side of the tank is the high
pressure filter for oil going to the main valve bank. The tank has an oil
level switch and temperature alarm set at 170°F in the tank. The tank
is also outfitted with a spin on breather. Never fill the tank through this
opening. Always use the filler pump supplied to ensure new oil passes
through the return filter.
5.1.1 Hydraulic Reservoir Oil Filling Procedure

1. Select a suitable grade of hydraulic oil for the outdoor ambient
temperature range as detailed in the lubrication table found in
Chapter 7. Never attempt to pour oil directly into the hydraulic
reservoir. Use the oil filler pump provided to ensure new oil is
always filtered through the hydraulic reservoir’s return filter
system.
2. A ball valve has been provided under the reservoir to aid in draining
the tank when required. Always be prepared for oil spill
157
containment and have an adequate stock of clean up supplies

on site.
Figure 5–1: Hydraulic Reservoir
5.2 Hydraulic Valves

Refer to the operator’s control panel or hydraulic schematic on valve
locations where applicable.
Valve Description
Number
V7 Water Pump Speed Control
V9 Fine Feed Valve (Drilling)
V10 Mud Mixer Control Valve
V11 Head Opener
V12 Rod Slide
V13 Foot Clamp
V14 Chuck
V15 Chuck (Pressure Reducing Valve)
V16 Mainline Hoist Manual Brake Release Valve
158
V18 Pressure Reducing Valve - Foot Clamp

V19 Pressure Reducing Valve - Rod Slide
V20 Counterbalance Valve - Rod Slide
V21 Pressure Reducing Valve - Head Opener
V22 Counter Balance Valve - Head Opener
V23 Mud Mixer - Speed Control Valve D05 Manifold
V24 Mud Mixer - Sequence
V25 Fine Feed Pressure Control - D05 Manifold
V26 Fine Feed Rate Control - D05 Manifold
V28 Float (Thread Making/Breaking)
V29 Solenoid Valve - Rod Making/Breaking
V31 Mainline Hoist Brake Valve
V32 Pressure Reducing Valve, Brake Release
V33 Mainline Cable Tension (Pressure Relief Valve)
V34 Hoist Displacement Control
V35 Rotation Torque Limiting Valve-Thread Making
V36 Mainline Hoist Counterbalance Valve
V40 Set up Control Valve
V41 Counterbalance Valves - Mast Raising Cylinder
V42 Pilot Operated Check Valve (Head Feed)
V43 Diverter Valve
V44 Main Control Valve Bank
V44-01 Main Line Winch Proportional
V44-02 Main Line Winch Proportional
V44-03 Wireline Winch Proportional
V44-04 Fast Feed Valve
V44-05 Head Rotation Valve
V44-06 Auxiliary Valve
V45 Relief Valve - Setup Valve Bank V40
V46 Main Relief Valve (P1 Circuit)
V47 Auxiliary Relief Valve Adjustment
Table 5–1: Valves
5.2.1 D05 Manifold

The following figure outlines the D05 Manifold valve location.
159
V9 V10 V13 V14

V11 V12
V29 V17
V26
V24 V22 V20 V16
V28
V25 V23 V21 V19 V18 V15
V27
Figure 5–2: D05 Manifold
Pressure test point adapters are provided for set up and diagnostic
purposes.
Figure 5–3: Pressure Test Point Adapters
160
A quadra gauge or similar device is recommended.
Figure 5–4: Quadra Gauge
5.2.2 V7 Fluid Circulation Pump Flow Control

The V7 fluid circulation pump flow control is located in the lower section
of the OCP. It is used by the operator to increase or decrease the
volume of drilling fluid being pumped down the hole. Pump output is also
affected by engine RPM. Rotate the knob clockwise to decrease the
water/mud pump output. This valve is located in the lower operator’s
console. No adjustment is necessary, see Pump Pressure Settings,
secondary pump (P2) section.
Figure 5–5: V7 Fluid Circulation Pump Flow Control
161
5.2.3 V9 Fine Feed - Control Valve (Drilling)

Controls the flow and downward direction of travel to the two 11 ft (3.35
m) feed cylinders located in the lower level mast assembly for fine feed
and head float of the carriage. This is a three position valve is activated
manually with lever (#9) Maximum flow is 11 gpm (42 L/min) @ 2000 psi
(13.79 MPa).
5.2.4 V10 Mud Mixer - Control Valve

Controls the mud mixer. This valve is a two position on/off and is
activated manually by a lever (#10).
5.2.5 V11 Head Opener - Control Valve

Controls the direction of the head opening cylinder located on the head.
This is a three position spring return valve and is activated manually with
a lever (#11).
5.2.6 V12 Rod Slide - Control Valve

Controls the direction of travel on the rod slide, located in the lower mast
assembly. This is a three position spring return valve and is activated
manually with a lever (#12).
5.2.7 V13 Foot Clamp - Control Valve

Controls the opening and closing of the foot clamp located in the lower
portion of the lower mast assembly. This valve is a two position on/off
with a manual lock to keep the foot clamp closed. Valve is activated
manually by lever (#13).
5.2.8 V14 Chuck - Control Valve

Controls the opening and closing of the chuck. This valve is a two
position on/off with a manual lock to keep the chuck closed. Valve is
activated manually by a lever (#14) on the control console.
162
5.2.9 V15 Pressure Reducing Valve - Chuck

This cartridge is located under the chuck control valve (#14). Set chuck
pressure reducing valve:
●● connect the quadra gauge to the test port at the back of the chuck
pressure reducing valve
●● start engine and leave at idle
●● adjust the pressure reducing valve to 1400 psi (9.65 MPa) using an
Allen key and a 9/16” wrench to unlock the jam nut
●● check pressure with control lever in both positions
●● lock jam nut
●● remove the quadra gauge
Figure 5–6: Pressure Reducing Valve
5.2.10 V16 Mainline Hoist Manual Brake Release Valve

Turn handle counterclockwise to release while drilling and clockwise
to apply brake while hoisting or lowering rods. Monitor brake pressure
gauge to verify if the brake is applied or released - 600 psi (4 MPa)
brake released, 0 psi (MPa) brake applied.
Check main line winch brake release:
●● disconnect and plug brake hose at winch

●● move the brake release control valve handle counterclockwise to
the “release” position
●● main line winch release gauge should read 600 psi (4.14 MPa) (prv
setting)
●● move the brake release control valve handle clockwise to the
“apply” position
163
●● main line winch release gauge should read 0 psi (MPa) (prv setting)
●● stop engine, reconnect brake hose and retest
●● monitor main line winch brake release gauge
Figure 5–7: Manual Brake Release Valve
5.2.11 V18 Pressure Reducing Valve - Foot Clamp

Set rod clamp pressure:
●● plug A & B ports on the rod clamp

●● connect quadra gauge to the test port at the back of the rod clamp
●● activate the rod clamp directional valve
●● adjust the rod clamp pressure reducing valve to 800 psi (5.52 MPa)
using a 5/32” Allen key and 9/16” wrench
●● lock jam nut
164
●● remove quadra gauge
Figure 5–8: Pressure Reducing Valve - Foot Clamp
5.2.12 V19 Pressure Reducing Valve - Rod Slide

Adjust rod slide pressure reducing valve:
●● plug A & B ports on the rod slide

●● connect quadra gauge to the test port at the back of the rod slide
●● activate the rod slide directional valve
●● adjust the rod slide pressure reducing valve to 2000 psi (13.79
MPa) using a 5/32” Allen key and 9/16” wrench
●● lock jam nut
Figure 5–9: Pressure Reducing Valve - Rod Slide
165
5.2.13 V20 Counterbalance Valve - Rod Slide

The rod slide counterbalance valve prevents the slide creeping while
drilling. These valves are located under V11 and are set at the factory.
Do not adjust without first consulting a Boart Longyear technician.
5.2.14 V21 Pressure Reducing Valve - Head Opener

Adjust head opener pressure reducing valve:
●● plug A & B ports on the head opener

●● connect quadra gauge to the test port at the back of the head
opener pressure reducing valve
●● activate the head opener directional valve
●● adjust the head opener pressure reducing valve to 2000 psi (13.79
MPa) using a 5/32” Allen key and 9/16” wrench
●● lock jam nut
Figure 5–10: Pressure Reducing Valve - Head Opener
5.2.15 V22 Counter Balance Valve - Head Opener

Prevents the head from running away during opening and closing.
If hydraulic failure occurs while open, the head is held in place by
these valves. Do not adjust without first consulting a Boart Longyear
technician.
166
5.2.16 V23 Mud Mixer - Speed Control Valve D05

Manifold
Controls the speed of the mud mixer motor. This valve is proportional
and located in the D05 manifold. Valve is activated manually by a knob
(#37) on the control console. Maximum flow is 11 gpm (40 L/min) @
1800 psi (125 bar).
5.2.17 V24 Mud Mixer - Sequence Valve

Adjust mud mixer sequence valve:
●● connect mud mixer hoses together

●● connect quadra gauge to the test port on the front of the sequence
valve located under the mud mixer directional control valve
●● open the flow control valve under the test port by turning
counterclockwise
●● pull the mud mixer control lever to the “on” position
●● monitor the quadra gauge, the pressure should drop from 2000 to
1800 psi (13.8 to 13.1 MPa)
●● if necessary, adjust the sequencing valve screw on the back of the
valve using a 1/2” and a 9/16” wrench
●● lock jam nut
Figure 5–11: Mud Mixer - Sequence
5.2.18 V25 Fine Feed Pressure Control - D05 Manifold

Allows the operator to adjust the fine feed pressure of oil entering the
feed cylinders. This valve (#4) is located in the feed control manifold, on
the control console.
167
Adjust fine feed pressure reducing valve:
●● plug A & B ports

●● move the fine feed control lever forward to the “feed down” position
●● using a 5/32” Allen key and 9/16” wrench, adjust the pressure
reducing valve counterclockwise and then clockwise - note the
reading on the feed pressure gauge to ensure that the feed
pressure can be reduced
●● leave the pressure reducing valve set at 2000 psi (13.79 MPa), full
pressure
●● return the control lever to neutral
5.2.19 V26 Fine Feed Rate Control - D05 Manifold

Allows the operator to adjust the fine feed rate of the carriage during fine
feed mode by metering the oil out of the feed cylinders. This valve (#36)
is located in the D05 manifold, on the control console.
5.2.20 V28 Float (Thread Making/Breaking)
Before adjusting V28, it is important to first adjust the rotational torque

limiting relief valve (V30) for the size of rods being used. See section V30.
This is the pressure reducing/relieving valve cartridge located in the D05

manifold. It is adjusted to control the “float” weight of the rotation unit
while making up rod joints. The adjustment to control the “float” weight
of the rotation unit while breaking rod joints is on the rear side of the
valve.
To disable the rod making/float down function from influencing this

adjustment, disconnect electrical plugs at the V29 solenoid valve.
The forward and reverse rotation speeds of the head for rod making
and breaking have been factory set with the two-speed control on
the console in the low speed mode, the engine at 1800 rpm and the
transmission in 1st gear. If further adjustment is required, the remote
panel cover must be opened and the resistor pot’s adjusted while
operating the rod making/breaking joystick. The resistor pot’s are
located outside the main rotation joystick housing. It is advisable to
disconnect the electrical plugs at V29 while adjusting the rotation speed.
Reattach the plugs when settings are complete.
168
Rod making adjustment (front of panel):
Figure 5–12: Rod Making Adjustment - Front of Panel
Rod breaking adjustment (rear of panel):
Figure 5–13: Rod Breaking Adjustment - Rear of Panel
5.2.20.1 Rod Making/Breaking Adjustment

Review the Pre-Start Check List and Start Up Procedures before
proceeding with the following steps.
1. Locate V28 relief valves on D05 manifold.
2. Set the PQ Head Two Speed Control on the console to low and the
head transmission in 1st gear for making/breaking thread joints.
3. Start the engine and let the hydraulic system warm up to the
operating temperature before calibrating. Adjust engine throttle to
1800 rpm.
4. Open the chuck and foot clamp.
169
5. Insert a rod into the foot clamp with 6” - 12” (15 - 30 cm) protruding
above the clamp and close the foot clamp. Always use proper
thread lubricant on threads.
6. Insert a rod through the chuck.
5.2.20.2 Rod Making Adjustment (V28)

1. Push the rod making/breaking joystick forward into the rod making
position.
2. Adjust the cartridge on the front side of the valve body until the
head just starts to float downwards.
3. Experiment with adjusting the appropriate downward head float

speed while rotating the head slowly (V28).
4. Open the chuck and start the rod threads by hand.
5. Close the chuck and engage the rod making joystick while checking
for thread galling or heating of the rod joint. Re-adjust if necessary.
5.2.20.3 Rod Breaking Adjustment (V28)

1. Pull the rod making/breaking joystick backwards into the rod
breaking position.
2. Adjust the cartridge on the rear side of the valve body until the
head just starts to float upwards.
3. Experiment with adjusting the appropriate upward head float speed

while rotating the head slowly counterclockwise (V28).
4. Thread together rod joints as per rod making instructions above.
5. Engage the rod breaking joystick while checking for thread galling
or heating of the rod joint. Re-adjust if necessary.
5.2.21 V29 Solenoid Valve - Rod Making/Breaking

An electrical signal from the rod making/breaking joystick shifts this
valve allowing the rotation unit to “float up” or “float down” at a controlled
rate while making/breaking a rod joint.
170
5.2.22 V31 Wireline Hoist Counterbalance Valve

Counterbalance valve V31 is located in the wireline hoist motor
manifold. It is a 3-port pilot operated counterbalance valve used to hold
the winch load.
5.2.23 V32 Pressure Reducing Valve, Hoist Brake

Release
The mainline hoist spring applied hydraulically released (SAHR) brake
is limited to a maximum operating pressure 1200 psi. Pressure reducing
valve V32 is located in the mainline hoist brake release circuit to reduce
system pressure to protect the SAHR brake.
5.2.24 V33 Main Line Cable Tension (Pressure Relief

Valve)
This is a pressure reducing valve remotely controlled from the control
panel. It sends a signal to open the main winch counterbalance valve to
control cable tension.
5.2.25 V34 Mainline Hoist Displacement Control

The mainline hoist motor has an on/off solenoid-operated displacement
control to allow the hoist to operate at a higher speed for increased
productivity in shallow holes. The motor defaults to max displacement
with the solenoid de-energized.
The solenoid is powered through a manually operated two position

switch located on the OCP between the fast feed and hoist control
joysticks. The rabbit position is used for higher speed, shallow hole
hoisting offering roughly 50% of hoist lifting capacity; the turtle position
is for deeper hole work providing full hoist lifting capacity at a lower
speed.
5.2.26 V35 Rotation Torque Limiting Valve-Thread

Making
Note: Always use first gear low range when making up rod joints. Use
proper thread lubrication to prevent possible thread damage.
171
This relief valve determines the rod make-up torque during the thread
making operation. It is situated at the bottom right hand side of the
control stand and limits the rotation torque available for pre-torquing rod
joints. The adjustment screw is turned clockwise to increase the make
up torque.
Valve adjustment:
●● Turn the adjustment screw fully counterclockwise.

●● Start the engine and set the throttle to 1800 rpm
●● Place the transmission in first gear
●● Turn the rotation speed control fully counter-clockwise (low speed)
●● Close both the chuck and footclamp on a rod in a mast with the
head positioned at the bottom of the feed stroke
●● Place the rod making/breaking joystick forward into the rod making
position
●● Monitor the pressure on the torque gauge while adjusting the
torque limit valve screw
●● Adjust to the proper pressure for the rod size being used
Note: Turn clockwise to increase pressure.
Table 5–2: Pressure Settings for Rod
172
●● Return all levers to the neutral position and shut down the engine
Figure 5–14: V35 Rotation Torque Limiting Valve
Note: Always use first gear low range when making up rod joints. Use
proper thread lubrication to prevent possible thread damage.
5.2.27 V36 Mainline Hoist Counterbalance Valve

The V36 Mainline Hoist Brake Valve is a 3 port counterbalance valve
with “pilot to open assist.” It is installed on the mainline hoist motor
control manifold to prevent overrunning loads and block flow (hold
the load) until pilot pressure is applied. The counterbalance valve
pilot pressure signal is normally generated in the hoist control circuit
whenever the main hoist control valve is shifted by the operator to
lower the load. The counterbalance valve will remain closed until
sufficient pilot pressure is applied to the spool to open the valve. It is not
negatively affected by system back pressure.
Once the counterbalance valve cracks open, pilot pressure becomes

flow dependent and modulates the valve spool opening thus controlling
the speed of the descending load. The park brake (friction brake) is a
load holding brake only and has nothing to do with dynamic breaking or
controlling the rate of load decent. This counterbalance valve is pre-
set to 5000 psi. DO NOT TAMPER WITH THIS SETTING. Any setting
below this will limit the maximum load the hoist can suspend.
5.2.28 V37 Main Relief - Fluid Circulation Pump

This pressure relief valve is located on the outlet of the fluid circulation
pump to protect the pump when the inner tube blocks fluid flow or when
resistance to fluid flow is excessive. It is manually adjustable by the
driller to suit drilling conditions. Turning the adjustment bolt in clockwise
increases the pressure setting.
173
5.2.29 V40 Auxiliary Control Valve - Drill Setup

Controls the flow and direction of travel to the two mast raising cylinders,
mast extension and retraction, mast dump and retraction, levelling jacks
and outriggers. Stroke is controlled by a manual lever.
Figure 5–15: Auxiliary Control Valve - Drill Setup
5.2.30 V41 Counterbalance Valves - Mast Raising

Cylinder
Note: These cartridges are set at the factory.
Prevents a runaway load from occurring. These valves also prevent

the mast from falling if all hydraulic pressure is lost during the raising
or lowering of the mast. The counterbalance valves would lock the
cylinders in place, preventing any further movement. These valves are
part of the cylinder itself, located at the rod end of each assembly.
5.2.31 V43 Diverter Valve

This diverter valve is a manually operated 2-position 3-way valve. Its
purpose is to isolate the set up controls (mast raisng, dump and jack
functions) while drilling to prevent inadvertent operation. This valve is
replaced by a solenoid operated version on drills manufactured with the
track drive option.
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5.2.32 Main Valve Bank V44

The main valve bank is located under the control panel assembly and
consists of four functions, mainline hoist, wireline, winch, fast feed, and
rotation. The main relief V46 is set at 4,800 psi. See the Main Valve
Bank Pressure Setting section for setting up the valve functions.
Figure 5–16: Main Valve Bank V44
5.2.33 Main Hoist (V44-01/V44-02)

Controls the speed and direction of rotation on the main line winch for
hoisting or lowering operations. This valve is proportional and located in
the main valve bank. This function utilizes two valve spools energized
in parallel to maximize flow. Stroke is controlled electrically by a joystick
(#7) on the control console and manual override handles at the main
control valve.
No adjustment required.
5.2.33.1 Setting Flow Rate

1. Connect a flow meter to the main hoist with “A” port connected to
the inlet of the flow meter and “B” port connected to the outlet of the
flow meter.
2. Slowly engage each main line spool section manually to verify 40

gpm (151 L/min) for each section.
3. Adjust the manual spool stop adjustment screws (2) on top of the
manual control handle cap counterclockwise to allow 40 gpm (151
L/min) from each valve section in both directions.
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Note: The maximum oil flow is limited to 40 gpm (151 L/min) for

each valve section.
4. Slowly engage the main line hoist joystick to verify a combined flow
of 80 gpm (302 L/min).
5.2.34 Wireline Hoist (V44-03)

Controls the flow and direction of rotation on the wireline hoist motor
located on the base frame. This valve is proportional and is located in
the main valve bank. Stroke is controlled electrically by a joystick (#7)
on the control console and with a manual override handle at the main
control valve.
Refer to the Start Up Procedures before proceeding with the following

steps to set the Wireline Hoist pressure.
1. Block the work ports on the wireline motor and plug the hoses.
2. Start the engine and let the hydraulics warm up to operating

temperature before setting pressure.
3. To adjust work port pressure, remove the top Allen key plug
nearest to the manual control handle for the wireline hoist.
Ref. Allen
Key Plug
Wireline Hoist
Port Relief
(V44-03)
Figure 5–17: Wireline Hoist Port Relief
4. Insert the adjusting tool in the port and loosen the lock
counterclockwise.
5. Slowly move the wireline joystick forward and hold into position to
adjust.
6. Insert a 0.12” (3 mm) Allen key in the adjusting tool. Turn the Allen
key until the wireline hoist pressure gauge, which is located on the
control console reads 3,000 psi (20.68 MPa).
7. Lock the adjusting tool Allen screw and return the wireline joystick
to neutral.
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8. Turn the engine off and reconnect the wireline hose to the motor.

manual control handle cap counterclockwise to allow maximum
flow allowable from the valve section.
2. The maximum oil flow is limited by the spool size (34.3 gpm / 129.8
L/min).
5.2.35 Fast Feed (V44-04)

Controls the flow and direction of travel to the two 11 ft (3.35 m) feed
cylinders located in the lower mast section for fast feed of the carriage.
This valve is proportional and is located in the main valve bank. Stroke
is controlled electrically by a joystick (#5) on the control console and
with a manual override handle at the main control valve.

steps to set the Fast Feed pressure.

2. Slowly move the fast feed joystick forward with the chuck open.
Allow the feed cylinder to bottom out.
3. To adjust the load sense work port pressure, remove the top Allen
key plug nearest to the manual control handle for the fast feed.
Figure 5–18: Fast Feed Setting
4. Insert the adjusting tool in the port and loosen the lock
counterclockwise.
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5. Slowly move the fast feed joystick forward and hold into position to
adjust.
6. Insert a 0.12” (3 mm) Allen key in the adjusting tool. Turn the Allen
key until the system pressure gauge, which is located on the control
console, reads 2,000 psi (13.79 MPa).
7. Lock the adjusting tool Allen screw and return the fast feed joystick
to neutral.
8. Turn the engine off.

manual control handle cap counterclockwise to allow maximum
flow allowable from the valve section.
2. The maximum oil flow is limited by the spool size (47.6 gpm / 180.2
L/min).
5.2.36 Rotation Circuit (V44-05)

Controls the flow and direction of the rotation motor on the head. This
valve is proportional and is located in the main valve bank. Stroke is
controlled electrically by a knob (#3) on the control console and with a
manual handle over ride at the main control valve.
No adjustment required.

1. Disconnect the 1” (2.54 cm) ID hoses going to the rotation motor at
the motor end. Cap the open connections on the motor.
2. Connect a flowmeter to the rotation motor hoses with the hose from
“A” port connected to the inlet of the flow meter.
3. Review the Pre-Start check list.
4. Ensure the load valve on the flow meter if fully open and ensure the
control console functions are in the following position:
○○ Fine Feed Pressure - all the way counterclockwise to open

○○ Fine Feed Rate - all the way clockwise to close
○○ Fast Feed joystick - neutral
○○ Rotation joystick - neutral
○○ Wireline Hoist/ Main Hoist joystick - neutral
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○○ Mud Mixer speed control - all the way clockwise to turn off
○○ Water Pump speed control - all the way counterclockwise to turn
off
○○ Chuck - closed
○○ Foot Clamp - either open or closed
○○ Drilling lever - neutral
temperature before setting the flows.
7. Slowly rotate the rotation control knob clockwise.
8. Monitor the oil flow through a flowmeter and adjust the first
adjustment screw on top of the manual handle spool stop (closest
to the lever) for the rotation valve until the correct flow is obtained
(51 gpm).
Manual Spool Stop

Adjustment Screws
Figure 5–19: Manual Spool Stop
9. Lock the adjustment screw and return the rotation joystick back to
neutral position.
10. Shut the engine off, remove the flowmeter and reconnect the
rotation hoses to the hydraulic motor.
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5.2.37 V44-06 Auxiliary - Main Control Valve

This valve section is installed in the main control valve for an option
not supplied on this drill. It is electrically controlled by variable speed
selector (#2) on the operator’s console.
Maximum allowable flow is 44 gpm (167L/min) @ 2500 psi (17.25 MPa).
5.2.38 V46 Main Relief P1 Circuit

The main relief valve for the P1 pump circuit is located in the inlet of the
Main Drill Control Valve Bank V44. The following process can be used
to set this relief valve.
1. Disconnect the two rotation hoses from the rotation motor, and plug
the open hoses and cap the open motor fittings.

3. Remove the plastic protective cap on the primary pump controller

adjustment screw. Loosen the jam nut and turn the Allen screw
clockwise to increase the pump pressure up to a maximum of 4,800
psi (33.09 MPa).
Figure 5–20: Main Valve Bank Relief Setting V46
4. Slowly move the rotation joystick forward and lock into position.
5. Adjust the main relief valve V46 on the inlet side of the main valve
bank until the system pressure gauge, located on the control
console, reaches 5000 psi (345 bar).
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6. Reset the primary pump pressure to 4,500 psi (31.03 MPa) at the
adjustment screw on the pump controller.
Adjustment
Screw
Figure 5–21: Adjustment Screw on Pump Controller
7. Return the rotation joystick to the neutral position, turn the engine
off and reconnect the rotation hoses to the hydraulic motor.
5.2.39 V47 Auxiliary Relief Valve Adjustment - P3

Circuit
Adjust relief valve in the auxiliary valve bank:
●● install pressure gauge in the “P” port of the control valve

●● temporarily adjust auxiliary pressure to 2200 psi (15.19 MPa) with
“A”&“B” ports blocked on the optional front jack valve section
●● activate the front jack directional valve lever
●● adjust the relief valve to 2000 psi (13.79 MPa)
●● re-adjust the auxiliary pressure pump to 2000 psi (13.79 MPa)
Figure 5–22: Auxiliary Control Valve - Drill Setup

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5.2.40 V48 Primary Cooler Fan Circuit Relief Valve

The V48 Primary Cooler Fan Circuit Relief Valve is located in Gear
Pump P4 Mounted on the engine PTO. V48 is installed to protect the C1
Primary Cooler fan circuit. This is a direct acting relief valve catridge.
5.2.41 V54 Traction Control Valve (Optional)

The traction control valve is supplied when the track drive option is
ordered. It is a two spool electro-hydraulic proportional model providing
flow to the traction motors on the track module. It is activated by the
radio remote controller for the track drive.
5.3 Counterbalance Valves
Counterbalance valves are load holding devices that may have to be

serviced or replaced from time to time. These valves should only be
serviced by trained hydraulic service personnel and must be reset to the
values stated in the hydraulic schematic. Always ensure that any load
locked by a counterbalance valve is properly supported prior to service.
Failure to do so could result in equipment damage, personal injury or
death.
Never substitute one valve cartridge for another. There are a multitude of
cartridge ratios, settings and designs closely matched to the application.
Inadvertent substitution could result in equipment damage, personal
injury or death.
Never work under a suspended load.
5.3.1 Setting Counterbalance Valves

Some counter balance valves cartridges can be adjusted on the
machine but certain applications (such as the mainline hoist) may
dictate that a valve be set in a test fixture. Counter balance valve
cartridges are available in a multitude of cavity sizes, and the test
manifold must match the cartridge being tested. The test fixture must
have a pressure supply that can exceed the desired setting of the
counterbalance valve cartridge by at least 10%.
The following procedure is a general guideline:
1. Ensure load is lowered/securely supported prior to removing the

counterbalance valve.
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2. Clean/wipe away any dirt around the cartridge before removal.
3. Remove the valve cartridge and use a suitable method to capture

any oil.
4. Plug the open valve cavity with a clean lint free cloth.
5. Install the clean cartridge into the test manifold.
6. Slowly raise the load pressure of the cartridge in the test fixture
to the desired value indicated on the hydraulic schematic. If the
cartridge relieves pressure at that setting, no further adjustment will
be required. If the cartridge fails to relieve the load pressure at the
desired setting, re-adjustment or replacement of the valve will be
necessary.
5.4 Hydraulic Pumps

LF230 Hydraulic Pumps
P1 Main Hydraulic Pump
P2 Secondary Hydraulic Pump
P3 Auxiliary Pump
P4 PTO Hydraulic Pump
P5 Optional Pump
P6 Head Lubrication Pump
P7 Hydraulic Filler Pump
Table 5–3: Hydraulic Pumps
5.4.1 Primary Pump (P1)

The primary pump is an open loop axial piston type with a supercharged
inlet. The pump is load sensing and pressure compensated. Functions
controlled by the pump are: rotation; fast feed; main line winch; and wireline
winch.
Review the Pre-Start check list.

steps to set the primary pump pressures.
The primary pump has settings for standby pump pressure and system
pump pressure. These settings are factory set and should not require
changing. Should adjustments be required, follow the steps below.
1. Disconnect the two rotation hoses from the motor, plug the open
hoses and cap the open motor fittings.
183

temperature before setting pressures.
3. To adjust the standby pressure, remove the plastic protective cap

on the pump controller adjustment screw. Loosen the jam nut and
turn the Allen screw clockwise to increase to 420 psi (2.90 MPa).
Use the system pressure gauge located on the control console to
monitor this pressure when setting.
4. Slowly move the rotation joystick forward and lock into position to
pressurize the primary pump.
5. To adjust the system pump pressure, remove the plastic cap on the
pump controller adjustment screw. Loosen the jam nut and turn the
Allen screw clockwise to increase the pump pressure until the
system pressure gauge reads 4500 psi (31.03 MPa).
Adjustment
Screw
Figure 5–23: Adjust System Pump Pressure
6. Return the rotation joystick to the neutral position, turn the engine
off, and reconnect the rotation hoses.
5.4.2 Secondary Pump (P2)

The secondary pump is an open loop, load sensing, pressure
compensated axial piston pump. This pump provides the required flow
and hydraulic pressure to operate the water pump.
Setting the standby pressure:
●● connect a quadra gauge to test coupler on the bottom of the

secondary pump flow control
●● remove the LS hose at the secondary pump compensator
●● plug the hose
●● leave the compensator open to atmosphere
●● close the secondary pump flow control by turning clockwise
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●● start the engine and leave at idle

●● read the standby pressure on the quadra gauge
●● adjust the standby pressure to 305 psi (2.10 MPa) (closest
adjustment to the pump) by turning the thumb screw and using the
box end of the 11/16” wrench to unlock the jam nut
●● lock the jam nut
●● reconnect the LS hose to the flow control
Setting the compensator pressure:

●● open the flow control by turning counterclockwise
●● close the flow meter flow control valve and monitor the pressure on
the quadra gauge
●● adjust the compensator to 3000 psi (20.68 MPa) (furthest
adjustment from the pump) using a 7/16” wrench and a 1/2” wrench
to unlock the jam nut
●● lock the jam nut
●● open the flow meter flow control valve
Figure 5–24: Flow Meter Control Valve
5.4.3 Auxiliary Pump (P3)

The auxiliary pump is an open loop, pressure compensated, axial piston
pump. It supplies oil to the set up valve bank V40 and the D05 manifold
located in the operator’s console.
Setting the compensator pressure:
●● place all the control levers to neutral

●● connect a quadra gauge to test at the back of the auxiliary pump
gauge in the panel
185

●● adjust the compensator to 2000 psi (13.79 MPa) (furthest
adjustment from the pump) using a 1/8” Allen key and a 7/16”
wrench to
●● unlock the jam nut
●● lock the jam nut after setting compensator pressure
Figure 5–25: Lock the Jam Nut
5.4.4 PTO Pump (P4)

This PTO mounted gear pump (P4) provides oil to run the fan on the
hydraulic oil cooler.
Figure 5–26: PTO Pump
186
5.4.5 Optional Pump (P5)

An optional P5 pump is available to supply oil for a larger capacity mud
mixer. This pump is installed between the P2 and P3 pumps in the
engine pump group. It is a variable displacement pressure compensated
load sensing axial piston pump.
5.4.6 Head Lubrication Pump (P6)

The head lubrication pump on the LF230 is a PTO driven pump, directly
mounted to the drill head gear box. Fluid flow is directly proportional to
spindle RPM.
5.4.7 Hydraulic Filler Pump (P7)

Hand pump used to fill hydraulic tank from oil source. Prior to oil
entering the tank, the oil is pumped through a filter to help maintain
system cleanliness.
5.5 Fluid Conditioners and Filters

LF230 Fluid Conditioners
C1 Main Hydraulic Cooler
C2 Primary Pressure Filter
C3 Main Return Filter
C4 Hydraulic Tank Filler Filter
C5 Hydraulic Reservoir Breather
C6 Head Lubrication Oil Filter
C7 Head Lubrication Oil Cooler
Table 5–4: Fluid Conditioners
There are 4 main filters on the LF230 hydraulic system:
●● A primary pressure filter C2 located on the outside of the hydraulic

reservoir for the P1 hydraulic circuit.
●● Two return filters C3 installed in the top of the hydraulic reservoir to
filter the bulk of the hydraulic oil returning to the tank.
●● A spin on breather element C5 located on the top of the hydraulic
reservoir to filter airborne contaminates as the tank draws in
outside air during normal operation.
The pressure and return filter elements must be changed regularly either
when the dirt indicator shows dirty or every 500 hours of operation,
187
whichever comes first. Hydraulic filters must be serviced on a regular

basis otherwise erratic machine operation and or permanent damage to
more expensive hydraulic components will occur.
5.5.1 C1 Main Hydraulic Cooler

The main hydraulic cooler C1 on the LF230 is located at the engine
end of the rig. It is an air/oil heat exchanger with a hydraulically driven
cooling fan. The speed of the cooling fan is affected by engine speed
and the setting of relief valve V48.
5.5.2 C2 Primary Pressure Filter

Filters all pressurized oil leaving the P1 primary pump. The primary
pressure filter is fitted with a pressure by-pass and a clog indicator. The
filter housing is mounted to a bracket on the side surface of the tank.
5.5.2.1 Filter Element Change Procedure

1. All filter element changes are to be completed with the engine off.
2. The removal of the filter element will open the hydraulic system to
atmosphere. Hydraulic components are very sensitive to any
amount of dirt, care must be taken to clean the immediate
work area in advance to protect the hydraulic system. Wipe any
dirt from the top surface of the pressure filter housing and protect
from falling debris.
3. Always be prepared for oil spill containment and have an adequate

stock of clean up supplies on site.
188
4. Loosen the top cap from the filter housing using a 1-1/16” box end
wrench as shown in fig 5-3. Turn the cap counter clockwise to
remove it..
Figure 5–27: Loosen Top Cap with Wrench
Figure 5–28: Remove Cap
5. Remove filter element by lifting straight out. Take care to keep

debris from falling into tank and prevent filter element from dripping
on the drill rig or ground.
189
6. Install new filter element by lowering straight into filter bowl. Make
sure the filter element is seated into the filter bowl correctly.
Figure 5–29: Replace Filter
7. Inspect the o-ring on the cap for damage and replace if necessary.
8. Apply a small amount of never seize to the cap threads and replace
cover. Tighten the cover using 1-1/16” wrench until properly seated,
then back off ¼ turn.
9. Start engine and increase engine speed to approximately 1500 rpm

and run fast feed up and down for a few minutes to push the air out
of the filter housing.
10. Slow engine to idle before shutting down and allow the tank oil to
de-aerate for 30 minutes prior to drill use.
5.5.3 C3 Main Return Filter

Filters the bulk of the hydraulic oil returning to the main reservoir.
The return filter is equipped with an internal pressure by-pass and a
clog indicator. The filter housing is mounted on the top surface of the
hydraulic reservoir.
5.5.3.1 Filter Element Change Procedure

190
2. The removal of the filter element will open the hydraulic system
to atmosphere. Hydraulic components are very sensitive to any
amount of dirt, care must be taken to clean the immediate work
area in advance to protect the hydraulic system. Wipe any dirt from
the top surface of the filter housing and protect from falling debris.

4. Remove the top cover from the filter housing using a ½” box end
wrench as shown in fig 5-6.
Figure 5–30: Return Filter
5. Remove filter element by lifting straight out. Take care to keep

debris from falling into tank and prevent filter element from dripping
on the drill rig or ground.
Figure 5–31: Replace Filter
6. Install new filter element by lowering straight into filter bowl. Make
sure the filter element is seated into the filter bowl correctly.
191
7. Inspect the o-ring on the cover for damage and replace if

necessary.
8. Replace the top cover. Tighten the cover using ½” wrench until
properly seated.
9. Start engine and increase engine speed to approximately 1500 rpm

and run fast feed up and down for a few minutes to push the air out
of the filter housing.
10. Slow engine to idle before shutting down and allow the tank oil to
de-aerate for 30 minutes prior to drill use.
5.5.4 C4 Hydraulic Tank Filler Filter
5.5.5 C5 Hydraulic Reservoir Breather

Filters all air prior to entering the tank. The tank breather is a spin-on
element and is mounted to the top surface of the hydraulic tank.
5.5.5.1 Filter Change Procedure

2. Sweep away all debris from the top surface of the tank and protect
3. Turn the element counter clockwise by hand, as viewed looking

down to remove.
4. Replace with new element by turning element clockwise by hand,

as viewed looking down.
5.5.6 C6 Drill Head Lubrication Oil Filter

See Chapter 6 for details on this filter.
5.5.7 C7 Head Cooler Hydraulic

The drill head oil cooler C7 on the LF230 is located in front of the C1
Cooler. It is an air/ oil heat exchanger. Air flow through the cooler is
provided by the C1 cooler fan. This cooler is supplied with an integrated
thermal bypass for cold start protection. Oil will bypass the cooler
element until oil temperature rises above 45° C.
192
5.6 Motors
LF230 Hydraulic Motors
M1 Main Rotation Motor
M2 Mainline Hoist Motor
M3 Wireline Winch Motor
M4 Water Pump Motor
M5 C1 Cooler Fan Motor
M6 Mud Mixer Motor
Table 5–5: Hydraulic Motors
5.6.1 M1 Main Rotation Motor

This motor is a bi-directional, bent axis, variable displacement, piston
type used to drive the rotation of the drill head. The motor displacement
is controlled by varying a pilot signal sent to the motor displacement
controller.
5.6.1.1 Minimum Displacement Adjustment Procedure

The minimum displacement of the motor is factory set and should not
need to be adjusted. However, if the motor minimum displacement
does come out of adjustment use the following procedure to reset the
minimum displacement.
1. Run drill until hydraulic oil is at operating temperature and then

lower drill head until it bottoms out using fast feed.
2. With the engine at 2200 rpm and the rotation lever in the neutral
position, engage 1st gear and turn the rotation speed knob
clockwise until it stops.
3. Using a photo tachometer adjust the minimum displacement screw

until the head turns at 199 rpm.
○○ Loosen jam nut with 3/4 inch wrench and adjust displacement
with 1/4 inch Allen key.
○○ Clockwise to lower speed, counter clockwise to raise speed.
○○ Tighten jam nut and make sure speed has not changed.
4. Disengage rotation and slow engine before shutting off engine.
193
5.6.1.2 Maximum Displacement Adjustment Procedure

The maximum displacement of the motor is factory set and should not
need to be adjusted. However, if the motor maximum displacement
does come out of adjustment use the following procedure to reset the
maximum displacement.

2. With the engine at 2200 rpm and the rotation lever in the neutral
position, engage 1st gear and turn the rotation speed knob counter
clockwise until it stops.
3. Using a photo tachometer adjust the maximum displacement screw

until the head turns at 122 rpm.
○○ Loosen jam nut with 3/4 inch wrench and adjust displacement
with 1/4 inch Allen key.
○○ Counter clockwise to lower speed, clockwise to raise speed.
4. Disengage rotation and slow engine before shutting off engine.
5.6.1.3 Rotation Speed Control Range Adjustment

The speed control range adjustment is factory set and should not need
to be adjusted. However, if the speed control range adjustment does
come out of adjustment use the following procedure to reset the speed
control range.

2. With engine off disconnect the B side hose from the motor and cap
and plug the open ports.
○○ The plug and cap will need to resist primary pump pressure.
○○ Use a suitable container to capture the oil that runs out of the
open ports.
3. Start engine and set speed to 2200 rpm for the 8.3L Tier III (1800
for the 9.0L Tier 4i), and engage full forward rotation.
4. Turn the rotary pressure gauge display to position 3.
5. Adjust the rotation speed knob (V45) on the D05 manifold valve
until the rotary pressure gauge reads 190 psi.
6. Using a photo tachometer adjust the motor speed control range

until the head speed just starts to decrease.
○○ Break off tamper proof cap if still installed.
194
○○ Loosen jam nut and adjust speed control range with Allen key.
○○ Counter clockwise to raise speed, clockwise to lower speed.
7. Disengage rotation, slow engine before shutting off engine, and
reconnect the B side motor hose.
5.6.2 M2 Mainline Hoist Motor

This motor provides the torque to turn the mainline hoist. This motor is a
bent axis variable displacement piston motor with a two position control.
For more information on the care and maintenance of this motor, please
refer to the RW300 Braden Hoist Manual located in Appendix D.
5.6.3 M3 Wireline Winch Motor

This motor is an integrated motor gearbox design used to rotate the
wireline winch drum.
5.6.4 M4 Water Pump Motor

This motor provides the torque to turn the water pump. The motor is a
Gerotor type and turns in one direction only.
No adjustments required.
5.6.5 M5 C1 Cooler Fan Motor

This motor provides the torque to turn the hydraulic cooler fan. The
motor is a Gerotor type with case drain line and turns in one direction
only.
195
5.6.6 M6 Mud Mixer Motor (Optional)

This is a bi-directional geroler type motor providing rotation to the
optional mud mixer impeller. It is controlled with the variable flow control
valve V7.
5.7 Actuators
LF230 Actuators
A1 Feed Cylinders
A2 Hydraulic Chuck
A3 Foot Clamp Cylinders
A4 Head Opener Cylinder
A5 Rod Slide Cylinder
A6 Mast Raising Cylinders
A7 Mast Dump Cylinder
A8 Mast Extend Cylinder
A9 Jack Cylinders
A10 Outrigger Cylinders
Table 5–6: Actuators
5.7.1 A1 Feed Cylinders

The feed cylinders act in parallel to provide axial movement of the drill
head. This provides the down force needed at the drill bit and the up
force required when lifting the entire drill string. Power is provided to this
function from the pump P2. There are two controls for the feed function,
fast and fine feed.
The fast feed control is an electro hydraulic lift to shift joystick located
on the OCP, and the fine feed control is a manually controlled hydraulic
valve located on the D05 manifold. The fine feed control is required for
drilling.
196
5.7.2 A2 Hydraulic Chuck

The Nitro ChuckTM is a spring applied hydraulic release rod clamp used
to rotate the drill string. A stationary double acting hydraulic cylinder is
built into the base of the chuck to open the chuck by compressing the
nitrogen gas springs as required. A detailed cross section of the chuck
and assembly details are provided in Chapter 7.
5.7.3 A3 Foot Clamp Cylinders

These double acting cylinders open and close the rod clamp jaws. The
jaws close when oil is applied to the rod side of the cylinders.
Note: The jaws have a slope on the backside to allow the jaws to apply
more clamping force with increased rod string weight. The two rod
clamp cylinders are built into the rod clamp assembly.
5.7.4 A4 Head Opener Cylinder

This cylinder is a double acting type cylinder used to pivot the head in
and out of the mast.
5.7.5 A5 Rod Slide Cylinder

This cylinder is a double acting type cylinder used to extend and retract
the rod tray in the mast.
197
5.7.6 A6 Mast Raising Cylinders

The mast is raised and lowered via two double-acting telescopic
hydraulic cylinders. Dual counterbalance valves are installed in a
manifold at the base of each cylinder to prevent the mast from falling in
the event of a hose failure.
Figure 5–32: Mast Raising Cylinder
5.7.7 A7 Mast Dump Cylinders

These cylinders are a double acting type cylinder used to slide (re-
position) the mast assembly down to allow the footplates to touch the
ground.
5.7.8 A8 Mast Extension Cylinder

This cylinder is double acting and is used to extend or retract the
telescoping section of the mast. The rod side of the cylinder is fed
through the hollow rod. The oil enters the rod side of the cylinder from
the hollow rod through a passage near the piston. The base side is fed
through a smaller tube within the hollow rod. The tube separates the rod
side oil from the base side oil and passes through the piston into the
base side cylinder volume.
198
5.7.9 A9 Jack Cylinders (Optional)

An optional jack package is available for the LF230. These four jack
cylinders are used to level the drill rig for drilling.
Each actuator has dual integral pilot operated check valves

(counterbalance valves on later models) built into the head of the
cylinder to prevent the cylinder from retracting in the event of a failed
hydraulic hose.
5.7.10 A10 Outrigger Cylinders (Optional)
199
200
Contents
6.1 Electrical Control System....................................................................... 203
6.2 Fast/Slow Selector Switch...................................................................... 204
6.3 Winch Joystick Switch........................................................................... 206
6.4 Wireline/Mainline (Small) Joystick Switch............................................ 207
6.5 Fast Feed Joystick.................................................................................. 209
6.6 Auxiliary Pot............................................................................................ 210
6.7 Rod Make/Break Function (Make/Break Cube)..................................... 212
6.7.1 Rod Breaking............................................................................... 212
6.7.1.1 Head Float Up V29 Activation............................................. 213
6.7.2 Rod Making................................................................................. 214
6.7.2.1 Head Float Down V29 Activation........................................ 214
6.8 Safety Devices......................................................................................... 214
201
202
6.1 Electrical Control System

The electrical control system derives its electrical power from the
engine/battery. In this case the nominal 12VDC is variable depending on
battery condition. It enters the control console and connects to a circuit
interrupter 15A rated labelled “+12VDC”. This is the test point to earth to
verify local 12VDC within the console.
The control scheme is fail safe , as all control power has to pass through
a relay labeled “R1” and is only energised when the ignition switch is in
the ON position. The E-stop button is located on the left side of the
console fascia and is illuminated at all times to increase the visibility of
its location. It is normally pulled out closing its normally open contact,
thus depressing will open its contact. Wire “IGN” is the input wire and
wire “IGNA” is the output wire supplying power to relay “R1”, this relay
has two sets of normal open contacts, both are used in parallel. In the
vent the E-stop is pushed this relay will be de-energized, removing all
power to the devices in the console.
Figure 6–1: E-stop
The interconnection cable “C12” from receptacle “C12” makes the

connection to the ignition switch using “Pin 2” of the receptacle & the
white the cable. When the ignition switch is on 12vdc is supplied from
the ignition switch to energise “R1”. Upon energising “R1” a connection
is made from wire “+12VDC” & “+12V through pins “8” & “6”, also
through pins “1” & “2” and +12v is present at the terminal strip as
marked. These terminals feed each of the function circuit interrupters
namely, ”R234” Winch V10, “FCP” Feed Fast/Slow Selector switch,
“R+12” Winch Joystick , Fast Feed Joystick, Auxiliary Potentiometer,
203
Rotation Speed Potentiometer & The voltage divider board for rod
making/breaking.
Figure 6–2: Typical Connector
The presence of a nominal voltage on wire “+12V” from relay “R1” also
provides power to the warning horn and a reference signal to the engine
computer , a loss of the reference signal will shut down the engine. This
output leaves the console through receptacle “C12” pins 3&4 into the
cable “C12” on the blue & black wires to a fuse in the engine control
panel.
It should be noted that the “RED” illuminated light in the E-stop confirms
that the cable “C12” is connected & functioning.
This receptacle “C12” also provides return earth (0VDC) to the machine
located “High Oil Temp.” sensing device through the “C12” receptacle
pin 1, continuing out on the “C12” cable brown wire connecting in the
sensing switch normally open contact red/white wire. Also this same
brown wire connects to the “Low Oil” sensing, again with a normally
open contact. These two sensing devices connect to the audible horn
which will sound in the event of a problem.
6.2 Fast/Slow Selector Switch

The “Fast/Slow” selector switch is located just right of centre of the
console fascia. It is fed from circuit interrupter “FCP” rated at 2A, on wire
204
7 (light blue), upon selecting “Fast” the contact block closes joining wire
7 to wire 5 (red) providing power to relay “R4”.
Figure 6–3: Fast/Slow Selector Switch
Relay R4 internal contacts on pin 8 receives power from circuit

interrupter R234 on wire R234, closing of the internal contact provides
the power to wire 6 (red ) feeding receptacle C10 pin 2.
Wire 5 (red)
Wire 7
Figure 6–4: Relay R4
205
Cable “ C10” white wire internal, feeds the signal to “Valve V10” terminal
1, activating the valve. The earth wire (0VDC) is on terminal number 2
(black wire in cable) returning to receptacle “C10” pin 4.
Figure 6–5: C10 Pin 4
Relay “R4” when energised will show an orange flag in the top viewing
window of the relay confirming operation. This is typical of all relays.
Figure 6–6: Relay R4
6.3 Winch Joystick Switch

This joystick is located on the right hand side of the control fascia.
Control power originates from circuit interrupter “R12” rated at 10A
through wire “R+12V” (dark blue) feeding the minus terminal of the
joystick. This terminal interconnects with in the joystick to a normally
open switch, when the joystick is in the neutral position, this contact will
206
be open, upon movement in either direction this switch closes

energizing wire “1” connected to terminal marked plus.
Figure 6–7: Winch Joystick Switch
The joystick provides a variable voltage starting at the neutral position,

pulling downward reduces the signal voltage from a nominal 7 volts,
pushing forward increases this signal voltage.
It should be noted that the nominal voltage will vary with the battery
condition. The Danfoss valve will compensate for the variable voltage
automatically. The movement of the joystick in either direction will output
on terminal “s” of the joystick, wire “2” (red). This wire 2 feeds the small
joystick labelled “Wire Line/Main Line”.
6.4 Wireline/Mainline (Small) Joystick Switch

When “Wireline” is selected, it closes a contact block joining wire “2”
to wire “4”, a variable voltage signal wire from the winch joystick ,
continuing to receptacle “C3” pin 2, into cable “C3” white wire to valve
“V44-03” terminal 2.
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The earth wire “0VDC” is on terminal 2 (black wire) returning in the “C3”
cable to the receptacle.
Figure 6–8: Small Joystick Switch
Cable ‘C3” also carries the “power up” wire for the Danfoss valve
electronic circuit, this wire originates from the “Winch Joystick” terminal
“plus” wire “1” (red colour). It runs from the joystick to the receptacle pin
3, onto cable “C3” blue wire, to terminal 1 of Valve “V44-03”.
Figure 6–9: Cable C3
Note: This small joystick is a three position, the centre position is

neutral, no signals leaving.
When “Mainline” is selected, it closes a contact block joining wire”2”

to wire”3”, a variable voltage signal wire from the winch joystick ,
continuing to receptacle“C1 & C2” pin 2, into cables “C1 & C2” white
wires to valves “V44-01 &V44-02” terminals 2.
The earth wire “0VDC” is on terminal earth (black wire)returning in the

“C1 & C2” cables to the receptacles pin 4.
Cable ‘C1 & C2” also carries the “power up” wires for the Danfoss valve
electronic circuit, this wire originates from the “Winch Joystick” terminal
“plus” wire “1” (red colour). It runs from the joystick to the receptacle pin
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3, onto cables “C1 & C2” blue wire, to terminal 1 of Valves “V44-
01&V44-02”.
Figure 6–10: Small Joystick Switch
6.5 Fast Feed Joystick

The joystick is located in the centre area of the console fascia, control
power originates from circuit interrupter “R12” rated at 10A, using an
output wire “R+12V” (dark blue).
The “R+12V” wire connects to the minus terminal of the joystick, the
joystick has an internal switch that closes with any movement from the
neutral position and remains closed, it opens only in the neutral position.
Upon movement & closing of the internal switch , power is sent out from
terminal “plus” , wire “9”, this wire 9 provides power to the voltage
divider with in the joystick, outputting a variable voltage signal on wire
“8. Also valve “V44-04” Danfoss block has power provided through
receptacle “C4” pin 3, out on cable “C4” blue wire to terminal 1 of valve.
Figure 6–11: Fast Feed Joystick
As the joystick provides a variable voltage with movement from the

neutral center position, pulling downward will reduce the signal voltage
209
from a nominal of 7 volts, pushing forward will increase this signal

voltage.
Figure 6–12: Breakers
The signal voltage leaves the joystick on terminal “s” , wire “8” and is
sent to the rod slide limit switch first. This limit switch prevents activation
of the feed when the rod slide is in operation. (the head will hit it). This
wire “ 8” (red colour), goes to the terminal strip , then to receptacle “C11”
pin 3, continuing out in cable “C11” blue wire, to the limit switch, this
limit switch is normally closed during drilling operation. The continuing
circuit it leaves the limit switch as wire “8A” returning in the same cable
“C11” white wire to the receptacle. From the receptacle “C11” it goes to
the terminal strip leaving to receptacle “C4” pin 2, continuing out in cable
“C4” white wire, to valve V44-04 terminal 2. This completes the interlock
circuit.
This interlock circuit prevents any response of movement of the “Fast

Feed “ (head) when the rod slide tray is in the down position. Earth
“0VDC” is located on receptacle “C4” pin 4, cable “C4” black wire, valve
“V44-04” terminal earth.
6.6 Auxiliary Pot

This pot is located on the left side of the console fascia. Control power
originates from circuit interrupter “R12” rated at 10A through wire
“R+12V” (dark blue) to terminal 1 of the pot.
The earth return “0VDC” (black wire) is on terminal 3, the variable

voltage signal is on terminal 2,(red wire) “18”. The red wire “18”
continues to the terminal strip, then on to receptacle “C6” continuing out
in cable “C6” white wire to valve V44-06 terminal 2.
Power to the Danfoss valve is derived from wire “R+12V’ (dark blue)
going to receptacle “C6” pin 3, continuing in cable “C6” blue wire to
valve V44-06 terminal 1. The earth return wire “0VDC” is carried through
210
receptacle “C6” pin 4, continuing in cable C6” black wire to valve V44-06
earth terminal.
Figure 6–13: Auxillary Pot
This pot will provide a variable signal voltage of approximately 4 volts

through 9 volts.
Rotation Speed Joystick (revised from knob type pot).
This joystick is located on the left side of the console fascia, control
power originates from circuit interrupter “R12” rated at 10A, through wire
“R+12V” (dark blue). This is connected with a 2K ohm resistor that is
installed just before the connection to the pot. It is heat shrink protected
in the wire.
Figure 6–14: Rotation Speed Joystick
This circuit is a voltage divider using terminal 1 as power, terminal 3 as

earth, and terminal 2 as the variable signal voltage. Movement of the
control upwards will increase the signal voltage on terminal 2 , wire 11.
Like wise, movement of the control downwards will decrease the signal
voltage on terminal 2, wire 11. This voltage should vary from a minimum
of 3 volts to a maximum of 7 volts, again this might vary with the battery
condition. Also the movement of the joystick from the most downward
211
position opens or closes a micro-switch on wires IGNC & IGND. This

determines whether the joystick is in the off position, relative to rotation.
A separate section at the end of this guide called Safety details this
function.
The variable signal voltage on wire 11, feeds into a contact block
located on the joystick labelled “Rod Breaking/Drilling/Rod Making”, this
selector is located next to the “Rotation Pot”. Wire “11” is connected to
wire “10A” through to wire “10” only when the joystick is in the centre
position (neutral). Movement to “Rod Making or Breaking” will open this
circuit , removing the speed pot signal voltage to wire “10”.
In the drilling mode, wire “10” (red) connects to receptacle “C5” pin 2,
continues in cable “C5” on the white wire to valve “V44-05” terminal
2. This is the input variable voltage signal to the Danfoss valve. The
earth return “0VDC” is located on terminal marked earth, continuing
back in cable “C5” on the black wire to the “C5” receptacle pin 4. The
power source “R+12V” for the Danfoss valve “V44-05” is on pin 3 of
the receptacle, continuing out in cable “C5” blue wire to valve “V44-05”
terminal 1.
6.7 Rod Make/Break Function (Make/Break Cube)

The following graphic is provided as a reference for pin-outs.
Figure 6–15: Pin-outs Reference
6.7.1 Rod Breaking

Rod breaking is accomplished with a preset signal voltage that is set
within the voltage divider network located within the cube.
The signal voltage on pin 7 of the cube base is connected to the red
wire #13. The preset signal voltage level is approx 8.5 volts going to the
212
make/break switch contact blocks on wire #13 and joins wire #10 when
the rod breaking switch is selected.
Wire #10 continues to the terminal block #10, leading to receptacle C5

white wire, then out through cable C5 white wire to V44-05 pin #2.
+12Vdc is supplied to the V44-05 valve starting at the R+12V terminal

group which is powered by the R12 10 amp circuit breaker, then to the
C5-M12 connector blue wire labelled R+12V-C5, then through the C5
cable on the blue wire to V44-05 pin #1.
0VDC is supplied to V44-05 starting at the 0Vdc terminal block group

inside the operator control panel, then to the C5-M12 connector black
wire labelled 0Vdc, then through the C5 cable on the black wire to
V44-05 pin #4.
Figure 6–16: Rod Making/Breaking Cube
6.7.1.1 Head Float Up V29 Activation

Selecting rod breaking also closes a secondary contact block on the
make/break switch. This is +12Vdc power source coming from circuit
breaker FCP@2A, blue wire #7 which connects to wire #5 energizing
relay #3 when the switch is closed.
Energizing this relay closes the contacts joining blue wire labelled
R+12V from the 5 amp Circuit breaker to wire #17 going to terminal #3,
this feeds +12Vdc to the C7-M12 white wire, then through the cable
white wire to head float up valve V29 terminal #1.
0VDC is supplied to V7 starting at the 0Vdc terminal block group inside

the operator control panel, then to the C7-M12 connector black wire
labelled 0Vdc, then through the C7 cable on the black wire to V29 pin
#2.
213
6.7.2 Rod Making

Rod making is accomplished with a preset signal voltage that is set
within the voltage divider network located within the cube.
The signal voltage on pin 8 of the cube base is connected to the red
wire #12. The preset signal voltage level is approx 5 volts going to the
make/break switch contact blocks on wire #12 and joins wire #10 when
the rod making switch is selected.
Wire #10 continues to the terminal block #10, leading to receptacle C5

white wire, then out through cable C5 white wire to V44-05 pin #2.
+12Vdc is supplied to the V44-05 valve starting at the R+12V terminal

group which is powered by the R12 10 amp circuit breaker, then to the
C5-M12 connector blue wire labelled R+12V-C5, then through the C5
cable on the blue wire to V44-05 pin #1.
0VDC is supplied to V44-05 starting at the 0Vdc terminal block group

inside the operator control panel, then to the C5-M12 connector black
wire labelled 0Vdc, then through the C5 cable on the black wire to V44-
05 pin #4.
6.7.2.1 Head Float Down V29 Activation

Selecting rod making also closes a secondary contact block on the
make/break switch. This is +12Vdc power source coming from circuit
breaker FCP@2A, blue wire #7 which connects to wire #5 energizing
relay #2 when the switch is closed.
Energizing this relay closes the contacts joining blue wire labelled
R+12V from the 5 amp Circuit breaker to wire #17 going to terminal #3,
this feeds +12Vdc to the C7-M12 white wire, then through the cable
white wire to head float down valve V29 terminal #1.
0VDC is supplied to V8 starting at the 0Vdc terminal block group inside

the operator control panel, then to the C8-M12 connector black wire
labelled 0Vdc, then through the C8 cable on the black wire to V29 pin
#2.
6.8 Safety Devices

Going into further detail on the safety devices which can & will prevent
operation of the engine or the hydraulics.
As discussed earlier, the power up source originates at the engine

ignition switch , terminal “IGN” which is battery voltage (+12vdc),
running through “Cable C12” white wire to pin 2 of the box mount
receptacle. This wire runs to the terminal strip , identified as “IGN”.
Terminal IGN is the first of a series circuit of the “E-stops”, starting with
214
the console mounted E-stop using wires IGN in & IGNA out. All the
contact blocks in this circuit are normally closed, and open on initiation.
IGNA goes to “C14” receptacle Pin 1, leaving in Cable C14, using the
brown wire. This cable terminates in the first remote E-stop enclosure,
using the brown wire to one side of the normally closed contact block.
The white wire on the other side of the contact block, completing the
circuit and returning in cable C14 to the receptacle pin 2. Pin 2 of this
receptacle is wired to the terminal strip location “IGNB”. The next series
E stop remote is wired to terminal “IGNB” going to receptacle “C15”, Pin
1 leaving in Cable C15, using the brown wire. This cable terminates in
the second remote E-stop enclosure,using the brown wire to one side of
the normally closed contact block. The white wire on the other side of
the contact block, completing the circuit and returning in cable C15 to
the receptacle pin 2. Pin 2 of this receptacle is wired to the terminal strip
location “IGNC”. Continuing in this safety line, “IGNC” connects to the
console mounted speed control joystick limit switch, this limit switch is
normally closed when fully pulled back, allowing the circuit to continue
as wire IGND, energizing relay “R1” & timer “TR”.
Figure 6–17: E-stop
When the circuit is complete as noted above, the contacts of relay

“R1” close allowing 12VDC battery voltage to the +12VDC terminals
in the console, this illuminates the console mounted E-stop button ,
proving the safety line is complete, allowing a circuit to be returned
to the engine initiating “RUN”. This accomplished from the closing of
the contacts of R1, providing power to +12v on the terminal strip in
the console,continuing to receptacle “C12” on the blue & black wires
pins 3 & 4. Leaving on cable “C12” to fuse in the engine console
enclosure, leaving the fuse on a RED wire to the three part terminal strip
connecting with the engine wiring purple wire marked “KEY”. Energising
this “KEY” wire with +12vdc tells the engine computer module that “all is
OK to start & run”.
This circuit has allowance for using the joystick “rotation “ that has been
set in the most downward position, to be moved upward. The timer relay
“TR” stays energised with its own internal contact closed, this contact is
in parallel with the joystick limit switch, upon moving the joystick
upwards, the joystick limit will open, and the timer will stay energized.
The purpose of this timer circuit is to prevent the engine from being
215
started when the joystick is in any position above full back. This
prevents starting the engine and having the drill rod rotate immediately.
Figure 6–18: Remote E-stop
216
Contents
7.1 Introduction............................................................................................. 219
7.1.1 Operational Requirements.......................................................... 219
7.1.2 Safety Requirements................................................................... 219
7.2 Tools and Equipment.............................................................................. 220
7.2.1 Suggested Assembly Torque Values for SAE Grade 8 Fasteners....
.................................................................................................... 222
7.3 Preventive Maintenance......................................................................... 223
7.3.1 Preventive Maintenance Schedule.............................................. 224
7.3.2 Lubrication Chart......................................................................... 225
7.3.3 Rig Pressure Setting Summary................................................... 226
7.3.4 Rig Component Weights............................................................. 226
7.4 Head Lubrication..................................................................................... 227
7.4.1 Head Oil Change......................................................................... 227
7.4.2 C6 Head Lubrication Oil Filter..................................................... 229
7.4.2.1 Filter Change Procedure..................................................... 229
7.5 Mainline Hoist.......................................................................................... 230
7.6 Wireline Hoist Assembly........................................................................ 230
7.6.1 Wireline Rope Installation............................................................ 238
7.6.2 Wireline Splicing.......................................................................... 240
7.7 PQ Head Disassembly Procedures....................................................... 240
7.8 PQ Head Reassembly Procedures........................................................ 257
7.8.1 Intermediate Gear Assembly....................................................... 262
7.8.2 Intermediate Shaft and Gear Assembly...................................... 268
7.8.3 Input Pinion and Shaft Assembly................................................ 274
7.8.4 Output Shaft Assembly (Spindle)................................................ 285
7.8.5 Output Carrier and Pump Mounting............................................ 295
7.8.6 Transmission Assembly.............................................................. 311
7.9 PQ Nitro Chuck ™.................................................................................. 312
7.9.1 PQ Chuck Cross Section............................................................. 313
217
7.10 PQ Nitro Gas Chuck................................................................................ 314

7.10.1 PQ Nitro Gas Chuck Disassembly Procedure............................. 314
7.10.2 Chuck Assembly Procedures...................................................... 334
7.10.3 Installation of New Jaws.............................................................. 348
7.10.4 Chuck Lubrication........................................................................ 348
7.10.5 Maintenance................................................................................ 349
7.10.6 Nitrogen Gas Springs.................................................................. 349
Tables
Table 7–1: Assembly Torque Values............................................................ 222
Table 7–2: Maintenance Schedule................................................................ 224
Table 7–3: Rig Pressure Setting Summary................................................... 226
Table 7–4: Rig Component Weights............................................................. 226
Table 7–5: Winch.......................................................................................... 239
218
7.1 Introduction
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 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.
7.1.1 Operational Requirements

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
machine.
7.1.2 Safety Requirements

Care, maintenance and service of construction equipment are important
processes to help ensure safety at worksites. However, accidents
associated with worksite 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.
219
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 these 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.
7.2 Tools and Equipment

Regardless of which system or method is used, make sure that the
following tools and equipment are available on-site.
A Tub of Thread Grease and Application Brush

A Wire Brush to clean Thread Sections
220
A set of Saw Horses of sufficient strength to hold the 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 with Nozzle to clean mud and grout from drill
rig and tools
Two 36” (or larger) Wrenches
These are handy on any drill site
Shovel, to remove cuttings from the area
Hammer, sometimes necessary to strike the casing to loosen thread

connections
221
Spirit Level or Angle Indicator for Drill Mast Alignment
Grease Gun with Pressure gauge for Crawler Track tensioning
Chain Wrench
7.2.1 Suggested Assembly Torque Values for SAE

Grade 8 Fasteners
The following table depicts suggested assembly torque values for SAE
grade 8 fasteners.
Size Dry lbf•ft (Nm) Lubricated lbf•ft

(Nm)
3/8-16 45 (61.0) 35 (47.5)
3/8-24 50 (67.8) 35 (47.5)
1/2-13 110 (149.1) 80 (108.5)
1/2-20 120 (162.7) 90 (122.0)
5/8-11 220 (298.3) 170 (230.5)
5/8-18 240 (325.4) 180 (244.0)
3/4-10 380 515.2) 280 (379.6)
3/4-16 420 (569.4) 320 (433.9)
Table 7–1: Assembly Torque Values
222
Failure to use the proper type and viscosity of planetary gear oil may
contribute to intermittent brake clutch slippage which could result in
property damage or severe injury. Some gear lubricants contain large
amounts of EP (extreme pressure) and anti-friction additives which may
contribute to brake clutch slippage or damage to brake friction discs or
seals. Oil viscosity with regard to ambient temperature is also critical
to reliable brake clutch operation. Manufacturer’s test indicate that
excessively heavy or thick gear oil may contribute to intermittent brake
clutch slippage. Make certain that the gear oil viscosity used in your
winch is correct for your prevailing ambient temperature.
7.3 Preventive Maintenance

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 all 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 trailing hoses from the control panels must be kept under
observation to avoid trapping and to pre-empt a failure of abraded
hoses.
The unit must be turned off and all lines 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 or bolt interfaces.
223
7.3.1 Preventive Maintenance Schedule

Before Every Every
Maintenance Action Each 250 500 Comments
Use Hours Hours
Visual walkaround inspection X
Check for fluid leaks X
Check engine oil and coolant level X
Check fuel level X
Check condition and ensure

Inspect emergency stops X
operation
Check condition, have
Inspect fire extinguisher(s) X
recharged or replaced if needed
Change power unit oil X Per lubrication schedule
Change power unit air filter X
Change engine oil and filter X
Change main pressure filter element X Or as indicated on filter indicator
Change return filter element X Or as indicated on filter indicator
Change hydraulic tank breather X
Change hydraulic oil X
Change head lube filter X
Inspect & clean all radiators X
Inspect & clean chuck jaws X
Inspect & clean rod clamp jaws X
Inspect chuck gas springs X
Inspect all wear material on head X
Table 7–2: Maintenance Schedule
224
7.3.2 Lubrication Chart
Figure 7–1: Lubrication Chart
225
7.3.3 Rig Pressure Setting Summary

LF230 Pressure Setting Summary
Function Valve Bar PSI
P1 MAIN COMPENSATOR 310 4500
P1 STANDBY COMPENSATOR 20 290
P2 STANDBY COMPENSATOR 20 290
P1 MAIN RELIEF V46 345 5000
P4 RELIEF V48 172 2500
V40 SET UP VALVE RELIEF V47 160 2300
PQ CHUCK V15 97 1400
FOOTCLAMP V16 55 800
MUD MIXER V24 125 1800
HOIST BRAKE RELEASE V32 35 500
WATER RELIEF V37 60 900
Table 7–3: Rig Pressure Setting Summary
7.3.4 Rig Component Weights

LF230 Component Weights
Engine – Bare 1310 kg
Hydraulic Pump Stack 120 kg
Wireline Hoist Empty (*No Level Wind) 610 kg
Wireline Rope Weight (Hoist Full) 570 kg
Hydraulic Tank ASM – Dry 250 kg
OCP 208 kg
Mainline Hoist 570 kg
Mast ASM – C/W Head 6436 kg
Lower Mast ASM C/W Dump Frame, Hoist, No 3640 kg
Head
Upper Mast C/W Crown Block 2006 kg
Head ASM 790 kg
Base Frame – Bare 1830 kg
Dump Frame – Bare 570 kg
Crown Block ASM 170 kg
Water Pump ASM (Wet) 230 kg
Rod Rack - Complete 380 kg
Track Grp 5250 kg
Table 7–4: Rig Component Weights
226
7.4 Head Lubrication
7.4.1 Head Oil Change

Nominal Head capacity is roughly 10 liters as detailed in the Lubrication
Chart.
1. Shut off the Engine.
2. Drain the oil by removing one of the plugs in the bottom of the oil
pan.
3. Use a small filler pump to pump oil directly into the head from a 20L
pail. A filler port is located on the side of the transmission cover.
4. A visual sight tube and decal is located on the side of the head to
aid in filling. The drill must be level in all directions with the head
assembly in the vertical position when determining the proper full
level.
Do not overfill the drill head, overheating will occur.
227
Schedule: Change Interval 250 hrs.
PQ Head A
Reservoir
Assembly
B
Figure 7–2: PQ Head Drive Group
A—To check the maximum or full level when the spindle is not rotating,
the oil level should be 1” (2.54 cm) below the top elbow of the sight tube
when the head is in a vertical position.
B—To check the maximum or full level when the spindle is rotating in
4th gear at 1250 rpm, the oil level should be 1” (2.54 cm) above the
bottom elbow of the sight tube when the head is in a vertical position to
ensure new oil passes through the return filter.
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7.4.2 C6 Head Lubrication Oil Filter

Filters gear oil in the gear drive head. The head pressure filter is
equipped with an internal pressure by-pass and a clog indicator. The
filter housing is mounted to a bracket on the side surface of the
hydraulic reservoir.
C6
Figure 7–3: Head Oil Lubrication Filter C6
7.4.2.1 Filter Change Procedure

1. Lower drill head using fast feed until it is lower than the filter.
3. Wipe any dirt from the top surface of the filter housing and protect

5. Slowly unscrew one of the hoses that connects to the filter housing
to allow the vacuum to be broken. Retighten hose once air stops
rushing in.
6. Remove the filter bowl from the filter head by turning counter
clockwise, as viewed from the bottom. Unscrew filter bowl using
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1 1/16 inch wrench. Take care to prevent oil from dripping on the
ground.
7. Remove filter element from the filter head by pulling down on it.
8. Replace filter element by pushing new element back onto filter

head. Make sure filter element is seated onto the filter head
correctly.
9. Inspect the o-ring on the cover for damage and replace if

necessary.
10. Install filter bowl and tighten.
11. Start engine and turn engine speed up to approximately 1500 rpm.
12. Engage 4th gear on the gear box and slowly engage rotation
forward for a few minutes to push the air out of the filter housing.
13. Disengage rotation and slow engine to idle before shutting down
and allow the gear drive head oil to de-aerate for 30 minutes prior
to drill use.
7.5 Mainline Hoist

The mainline hoist mounting bolts are to be torqued to 835 ft lbs (lubed)
during installation.
Please refer to Appendix D: Braden RW300 Service Manual for detailed

information on this hoist.
A detailed Braden Parts Manual is supplied with your drill, refer to that for
ordering spare parts for the Mainline Hoist.
7.6 Wireline Hoist Assembly

The following section outlines the steps to strip and assemble the
3300m capacity wireline hoist.
1. Lower the drill head until the feed cylinders bottom out.
2. Remove overshot.
230
3. Set up an empty wire rope spool on a fixed axle to capture wire

rope as it is unwound from the existing winch drum.
4. Manually thread the wire rope onto the take up drum and slowly
power the rope off the winch drum onto the take up drum using a
helper to keep tension on the rope.
Ensure that helper does not become entangled in the wire rope.
Never wrap the wire rope around fingers or hands as this could
result in severe personal injury.
5. Once the wire rope has been unspooled, stop the engine and shut
off power at master disconnect.
Follow the lock-out and tag-out procedures as per the site’s

requirement
6. Remove the guard from wireline winch motor.
7. Remove hydraulic hoses and cap ends to contain oil.
8. Orient the level-wind mechanism to expose the lifting points.
9. Remove the screws, washers and nuts that secure the wireline
winch to the base frame.
10. Attach a properly rated overhead lifting device to the hoist using the
identified lifting points and remove the empty wireline winch from
the base frame and transfer it to a safe work space.
11. Remove 4 screws, 4 washers and the end plate as shown in figure
7-3.
Figure 7–4: Wireline Drum Assembly
231
12. Remove the retaining ring, sprocket and key as shown in figure 7-4.
13. Remove the large retaining ring as shown in figure 7-5.
232
14. Remove all of the screws, washers, covers, bearings and shaft
retainers from the motor side of the winch as shown in figure 7-6.
15. Remove the level wind mechanism from the winch as shown in
figure 7-7.
233
16. Remove 4 screws and the end plate as shown in figure 7-8.
17. Remove 3 screws, 3 washers and the spacer bar as shown in

figure 7-9.
234
18. Carefully flex and remove the guard from the winch as shown in
figure 7-10.
19. Remove 4 screws, retaining plate and shaft bearing as shown in

figure 7-11.
235
20. Remove 4 screws, 4 washers and the winch end plat as shown in
figure 7-12.
21. Remove 8 screws and the winch shaft as shown in figure 7-13.
22. Remove the screws and the end plate as shown in figure 7-14.
236
23. Locate the 9 nuts inside the drum as shown in figure 7-15.
24. Remove 9 nuts, 9 washers and the drum as shown in figure 7-16.
25. Reassemble the hoist and level wind mechanism in reverse order
using the newly supplied Drum, Drum End Plate and hardware.
26. Attach a properly rated overhead lifting device to the hoist using the
identified lifting points.
27. Position the hoist back into its mounting location on the base frame.
28. Secure the wireline to the base frame using the previously removed
hardware.
29. Orient the level-wind mechanism to a position suitable for reloading

the wire rope from the spool.
30. Reattach all hydraulic hoses to the hoist.
31. Reattach the Motor Guard.
237
7.6.1 Wireline Rope Installation
Exercise caution when loading wire rope. Ensure that any helper does not
become entangled in wire rope. Never wrap the wire rope around fingers
or hands as this could result in severe personal injury.
●● Wireline rope length shall not exceed the specified length.

●● Wireline rope must be loaded onto the winch drum with a tension of
1200-1500 lbs during installation to avoid tangles and snags during
the first few weeks of operation.
●● Always load wireline rope in the direction of its natural curvature.
Never wind wire rope from the top of one reel to the bottom of
another.
●● Wireline rope must come off the bottom of the winch drum and over
the top sheaves following the natural curvature of the rope as
shown in Figure 7-17.
Figure 7–18: Rope Installation Wrap Direction Detail
238
●● Ensure the proper timing sprocket is installed for the size of cable
being loaded. A small variation in wire rope diameter from the rope
manufacturer can negatively impact the lay of the cable on the
drum. Use a vernier caliper to measure the width of the rope being
loaded and the following table to select the proper timing sprocket.
LF230 Winch
Rope Sprocket Rope Diameter Nominal Wraps
6 mm 18T 6.000 mm 114
6 mm 19T 6.200 mm 110
6 mm 19T 6.300 mm 109
1/4” 19T 6.350 mm 108
1/4” 20T 6.400 mm 107
1/4” 20T 6.502 mm 105
1/4” 21T 6.668 mm 102
Table 7–5: Winch
●● The first layer must have the minimum (nominal ) number of wraps
as identified in the table for subsequent layers to follow. Pay extra
attention to the lay of the first layer of rope during installation. Use a
soft mallet or pry bar to ensure there are no gaps between each
wrap of rope during the loading process per Figure 7-18.
Subsequent layers should better follow the first.
Figure 7–19: First Wrap
●● If the level wind is traveling too fast leaving gaps, go down one
sprocket size to decrease traverse speed. If the level wind is
moving too slow leaving humps, go up one sprocket size to
increase the traverse speed.
239
7.6.2 Wireline Splicing

1. Make two 2-3ft loops, using two nicopress sleeves on each side.
2. Space out the sleeves so they don’t run together over the sheave
wheels.
3. Crimp sleeves using a Nicopress crimping tool.
7.7 PQ Head Disassembly Procedures

1. Open the chuck and insert the lifting bail which was supplied
with the chuck. Remove the spindle nut bushing. Disconnect all
hydraulic hoses to the rotation motor and chuck.
Note: It is recommended that the head assembly be disassembled

in a shop environment with the use of overhead lifting capabilities.
This will be required to move and support the PQ Head.
2. Drain the head and transmission of oil. This can be accomplished

by removing a return line hydraulic hose from the transmission. The
position of the drill feed frame will determine which hydraulic return
line to remove.
3. Remove the head unit from the drill before starting disassembly of
the unit.
4. Place the head on a solid work table and block it up to support it.
Lay the head down so that the spindle is horizontal to the work
table.
5. Remove all hoses, fittings, gear shift lever etc. from the head (all
external components).
6. Remove the chuck with either the lifting bail or a suitable lifting
sling.
7. Remove the mounting group brackets and/or bulkheads.
8. Remove the four bolts which hold the rotation motor assembly. The
motor is siliconed to the transmission and will have to be pried off
to break the seal.
Note: The silicone seal, between the transmission and the input
carrier, will have to be worked apart in order to remove the
transmission.
9. Support the transmission, preferably with the aid of a crane and

sling arrangement. Remove the six mounting bolts that secure the
transmission to the input carrier.
240
10. Carefully slide the transmission back and out of the main housing.
11. Remove the lock wire from the two bolt heads on the retaining
washer on the transmission output shaft.
Figure 7–20: Transmission Output Shaft
12. Remove the two bolts, retaining washers and shim pack.
13. Slide the splined adapter forward off the transmission output shaft.
Figure 7–21: Splined Adapter
14. Remove the spindle bushing adapter nut.
241
Note: This is a right hand thread.
Figure 7–22: Spindle Bushing Adapter Nut
15. Remove the bolts from the lower carrier seal. Using the existing
1/2” UNC jack screw holes, remove the lower carrier seal.
Figure 7–23: Lower Carrier Seal
16. Using a punch, drive out the two oil seals.
242
17. Remove the six 3/8” UNC bolts and internal tooth lock washers
from the outer locking ring.
Figure 7–24: Outer Locking Ring
18. Thread off the outer locking ring.
Figure 7–25: Outer Locking Ring
243
19. Remove the two 1/2” UNC bolts from the intermediate lock plate.
Figure 7–26: Intermediate Lock Plate
20. Remove the intermediate lock plate. This plate will have to be pried
off due to a silicone seal.
244
21. Remove the 3/4” NPT plug from the bottom of the main housing.
This is a magnetic plug and must be cleaned.
Figure 7–28: Bottom of Main Housing
22. Using a 3/8” Allen wrench remove the six 1/2” UNC cap screws
from the input carrier.
Figure 7–29: Input Carrier
245
23. In the 1/2” UNC jack screw holes, insert two bolts and remove the
input carrier.
Figure 7–30: Input Carrier
Note: After removing the input carrier, remove the shim pack from
inside the input shaft bore.
24. Check to make sure all shims are located.
Figure 7–31: Shims
246
25. Remove inner lock ring from the spindle.
Figure 7–32: Spindle Thread
Note: It may be required to install a 3/8” UNC x 3/4” bolt in one of

the existing bolt holes on the inner lock ring to assist with removal.
Note: The spindle thread is a right hand thread.
26. Remove the bottom cone bearing from spindle.
Note: If problems persist in the removal of this cone bearing, you

may want to leave it on. It will drop off the spindle by itself during
removal of the main housing cover.
Figure 7–33: Bottom Cone Bearing
247
27. If the bearing is removed at this time, remove the large snap ring
from the spindle. This is the snap ring that holds the output gear in
place.
Figure 7–34: Large Snap Ring
28. Using the appropriate lifting devices, lift the PQ head and rotate
it so spindle is vertical to the work bench. Lower PQ head down
on blocks so that it is approximately 8” (200 mm) above the work
bench.
Note: Blocks must not interfere with the removal of the spindle.
29. Remove the six 1/2” UNC bolts and lock washers from the pump
mounting cover.
Figure 7–35: Pump Mounting Cover
30. Remove the pump mounting cover.
Note: The silicone seal must be broke free first.
248
31. Remove the 1/2” UNC bolts and lock washers from the output
carrier.
Figure 7–36: Output Carrier
32. Remove the output carrier.
Figure 7–37: Output Carrier Removal
33. Place the output carrier face down on the work bench. Using a
punch, drive the two oil seals out of the output carrier bore.
Note: The silicone seal must be broke free first.
249
34. If the large snap ring is removed from the spindle, the spindle can
now be removed.
Figure 7–38: Spindle Removed
35. To remove the spindle, insert two 3/4” UNC lifting eyes into the 3/4”
UNC tapped holes in the chuck adapter flange. Connect a chain or
sling and utilizing an overhead hoist to lift the spindle up and out of
the PQ head.
Note: Caution is advised so as not to damage the threads on the

spindle.
36. With the threaded end of the spindle resting on the work bench,
drive the output wear sleeve down and off the chuck adapter flange
portion of the spindle.
Figure 7–39: Spindle
250
Note: It is recommended that a punch made of a soft material be

used, preferably brass.
37. Now drive off the top cone bearing with the same punch.
Note: During the removal of the wear sleeves, be careful to avoid

damaging the spindle OD
38. Turn the spindle over so that the chuck adapter flange is resting on
the work bench. Remove the two wear sleeves.
39. Remove the eighteen 1/2” UNC x 1-3/4” cap srews.
40. Locate and remove the four 1/2” UNC x 3/4” setscrews. These
locations are the four jack screw locations.
Figure 7–40: Four Jack Screw Locations
41. Install four 1/2” UNC bolts with approximately 2” (50 mm) of thread
length.
42. Begin removal of the housing cap by tightening the jack screw bolts
in a cross hatch pattern.
43. When the housing cover has broke lose from the main housing by
approximately. 1/2”, install a proper lifting arrangement so as to lift
the housing cover off the main housing as level as possible.
Figure 7–41: Housing Cover Lifted
251
44. If the lower spindle cone bearing was left on the spindle, it will now
drop off and onto the work bench. The spindle, output gear and the
intermediate idle shaft and gear assembly will also be removed with
the main housing cover.
Figure 7–42: Gear Assembly Removed
45. Lay the main housing cover down flat on the work bench with the
output gear exposed.
Figure 7–43: Output Gear Exposed
252
46. Remove the larger spindle snap ring, spacer and output gear.
Figure 7–44: Large Spindle Snap Ring
47. Raise the cover up and off of the main spindle.
Figure 7–45: Cover Raised off Main Spindle
48. The intermediate idle shaft and gear assembly can be removed
with a soft punch or set up in a press and pressed out of the
intermediate shaft.
49. Turn the cover upside down and blocked up approximately 2” (50
mm) above the work bench.
50. Drive out the two remaining bearing races.
253
51. Slide the intermediate spacer off the intermediate idler shaft.
Figure 7–46: Intermediate Spacer
52. Slide the intermediate gear assembly off the intermediate idler
shaft.
Figure 7–47: Intermediate Idler Shaft
53. Remove the two intermediate idler shaft cone bearings.
54. Remove the cone bearing spacer.
55. Drive the bearing race down and off of the intermediate gear with a
punch.
56. Remove the bearing race spacer.
57. Drive the second bearing race off of the intermediate gear with a
punch.
254
58. Lift out the input pinion and shaft from the main housing. Place it
input side down on the work bench.
Figure 7–48: Input Pinion and Shaft
59. Remove the snap ring.
Figure 7–49: Snap Ring
255
60. Drive out the 1/4” (6.4 mm) x 3-1/4 (83 mm) dowel pin.
Figure 7–50: Dowel Pin
61. Remove the pump adapter tang.
Figure 7–51: Pump Adapter Tang
62. Remove the pump adapter.
Figure 7–52: Pump Adapter Removed
256
63. Remove the two input pinion and shaft cone bearings using
appropriate bearing pullers.
Figure 7–53: Input Pinion and Shaft Cone Bearings Removed
7.8 PQ Head Reassembly Procedures

1. Place the main housing, bottom end facing up, on a solid work
bench.
Figure 7–54: Main Housing Bottom Facing Up
257
All PQ Head internal parts must be free and clean of any foreign
matter. Extreme caution is advised in the handling and assembly
of the PQ Head due to the size and weight of parts. Watch for pinch
points during the disassembly and reassembly procedure.
All parts must be cleaned and free of dirt, burrs and RTV sealant. All
threaded holes must be cleaned of locktite and RTV sealant using
the appropriate size taps.
Take care to ensure that all internal oil galleries are clean and
unclogged.
2. Apply a film of oil on the bore diameter before installation.
Figure 7–55: Film of Oil on Bore Diameter
3. Install the bottom spindle bearing race using an appropriate driver.

Make sure race is pressed tight against bottom of counter bore.
Figure 7–56: Bottom Spindle Bearing Race
258
Figure 7–57: Race Tight Against Bottom of Counter Bore
4. Apply a thin film of oil on outside diameter of bearing race before

installation. Install bottom bearing input shaft race using appropriate
driver.
Figure 7–58: Oil on Outside Diameter of Bearing Race
Note: Clean and re-install magnetic pipe plug using an appropriate

pipe thread sealant.
Note: Notice the direction of race installation to accommodate input

shaft bearing. Install race approximately. 1/4” (0.64 cm) into the
bore.
259
5. Turn main housing over, face-up. Check dowel pins for signs of
wear or burrs.
Figure 7–59: Main Housing face-up
6. Place housing cover face-up. Apply a film of oil on bore diameter

before installation. Install top spindle bearing race using an
appropriate driver.
Figure 7–60: Top Spindle Bearing Race Installed
7. Ensure that bearing race is seated firmly at bottom of counter bore.
Figure 7–61: Bearing Race Seated Firmly
260
8. Apply a film of oil on bore diameter before installation. Install top

input shaft bearing race into bore approximately 1/4” deep.
Figure 7–62: Oil on Bore Diameter
Figure 7–63: Top Input Shaft Bearing Installed 1/4” Deep
9. Install the two 3/8” NPT pipe plugs using an appropriate pipe thread
sealant.
Figure 7–64: Two 3/8” NPT Pipe Plugs
261
7.8.1 Intermediate Gear Assembly

1. Install snap ring into snap ring groove in gear.
Figure 7–65: Snap Ring and Gear
Figure 7–66: Snap Ring Installed in Gear
2. Install bearing race spacer into gear.
262
Note: This spacer must be installed in the proper direction. The

measurement out to end of gear must be approximately 1-5/16”
(3.33 cm) both sides.
Figure 7–67: Bearing Race Spacer Installed in Gear
3. Press bearing races in, one on each side of snap ring.
Note: Note the orientation of races. When the races are pressed in,
they must be tight on spacer.
Figure 7–68: Press Bearing Races
263
Figure 7–69: Gear in Press
4. Place intermediate gear shaft on work bench. Large diameter

down.
Figure 7–70: Intermediate Gear Shaft
264
5. Slide intermediate shaft tapered roller bearing down the shaft till it
bottoms out. Note the orientation of the bearing.
Figure 7–71: Tapered Roller Bearing
6. Install intermediate gear on shaft.
Figure 7–72: Intermediate Gear on Shaft
265
7. Install bearing spacer.
Figure 7–73: Bearing Spacer
8. Slide intermediate shaft tapered roller bearing down the shaft and
into the intermediate gear.
Figure 7–74: Tapered Roller Bearing and Intermediate Gear
266
Figure 7–75: Tapered Roller Bearing Slid into Intermediate Gear
9. Install the intermediate spacer.
Figure 7–76: Intermediate Spacer
267
Figure 7–77: Intermediate Spacer Installed
7.8.2 Intermediate Shaft and Gear Assembly

1. With the PQ Head main housing resting flat on the work bench,
place the intermediate shaft and gear assembly into the bore.
Using a soft-face hammer, gently tap the intermediate shaft and
gear assembly in the housing bore. Ensure that the intermediate
shaft and gear assembly is square in the bore.
Figure 7–78: PQ Head Main Housing
2. Using a proper lifting sling, roll the main housing on its side, so as
to have access to the bottom bore.
268
Note: Take note of the orientation of the two 1/2” UNC threaded
holes, they must be at right angles to the main housing.
Figure 7–79: Main Housing on its Side
3. Use the intermediate lock plate and two 1/2” UNC bolts of the
appropriate length to draw the intermediate shaft into place in the
main housing. Tighten each bolt alternately, being careful not to
bottom out the bolts in the thread holes.
269
Figure 7–81: Intermediate Lock Plate Installed
Figure 7–82: UNC Bolts Tightened
4. When intermediate shaft is drawn into position, remove the

intermediate lock plate. There must a gap of approximately .060”
(0.15 cm) from end of the intermediate shaft and the bottom of the
counter bore.
Figure 7–83: Intermediate Shaft and Bottom of Counter Bore
270
5. Apply RTV high temp silicone to the outer edge of the intermediate
lock plate.
6. Install lock plate with the 1/4” NPT thread hole on your left hand
side. Apply Locktite 242 to the threads of the two 1/2” UNC x 1-1/2”
bolts.
Figure 7–85: Lock Plate Installed
271
Figure 7–86: Locktite Aplied to Threads
7. Install bolts part way, then apply RTV high temp sealant to the bolt
heads, to seal the bolt holes in the intermediate lock plate. Torque
these bolts to 50 lbf•ft (67.79 Nm).
Figure 7–87: RTV High Temp Sealant Applied
272
Figure 7–88: Bolts Torqued
8. Roll the main housing face up on the work bench. Raise and
block up the main housing approximately 8” (230 mm) off of work
bench. Make sure not to block the main spindle bore or the input
shaft bore. These bores must be left open to accommodate the
installation of the main spindle and the input gear shaft assembly.
Note: Main housing must be blocked up in a way that is very rigid

due to the weight and amount of force that must be applied to
complete the assembly.
Figure 7–89: Main Housing Blocked Up
9. Install a dial indicator inside the main housing. Position the dial
point on the face of the intermediate gear. Using a short pinch bar,
273
check for bearing end play of the intermediate gear assembly. It

must be between 0.002” to 0.004” (0.05 mm to 0.10 mm).
Figure 7–90: Dial Indicator
10. In the absence of a dial indicator the following method can be used
as a coarse means of determining end play: Place the appropriate
size feeler gauge 0.003” to 0.005” (0.076 mm to 0.127 mm), down
inside the bearing and resting on top of the race (roller contact
surface). Rotate the bearing. The bearing rollers should roll over
the proper feeler gauge size and should not roll over a feeler gauge
size greater than 0.005” (0.013 cm).
7.8.3 Input Pinion and Shaft Assembly

1. Using an appropriate driver and press the tapered roller bearing
onto the input pinion and shaft.
Figure 7–91: Tapered Roller Bearing and Input Pinion
Note: The correct orientation of the tapered roller bearing. Make

sure the bearing bottoms out on the shaft.
274
2. Install the 2nd bearing in the same manner.
Note: The “cover” side of the input pinion and shaft is the end of
the shaft that is shortest to the gear face. The “main housing” side
of the input pinion and shaft is the end of the shaft that is furthest
from the gear face.
Figure 7–92: Press Second Bearing
Figure 7–93: Second Bearing Pressed
275
3. Install the pump adapter into the bore of the input pinion and shaft.
Line up the matching holes.
Figure 7–94: Pump Adapter
4. Install the pump adaptor drive tang. Push the 1/4” (6.4 mm)
diameter dowel all the way through the input pinion and shaft,
pump adaptor and pump adapter drive tang.
Figure 7–95: Pump Adapter Drive Tang
276
5. Install the snap ring in the snap ring groove.
Figure 7–96: Snap Ring
6. Coat the input pinion and shaft bearing race, (in the main housing)
with a thin film of oil. Install the input pinion and shaft into the main
housing, meshing the pinion with the intermediate gear.
Note: Make sure that the pump adapter tang is in the vertical
position.
Pinch-point condition in this part of the assembly.
Figure 7–97: Input Pinion and Shaft Bearing Race
277
Figure 7–98: Pinch Point
7. Install the output gear inside the main housing while meshing with
the intermediate gear.
Pinch-point condition in this part of the assembly.
Figure 7–99: Output Gear
278
Figure 7–100: Output Gear Installed
8. Coat the face and the internal spline of the gear with a thin film of
oil. Place the output spacer on top of the spindle gear, centering it
on the bore diameter.
Figure 7–101: Internal Spline Coated with Oil
279
Figure 7–102: Output Spacer
9. Install four 1/2” x 5” UNC bolts (remove the heads), one in each
corner of the main housing. These will act as line-up pins for the
installation of the housing cover.
Figure 7–103: Four UNC Bolts Installed
280
10. Spread a coating of RTV high temp sealant in the groove in the top
of the intermediate shaft. Run a bead of RTV high temp sealant on
the face of the main housing, inside the bolt pattern.
Figure 7–104: RTV High Temp Sealant Spread in Groove and Shaft
11. Using an appropriate sling or chain method, sling the housing cover
in such a manner that it can be lifted vertically, while being
balanced and level.
Figure 7–105: Housing Cover
281
12. Lower the housing cover onto the four line up pins, letting the cover
down slowly so as to rest square and level on the top of the
intermediate shaft.
Figure 7–106: Housing Cover Lowered
13. Using a suitable washer or bar and appropriate 1/2” UNC bolt, draw
the cap down evenly to the face of the main housing.
The cap must be drawn down evenly or it will gall the intermediate
shaft. 1/2” UNC bolts of the appropriate length can be inserted into
the housing cover bolt holes in order to assist with this operation.
Care must be taken as not to bottom out the bolts in the thread holes
which would damage the threaded holes of the main housing. Once
the housing cover has seated firmly to the main housing, remove all
bolts, line up pins and the washer or bar from the intermediate shaft.
Figure 7–107: Cap Drawn Down Evenly to Main Housing
282
14. Coat the beginning of the thread on all 18-1/2” UNC x 1-3/4” cap
srews with RTV high heat sealant. Install the cap screws and
torque to 50 ft lbs in a cross-hatch pattern.
Figure 7–108: Beginning of Thread Coated with RTV Sealant
Figure 7–109: Torqued to 50 ft lbs
15. Install the five 1/2” UNC x 3/4” set screws. One in each of the four
jack screw locations and one in the center of the intermediate shaft.
This will protect the threads of the holes for removal of the housing
cover.
283
Note: Run a bead of RTV high heat sealant between the top edge
of the intermediate idle shaft and the mating bore chamfer of the
main housing cover
Figure 7–110: Five UNC Set Screws
Figure 7–111: Jack Screw Holes
Figure 7–112: Bead of RTV High Heat Sealant
284
7.8.4 Output Shaft Assembly (Spindle)

1. Place the spindle in a press. Apply a film of oil on the spindle
bearing shoulder. Assemble the top tapered bearing cone onto the
spindle with the large bearing OD towards the chuck flange on the
spindle.
Figure 7–113: Spindle in Press
Figure 7–114: Film of Oil on Spindle Bearing Shoulder
285
Figure 7–115: TopTapered Bearing Cone on Spindle
2. Place the output spacer over the spindle and on top of the bearing.
Figure 7–116: Output Spacer
286
3. Now place the output gear onto the spindle, as the gear will only be
used to press the top bearing cone into position against the chuck
adaptor flange and then removed.
Figure 7–117: Output Gear Placed on Spindle
4. Position a suitable piece of hollow tubing over the threaded section

of the spindle onto the output gear.
Figure 7–118: Hollow Tubing Placed Over Threaded Section
287
5. Press the top bearing into position against the chuck adaptor
flange.
Figure 7–119: Top Bearing Pressed Against Adaptor Flange
6. Place the spindle with the threaded section resting on the work
bench and the bearing up.
Note: Use a suitable material under the threaded end of the spindle
so as to protect the threads. Coat the top end of the spindle with a
thin film of oil.
Figure 7–120: Spindle Placed Bearing Up
288
Figure 7–121: Thin Film of Oil on Top of Spindle
7. Install the output wear sleeve on top of the spindle.
Figure 7–122: Output Wear Sleeve on Top of Spindle
289
8. Tap the output wear sleeve down the spindle chuck adaptor flange
so that it is approximately 0.030” (0.76 mm) below the face of the
chuck adaptor flange.
Figure 7–123: Output Wear Sleeve Tapped Down
9. Turn the spindle so that the chuck adaptor flange is resting on the
work bench and the thread end is up. Coat the machined diameter
between the two threaded portions of the spindle with a light film of
oil.
Figure 7–124: Spindle Turned Over
290
10. Place the first wear sleeve, lip down over the first threaded portion
of the spindle.
Figure 7–125: First Wear Sleeve
11. Using an appropriate driver, drive the wear sleeve down till it rests
on the shoulder of the beginning of the second threaded portion of
the spindle.
Take care as not to damage spindle threads while installing the wear
sleeve.
Figure 7–126: Wear Sleeve Driven Down

291
12. Place the second wear sleeve, lip up over the first threaded portion
of the spindle.
Figure 7–127: Second Wear Sleeve
13. Using an appropriate driver, drive the wear sleeve down till it is tight
against the first wear sleeve.
Take care as not to damage spindle threads while installing the wear
sleeve.
Figure 7–128: Second Wear Sleeve Driven Down

292
14. Using a utility knife, re-score the existing score lines of the two
wear sleeves.
Care must be take to avoid personal injury and external damage to

the wear sleeves in this part of the assembly procedure. The re-
scoring of the wear sleeves ensures a good clean break of the wear
sleeve lip. Any sharp jagged edges will cut the seals of the lower
seal carrier upon installation.
Figure 7–129: Re-score Existing Score Lines
15. Using an appropriate tool, cut through the lip of each wear sleeve.
Figure 7–130: Cut Through Lip of Each Wear Sleeve
293
16. Roll the lip off each wear sleeve by inserting a pair of needle nose
pliers into the lip and rolling the severed lip off the wear sleeve and
around the needle nose pliers.
The lip being removed from the wear sleeves is extremely sharp,
caution is advised.
Figure 7–131: Roll Lip Off Each Wear Sleeve
17. Turn the completed spindle up so that the threaded end of the
spindle is resting on the work bench. Using the 3/4” UNC tapped
holes in the spindle chuck adaptor flange, install the appropriate
lifting aid. Sling the spindle up and guide it through the main
housing being careful not to damage the threaded portions of the
spindle. A slight twist of the spindle may be required to line up the
spline of the spindle with the internal spline of the output gear. Be
sure that the tapered roller bearing on the spindle is completely
seated in the bearing race of the housing cover.
Figure 7–132: Sling Spindle Up and Guide Through Main Housing
294
7.8.5 Output Carrier and Pump Mounting

1. Place the output carrier, face down on the work bench. Install the
first oil seal lip down. Drive the seal down until it bottoms out on the
bottom of the counter bore.
Figure 7–133: Output Carrier Face Down
Figure 7–134: Oil Seal Installed Lip Down
295
2. Install the second oil seal, lip up. Drive the oil seal down to a
measurement of 1” (25.4 mm).
Figure 7–135: Second Oil Seal
Note: Make sure that the oil seal is installed square and not
blocking the grease fitting port.
Figure 7–136: Make Sure Oil Seal is Installed Square
3. Install the 1/8” NPT grease fitting. It must be installed in the proper
hole location so that grease enters between the oil seals and not
into the main housing cavity.
Figure 7–137: 1/8” NPT Grease Fitting
296
4. Install the 1/8” NPT plug.
Figure 7–138: 1/8” NPT Plug
5. Pack the oil seals with a multipurpose EP2 grease.
Figure 7–139: Seals Packed with Multipurpose EP2 Grease
6. Apply a bead of RTV high heat sealant to the flange area of the
output carrier, just inside the bolt circle.
Figure 7–140: RTV High Heat Sealant Applied to Flange Area
297
7. Apply a film of grease to the chuck adapter flange on output

spindle.
Figure 7–141: Chuck Adapter Flange
8. Install the output carrier with the 1/4” NPT port to the front of the
main housing.
Figure 7–142: Install Output Carrier
9. Install the eight 1/2” UNC x 1-1/2” bolts and lockwashers. Torque to
50 lbf•ft (67.79 Nm), using a cross hatch tightening pattern.
Figure 7–143: Install Eight UNC Bolts and Lockwashers
298
Figure 7–144: Torque to 50 lbf-ft
10. Place the pump mounting cover upside down on the work bench.
Apply a bead of RTV high heat sealant inside the bolt circle. Install
the pump mounting cover.
Note: The 1/4” (0.64 cm) NPT port must be on your right hand side
as viewed from the front of the main housing.
Figure 7–145: Pump Mounting Cover
299
Figure 7–146: Pump Mounting Cover Installed
11. Install the six 1/2” UNC x 1-1/2” bolts and lockwashers. Torque to
50 lbf•ft (67.79 Nm), using a cross hatch tightening pattern.
Figure 7–147: Six 1/2” UNC Bolts and Lockwashers Installed
300
12. Check this oil galley to insure it is free of RTV high temp sealant.
Figure 7–149: Insure Oil Galley is Free
13. Using the proper lifting devices, lift the PQ Head off the blocking
and rest it on the work bench.
Note: The spindle is horizontal to the work bench.
Note: Care must be used during this procedure so as not to

damage the oil seals in the output carrier. The spindle is not
secured in the PQ Head and may be dislodged.
Note: The output gear may have to be tapped back tight against
the output spacer and spindle bearing.
Avoid oil seal damage and the addition of any debris inside the main
housing.
Note: Install the snap ring in the snap ring grove in the splined
portion of the spindle.
Figure 7–150: Snap Ring Installed
301
Figure 7–151: Tap Output Gear Back Tight
14. Coat the bottom spindle bearing race and spindle threads with a
film of oil. Install the bottom spindle cone bearing.
Note: Observe correct orientation of the cone bearing.
Figure 7–152: Bottom Spindle Bearing Race Coated
Figure 7–153: Bottom Spindle Cone Bearing Installed
302
15. With the aid of the inner lock ring, the cone bearing can be installed
on the spindle.
Note: By using two 3/8” (0.95 cm) UNC x 5” (12.7 cm) bolts,
installed at 180° apart on the inner lock ring bolt circle, the lock ring
can be threaded onto the spindle, pressing the cone bearing on the
spindle, square and in line.
Figure 7–154: Cone Bearing Installed on Spindle
16. Tighten the inner lock ring until the cone bearing is seated in the
bearing race on the main housing.
Should be exercised so as not to damage the threaded section of the

output shaft.
17. Clean and coat the original shim pack, for the input pinion and
shaft, with a film of oil. Install the shim pack in the input pinion and
shaft bore of the main housing.
Figure 7–155: Original Shim Pack
303
Figure 7–156: Shim Pack Installed
18. Lay the input carrier flat on the work bench, lip up, and apply a
bead of RTV high heat sealant around the outside edge lip.
Figure 7–157: Input Carrier Flat on Work Bench
19. Install the input carrier in the input pinion and shaft bore of the main
housing. The correct position of the input carrier is with the large
counter bore on top with the input carrier protruding over the front
of the main housing.
Figure 7–158: Input Carrier Installed
304
20. Apply Locktite 242 to the threads of the six 1/2” x 1-3/4” cap
screws. Install and torque to 50 lbf•ft (67.79 Nm).
Figure 7–159: Locktite 242 Applied to Threads
21. Back off the inner lock ring one turn. Remove the two 3/8” UNC
x 5” bolts used for installation of the bearing. Install a 3/8” UNC x
3/4” bolt and flat washer. Torque the inner lock ring to preload the
output shaft for a rolling torque of approximately 70 lbf•in (7.91Nm).
305
Note: The output shaft should be rotated and the inner lock ring
tightened alternately several times to ensure that the bearings are
indeed seated in the housing and the torque value is maintained.
Figure 7–161: Torque Inner Locking Ring 70 lbf-in
22. Fit the in/lb torque wrench with a 9/16” socket and by utilizing the
3/8” UNC x 3/4” bolt and washer installed previously, thread the
inner lock ring up against the bearing to the required torque.
23. Remove the 3/8” UNC x 3/4” bolt, being careful not to disturb the
position of the inner lock ring.
24. After setting the proper torque and before removing of the
3/8” UNC x 3/4” bolt, scribe a line on the main housing and inner
lock ring.
25. Thread on the outer lock ring. Leave a distance of approximately.

0.060” (1.5 mm) between the inner and outer lock rings. Position
the outer lock ring so that it can be bolted to the inner lock ring.
Note: Double check your scribe lines to verify that the position of
the inner lock ring has not changed.
Figure 7–162: Outer Lock Ring
306
26. Apply “Locktite 242” and a 3/8” internal tooth lockwasher to each of
the six 3/8” UNC x 1-3/4” bolts. Install the bolts and washers and
torque in a cross hatch pattern to 120 lbf•in (7.9 Nm).
Figure 7–163: Locktite 242 Applied to 3/8” UNC Bolts
Figure 7–164: Torque to 120 lbf-in
27. Place the lower seal carrier face up on the work bench. Place the
first oil seal, lip down, into the lower seal carrier. Drive the first oil
seal down till it bottoms out on the bottom of the counter bore in the
lower seal carrier.
Figure 7–165: Lower Seal Carrier
307
Figure 7–166: First Oil Seal Driven Down
28. Place the second oil seal, lip up, into the lower seal carrier. Drive
the second oil seal down till it is flush with the top of the counter
bore in the lower seal carrier.
Figure 7–167: Second Oil Seal Lip Up
Figure 7–168: Check Gaps Between Two Seals
308
29. Install the 1/8” NPT grease fitting, #8 ORB plug and the 1/4” NPT
plug in the lower seal carrier. Pack the oil seals with a multipurpose
EP2 grease.
Figure 7–169: Install 1/8” NPT Grease Fitting
30. With the lower seal carrier sitting face up on the work bench, apply
a bead of RTV high temp sealant just inside the bolt circle and the
lip of the lower seal carrier.
Figure 7–170: Apply Bead of RTV High Temp Sealant
31. Install the lower seal carrier with the notch in the proper location so
as to allow access to the main housing 3/4” NPT return port.
Figure 7–171: Lower Seal Carrier Installed
309
32. Use eight 1/2” UNC x 1-1/2” bolts and lock washers to fasten the
lower seal carrier to the main housing. Torque to 50 lbf•ft (67.79
Nm) in a crosshatch tightening pattern.
Figure 7–172: Fasten Lower Seal Carrier to Main Housing
33. Put a bead of RTV high temp sealant around the flange of the
service cover. Put a bead of RTV high temp sealant around the
thread of the four 5/16” UNC x 3/4” bolts. Install the service cover
and hand tighten bolts.
Figure 7–173: RTV High Temp Sealant Around Service Cover
Figure 7–174: Service Cover Installed
310
34. Coat the remaining spindle thread with a film of multipurpose (EP2)
grease and then install the spindle nut. Four 3/8” UNC x 3/4” cap
screws are used in the spindle nut to secure desired spindle
bushing.
Figure 7–175: Spindle Nut Installed
7.8.6 Transmission Assembly

1. Position the transmission, machined surface down and output shaft
facing horizontal on the work bench.
2. Apply Shell Gadus S2 high speed coupling grease (BLY p/n

5402352) or equivalent to the inside splines of the splined adapter.
3. Slide the splined adapter on to the spline of the output shaft with
the machined OD of the splined adaptor against the transmission
output shaft bearing.
Figure 7–176: Machined Splined Adaptor
311
4. Install the shim pack and retaining washer with the two 7/16” UNF
x 1-1/2” bolts to the end of the transmission output shaft. Torque
these two bolts to 40 lbf•ft (54.23 Nm).
5. Using feeler gauges check the distance between the end of the
splined adapter and the retaining washer. There must be .005”
to .010” (0.013 to 0.025 cm) end play. Lockwire these two bolts
together.
6. Apply Shell Gadus S2 high speed coupling grease (BLY p/n

5402352) or equivalent to the to the outside of the splined adapter
and the internal spline of the input pinion and shaft. Apply a bead
of RTV high heat sealant to the mounting face of the transmission,
just inside the bolt hole mounting pattern.
7. Using a suitable sling and lifting device mount transmission to the

input carrier.
Do not force the transmission into place. Line the transmission and
main housing up, and gently rock the transmission until it slides into
place freely.
8. Apply “Locktite 242” to the threads of the six 1/2” UNC x 1-3/4”
bolts. Install with lock washers and torque to 50 lbf•ft (67.79 Nm).
7.9 PQ Nitro Chuck ™

This section describes the PQ Nitro Chuck ™ and its components.
312
7.9.1 PQ Chuck Cross Section
1—Chuck Spindle 2—Inner Cylinder 3—Chuck Piston 4—Outer Chuck Cylinder

5—Labyrinth Seal 6—Spring Retainer 7—Jaw Retainer 8—Mounting Adapter
9—Ball Bearing 10—Nitrogen Gas Spring 11—Internal Retaining Ring 12—Inner Cup Seal
13—Outer Cup Seal 14—Piston Cup Seal 15—O-ring 16—Backup Ring
17—O-ring 18—Backup Ring 19—Lower Spindle Wear Ring 20—Oil Guide Pin Seal
21—Retainer Guide Bushing 22— Dowel Pin, 1 Dia X 3-1/2 Lg 23—Dowel Pin, 3/8 Dia X 1 Lg 24—N/A
25—Bowl 26—O-ring 27—Grease Nipple 28—Set Screw, 1/2-13 UNC X
1-1/4
29—Internal Retaining Ring 30—External Retaining Ring 31—Wear Sleeve, Upper 32—N/A
33—Cap Screw, 3/8-16 UNC X 34—Cap Screw, 3/8-16 UNC X 35—Cap Screw, 1/2-20 UNF X 36—Cap Screw, 1/2-13 UNC X
1-1/4 Lg 3/4 Lg 2 Lg 1-1/2 Lg
37—Seal Kit 38—Support Plate 39—Grease
Figure 7–177: PQ Nitro Gas Chuck Planograph
313
7.10 PQ Nitro Gas Chuck
7.10.1 PQ Nitro Gas Chuck Disassembly Procedure

1. Before starting work on the PQ chuck observe all previous safety
warnings.
Never attempt to operate the chuck with any of the spring retainer
bolts loose or missing. Severe injury or death could result. Carefully
inspect the threads on the bolts and spindle and replace the spindle
and or bolts if the threads show any sign of damage or wear.
Tools required:
●● Lifting equipment
●● Full set of Imperial Alan key tools
●● Breaker bar
●● Pry bar
●● Torque wrench
Figure 7–178: PQ Chuck
314
2. Remove 4 x 3/8 UNC cap head screws (item 33) with an Allen key.
Figure 7–179: UNC Cap Screws Removed
3. Pull off cap ( item 21) manually, if the cap is tight, use a pry bar.
Figure 7–180: Cap Pulled Off
4. Remove guide retainer bushing (item 21) with hands, again if it is

tight remove with a pry bar.
Figure 7–181: Guide Retainer Bushing Removed
315
5. With this cover and bushing removed the chuck jaws can be seen.
Figure 7–182: Chuck Jaws Visible
6. Release the next flange by removing 7 x ½ UNC cap head screws

(item 36) with an appropriate Alan key.
Figure 7–183: Release Next Flange
Figure 7–184: Remove 7 UNC Cap Head Screws
316
7. Locate 2 small jacking screws and tighten to split the face of the
flange from the chuck.
Figure 7–185: Locate 2 Small Jacking Screws
8. When the flange (item 7) of the chuck is free of the face it can be
removed by hand, if the flange is tight use a bar to remove.
Figure 7–186: Chuck Removed By Hand
9. Remove the ring of bolts (item 35 – ½ 20UNF) that hold the next
flange into place.
317
Never attempt to operate the chuck during the assembly/

disassembly process. Always disassemble the chuck from the top
down.
Figure 7–187: Ring of Bolts
Figure 7–188: Ring of Bolts Removed
10. When these bolts are removed the Jaws are not secured in the
channel as tightly, and and can be removed easily.
Figure 7–189: Jaws Not Secured
318
11. Remove the Jaws by hand, these slide out at a 20 degree angle.
Figure 7–190: Remove Jaws by Hand
12. 7 Jaws are removed from the chuck altogether.
Figure 7–191: Jaws Removed from Chuck
13. Eye bolts can then be screwed in to the flange (item 6 Jaw retainer)
for lifting purposes.
Figure 7–192: Eye Bolts Screwed to Flange
319
14. This part (item 6) can then be lifted off of the chuck.
Figure 7–193: Ready to be Lifted
15. Remove Gas springs (item 10) one at a time. This is done by using
parrot grips.
Figure 7–194: Remove Gas Springs
16. Ensure not to grip the cylinder shaft, only grip the body of the
cylinder.
Figure 7–195: Grip the Body of the Cylinder
320
17. When all of the gas springs are removed store in a safe place as
these cylinders are pressurised with gas.
Figure 7–196: All Gas Springs Removed
18. Next remove the body using appropriate lifting equipment.
Figure 7–197: Remove the Body
19. Tap lightly on the outer chuck cylinder with a rubber mallet if the
section is tight coming off.
Figure 7–198: Body Coming Off
321
Figure 7–199: Body Removed
20. Grip the “crown” with fingers and pull outwards and upwards.
Figure 7–200: Crown Pulled Out
21. *TIP* When the crown is removed place in a safe position as it is

susceptible to bending/breaking.
Figure 7–201: Crown Removed
322
22. Remove O-ring with a pick, taking care not to scratch any surfaces.
Figure 7–202: Remove O-Ring
23. Pull the O-ring off of the top of the spindle.
Figure 7–203: Pull O-Ring Off Top of Spindle
24. Lift the outer cylinder of chuck with a crowbar to allow access and
removal of bolts.
*TIP*- Secure with a wedge to prevent the cylinder dropping whilst

removing.
Figure 7–204: Lift Outer Cylinder of Chuck
323
25. Remove the bolts securing the adapter mounting.
Figure 7–205: Adapter Mounting Bolts
Figure 7–206: Adapter Mounting Bolts Removed
26. Remove two Cap head bolts for insertion of lifting eyes. Remove
bolts that are 180 degrees opposite from each other.
Figure 7–207: Remove Cap Head Bolts
324
27. Insert Lifting eyes as shown.
Figure 7–208: Lifting Eyes Inserted
28. Remove outer cylinder section tapping lightly with a rubber mallet if
the section is tight.
Figure 7–209: Outer Cylinder Section
Figure 7–210: Outer Cylinder Removed
325
29. Remove seal (item 19 lower spindle wear ring) from main spindle.
Figure 7–211: Remove Seal From Main Spindle
30. With a screw driver prise off the snap ring starting with the notch at
the end of the snap ring.
Figure 7–212: Prise Off the Snap Ring
31. Remove snap ring from crown spindle.
Figure 7–213: Remove Snap Ring
326
32. Remove the Alan head bolts holding the main spindle onto the
bottom support plate.
Figure 7–214: Remove Alan Head Bolts
33. Use two bolts in the “Jack Holes” to jack the shaft from the face of
the flange.
Figure 7–215: Jack Shaft from the Face of the Flange
34. Use lifting eyes to lift the main spindle (item 1) free of the bottom
support plate.
Figure 7–216: Lift Main Spindle From Bottom Support Plate
327
Figure 7–217: Bottom Support
35. Mark the inside of the main piston section with a marker pen, this
mark should line up the extruding screw and the bolt hole in line
with it.
Figure 7–218: Mark Inside of Main
36. Remove the Alan head bolts holding the bottom adapter plate onto
the outer cylinder.
Figure 7–219: Remove Bottom Adapter Plate Alan Head Bolts
328
37. The top face is light enough to lift off by hand.
Figure 7–220: Lift Off Top Face
38. Remove the snap ring that secures the bearing. This is done with a
screw driver.
Figure 7–221: Remove Snap Ring
39. Remove the top race of the bearing.
Figure 7–222: Remove Top Race
329
40. Remove the bearing race.
Figure 7–223: Bearing Race
41. The bottom race is then tapped out carefully using a soft punch.
Tap out the bottom race slowly moving around the race so it comes
out evenly. Take care not to score the face of the cylinder.
Figure 7–224: Tap Bottom Race Out
42. Bottom race removed.
Figure 7–225: Bottom Race
330
Figure 7–226: Bottom Race Removed
43. Using the bolt holes used in step 26 insert 2 long bolts and gently
Jack the faces apart.
Figure 7–227: Jack Faces Apart
44. Using the same points again insert eye bolts to lift off the middle of
the cylinder section.
Figure 7–228: Lift Off Middle of Cylinder Section
331
45. Using a rubber mallet tap out the piston.
Figure 7–229: Tap Out the Piston
46. Use a screw driver to remove outer seals.
Figure 7–230: Remove Outer Seals
47. Use a screw driver to remove inner seals.
Figure 7–231: Remove Inner Seals
332
48. Use either an o ring pulling tool or a pick to remove o rings from
bowl (item 25). Turn over the part for next step.
Figure 7–232: Remove O-Rings From
49. Remove Alan head bolts on item 25 bowl.
Figure 7–233: Remove Alan Head Bolts
50. Use a Long punch and hammer to knock the two parts apart.
Figure 7–234: Long Punch and Hammer
333
Figure 7–235: Two Parts
7.10.2 Chuck Assembly Procedures

Refer to Planograph on previous page.
1. Install the three dowels (item # 23) into the piston (item #3).
Figure 7–236: Piston
2. Install the two urethane cup seals (item #13) on the piston (item #3)
outside diameter grooves. Be sure to coat the seals with hydraulic
oil before installation.
334
Note: The orientation of the seals should be as shown in the

planograph.
Figure 7–237: Urethane Cup Seals
3. Lubricate the inner urethane cup seal (item #12) with hydraulic oil
and install it inside groove of the piston bore (item #3).
Note: The orientation of the seals should be as shown in the

planograph.
Figure 7–238: Lubricate Inner Urethane Cup Seal
4. Lubricate the urethane cup seal (item #14) and install in outer
chuck cylinder (item #4).
335
Note: The location and proper orientation of seal should be as

shown in the planograph.
Figure 7–239: Outer Chuck Cylinder
5. Lubricate the O-ring (item #17) and the backup ring (item #18).
Install in the OD of the inner cylinder (item #2).
Note: The installation order should be as shown in the planograph.
Figure 7–240: Lubricate O-ring and Backup Ring
336
6. Install the external retaining ring (item #30) on the PQ chuck

spindle (item #1).
Figure 7–241: External Retaining Ring
7. Install the lower spindle wear ring (item #19) on the PQ chuck
spindle (item #1).
Figure 7–242: Lower Spindle Wear Ring
8. Lubricate and install the O-ring (item #15) and the back-up ring (item
#16) on the PQ chuck spindle OD
337
Note: The orientation and location should be as shown in the

planograph.
Figure 7–243: PQ Chuck Spindle
9. Install the upper spindle wear sleeve (item #31) on the PQ chuck
spindle.
Figure 7–244: Upper Spindle Wear Sleeve
10. Align dowel with the first hole to the right hand side of the O-ring
bussport of the outer cylinder (item #4).
338
Note: The piston dowel must align with outer cylinder for proper
assembly.
Figure 7–245: O-ring Bussport of the Outer Cylinder
11. Install the piston (item #3) into the outer cylinder (item #4). Gently
tap piston down into place until piston is flush to the bottom of the
outer cylinder.
Figure 7–246: Install the Piston
12. Install the inner cylinder (item #2) into the outer cylinder assembly
(item #11) from step 5. Tap into place using a soft face mallet. Use
two 3/8” UNC bolts of the proper length to align the parts.
339
Note: Be sure to align the two oil ports as shown.
Figure 7–247: Inner Cylinder Installed
13. Install the 3/8” UNC x 1-1/4” long socket head cap screws (item
#33) using an “anti-seize”, and torque to 35 ft-lbs.
Note: Boart Longyear strongly advises the use of Chevron Ultra-

Duty Premium Grease (Item #39), EP #NLG12, as the only
recommended grease for the PQ Nitro Chuck!
Figure 7–248: 3/8” UNC Long Socket Head Cap Screws Installed
14. Bolt the PQ chuck spindle (item #1) to the shipping plate, using 3/4”
UNC bolts.
OR
Bolt the PQ chuck spindle (item #1) to the head spindle using 3/4”
340
UNC bolts supplied with the drive head module and torque to 280
ft-lbs.
Figure 7–249: PQ Chuck Spindle Bolted to Shipping Plate
15. Install the internal retaining ring (item 29) in the PQ chuck spindle
bore (item #1).
Figure 7–250: Internal Retaining Ring
16. Grease the PQ chuck spindle OD with grease (item #39).
341
Note: Boart Longyear strongly advises the use of Chevron Ultra-

Duty Premium Grease (Item #39), EP #NLG12, as the only
recommended grease for the PQ Nitro Chuck!
Figure 7–251: Grease PQ Chuck Spindle OD
17. Bolt adapter plate (item #8) to piston (item #3).
Figure 7–252: Bolt Adapter Plate to Piston
342
18. Install cylinder assembly over spindle.
Figure 7–253: Cylinder Assembly
19. Install bearing (item #9) starting with lower thrust bearing race
(larger OD).
Figure 7–254: Lower Thrust Bearing Race
20. Install bearing roller race. Pack bearing with grease (item #39)
supplied.
Figure 7–255: Bearing Roller Race
343
21. Install upper thrust bearing race.
Figure 7–256: Upper Thrust Bearing Race
22. Install retaining ring (item #11).
Figure 7–257: Retaining Ring
23. Install Labyrinth seal (item #5).
Figure 7–258: Labrynth Seal
344
24. Install the 3/8” UNC x 1-1/4” long socket head cap screws (item
#33) and torque to 35 ft-lbs.
Figure 7–259: 3/8” Long Socket Cap Screws
25. Install bowl (item #25) onto spindle (item #1).
Figure 7–260: Install Bowl onto Spindle
26. Install gas springs (item #10).
Figure 7–261: Install Gas Springs
345
27. Install spring retainer (item #6).
Figure 7–262: Spring Retainer
28. Install 1/2”-20 UNC x 2” long socket head cap screws (item #35)
and torque to 90 ft-lbs.
Figure 7–263: 1/2” Long Socket Head Cap Screws
29. Install inner bushing (supplied separately).
30. Install jaws (supplied separately).
Figure 7–264: Install Jaws
31. Install jaw retainer (item #7).

346
32. Install 1/2”-20 UNC x 1-1/2” long socket head cap screws (item
#36) and torque to 80 ft-lbs.
33. Install upper bushing (supplied separately).
Figure 7–266: Upper Bushing
34. Install guide bushing retainer (item #21)
35. Install 1/2”-20 UNC x 3/4” long socket head cap screws (item #34)
and torque to 35 ft-lbs.

347
36. Chuck assembly shown on shipping plate.
Figure 7–268: Chuck Assembly on Shipping Plate
37. For chuck disassembly, follow the instructions in reverse order.

Installation of New Jaws
7.10.3 Installation of New Jaws

1. Remove the top bushing.
2. Remove jaws.
3. Remove the bottom bushing.
4. Clean jaw slots with diesel fuel or a solvent and lubricate with EP2
grease.
5. Reassemble using appropriate jaws and bushings.
6. Remove lower spindle bushing and replace with appropriate

bushing.
7.10.4 Chuck Lubrication

1. Lubricate the chuck as per the lubrication schedule in the General
Maintenance & Troubleshooting section.
348
7.10.5 Maintenance
Note: The lower spindle bushing and lower chuck bushing are NOT
used for HWT/PQ sizes. To insert PQ core barrel assembly, the upper
chuck bushing will have to be removed and replaced after insertion,
otherwise cuttings will infiltrate the area around the mitogen gas springs.
1. Inspect and clean jaws regularly. Replace in sets of seven only,

when worn.
2. For replacement parts, refer to the chuck assembly drawing in your

Parts Manual.
Do not open chuck while rotating otherwise bearing life will be

greatly reduced.
7.10.6 Nitrogen Gas Springs
We do not recommend field recharge of the gas springs, please contact

your Boart Longyear service representative for more information.
Nitrogen gas springs are designed to have a long service life. Inspect
the gas springs periodically while changing jaws (3 month intervals).
1. Remove the spring retainer to access the gas springs for inspection
and replacement.
2. Measure the free length of the exposed piston rod above the
barrel. If the gas spring is still charged with nitrogen, the rod will be
extended 1” (25mm). Replace any spring that does not meet this
requirement.
349
350
Contents
8.1 Fault Finding Tables............................................................................... 353
8.1.1 Fine Feed.................................................................................... 353
8.1.1.1 Symptom: Low Fine Feed Force - Lack of Force on Drill Bit
While Drilling......................................................................................... 353
8.1.1.2 Symptom: Poor Fine Feed Control While Drilling............... 354
8.1.2 Main Line Winch.......................................................................... 355
8.1.2.1 Symptom: Main Line Winch Brake Not Releasing While
Drilling ............................................................................................ 355
8.1.2.2 Symptom: Erratic Operation of the Main Line Winch While
Lowering Rods...................................................................................... 356
8.1.2.3 Symptom: Main Line Winch Slipping and not Holding the Rod
Weight when the Main Line Hoist Lever is Returned to Neutral Position...
............................................................................................ 356
8.1.3 Wireline Winch............................................................................ 357
8.1.3.1 Symptom: Erratic Operation of the Wireline Winch While
Lowering Overshot............................................................................... 357
8.1.3.2 Symptom: Wireline Winch will not Hold the Load with the
Control in the Neutral Position.............................................................. 357
8.1.4 D03 Auxiliary Manifold................................................................. 357
8.1.4.1 Symptom: None of the Functions Work on the D03 Auxiliary
Manifold ............................................................................................ 357
8.1.5 PQ Chuck.................................................................................... 358
8.1.5.1 Symptom: PQ Chuck Does not Open or Close................... 358
8.1.5.2 Symptom: PQ Chuck Slipping on Rods.............................. 358
Opening Chuck..................................................................................... 358
8.1.5.4 Symptom: PQ Chuck Noisy when Rotated Slowly in the Open
Position ............................................................................................ 359
8.1.5.5 Symptom: Rotation Speed Control V45 does not Function.359
8.1.6 Rod Clamp.................................................................................. 359
8.1.6.1 Symptom: Rod Clamp does not Open or Close Properly... 359
351
Copyright © 2007, 2011, 2016 Boart Longyear. All rights reserved. 5
006655
8.1.6.2 Symptom: Rod Clamp Slipping while Making or Breaking Rod

Joints ............................................................................................ 360
8.1.6.3 Symptom: Head Opener Not Working................................ 360
8.1.6.4 Symptom: Mud Mixer Not Working Properly....................... 360
8.1.6.5 Symptom: Rod Make/Break Head Float Not Working Properly.
............................................................................................ 361
8.1.6.6 Symptom: Rod Make Up Torque Problems........................ 361
8.1.6.7 Symptom: PQ Head Rotation Problems............................. 361
8.1.6.8 Symptom: Mud Pump Problems......................................... 364
8.1.6.9 Symptom: Auxiliary Set Up Valve V40 Problems................ 364
8.1.6.10 Symptom: Tramming Problems (Optional Track Mounted
Drill) ............................................................................................ 365
8.1.7 Engine......................................................................................... 366
8.1.7.1 Symptom: Engine Will Not Start From OCP....................... 366
8.1.8 Hydraulic Oil................................................................................ 368
8.1.8.1 Symptom: Hydraulic Oil Overheating.................................. 368
8.2 Engine - Monitor Fault Codes (J1939)................................................... 368
352
8.1 Fault Finding Tables
Refer to the Operation and Service manual and the Electrical and
Hydraulic Schematics in the parts manuals while using this fault finding
table.
Follow applicable Lock Out/Tag Out procedures to de-energize all

sources of energy prior to performing maintenance/troubleshooting
procedures.
8.1.1 Fine Feed
8.1.1.1 Symptom: Low Fine Feed Force - Lack of Force on

Drill Bit While Drilling
Probable Cause Solution
P3 auxiliary pump pressure not A. Turn rotary muilt-gauge to the P3
adjusted properly or defective pump pressure position, adjust P3
auxiliary pressure to 2000 psi.
B. Install a flow meter on the P and

T end ports of the DO3 manifold
and check condition of the pump. At
2200 RPM the pump should produce
11GPM @ 2000 psi.
V25 fine feed pressure reducing valve Adjust pressure to maximum setting
incorrectly adjusted or defective by turning the adjustment screw fully
clockwise.
V44-04 fast feed work port relief Check the work port relief setting
incorrectly adjusted or bypassing oil by running the feed cylinder to
the bottom of the feed stroke and
monitoring the rod torque gauge.
The relief setting should be 3000
psi. Adjust if necessary using the
Sauer Danfoss adjusting tool. (Ref.
#3549116) Isolate the V44-04 fast
feed valve from the fine feed circuit
to determine if the valve section is at
fault.
353

V24 mud mixer sequence valve Adjust the sequence valve setting
incorrectly adjusted or defective; to 1800 psi per instructions in the
fault occurs while drilling when V10 operation and service manual.
mud mixer on/off valve is activated to
power the mud mixer motor M6
Feed carriage too tight on mast rails Use a feeler gauge to check the
clearance between the carriage
nylatron wear bars and the mast rails.
The clearance between the wear bars
and mast rail should be a minimum
of 0.010 or 0.25 mm on each inside
rail. The clearance between the front
and rear wear bars and the mast rail
should be 0.005 or 0.13 mm. Add or
remove shims as necessary.
Bent or damaged mast rails Check mast rails for any visible
damage that may cause the carriage
to bend during travel. Repair if
necessary.
A1 head feed cylinder bypassing oil Test the feed cylinder for bypass. If
at piston or o-rings seals in aluminum the cylinder is bypassing oil under
feed cylinder manifold at base of pressure, first remove the aluminum
cylinder manifold from the end of the feed
cylinder to inspect the seals before
removing the complete cylinder for
repair.
Oil bypassing through the mainline A. Shut off V16 brake release valve to
winch brake circuit stop the oil from releasing the brake
to determine if the main line winch
brake circuit is faulty.
B. If the main line winch brake seal

is leaking, hydraulic oil will leak into
the case of the main winch and
completely fill the winch resulting
in hydraulic oil leaking out of either
the breather or the drum seal on the
opposite end of the winch.
8.1.1.2 Symptom: Poor Fine Feed Control While Drilling

A1 head feed cylinder bypassing oil Test the feed cylinder for bypass. If
at piston or o-rings seals in aluminum the cylinder is found to be bypassing
feed cylinder manifold at base of oil under pressure, first remove the
cylinder aluminum manifold from the end
of the feed cylinder to inspect the
seals before removing the complete
cylinder for repair.
354

V25 fine feed pressure reducing In order to maintain proper feed
valve incorrectly adjusted or defective control the V25 fine feed pressure
control valve must be gradually
turned counter-clockwise outwards
to reduce the feed pressure as rods
are added to the drill string thereby
increasing the weight on the bit.
Oil bypassing through the mainline A. Shut off V16 brake release valve to
winch brake circuit stop the oil from releasing the brake
to determine if the main line winch
brake circuit is faulty.
B. If the main line winch brake seal

is leaking, hydraulic oil will leak into
the case of the main winch and
completely fill the winch resulting
in hydraulic oil leaking out of either
the breather or the drum seal on the
opposite end of the winch.
8.1.2 Main Line Winch
8.1.2.1 Symptom: Main Line Winch Brake Not Releasing

While Drilling
Brake release valve V16 not being Ensure that the brake circuit is
used or is defective receiving 2000 psi to release the
brake by turning the rotary multi-
gauge to mainline hoist brake release
pressure position, with the fine feed
engaged in the downward feed
position.
Faulty shuttle valve in the main line If 2000 psi is seen on the rotary
winch V32 brake valve manifold pressure gauge as above, replace
the shuttle valve in the main winch
manifold to see if the brake will
release.
Damaged or warped steel or friction Likely caused by improper assembly
discs in the main winch or the brake not fully being released
while hoisting of while drilling.
Replace the damaged components
and find out what caused the failure
before putting the winch back into
service.
355
8.1.2.2 Symptom: Erratic Operation of the Main Line Winch

While Lowering Rods
Faulty counterbalance valve V36 in If the load tends to run away while
the main line winch manifold lowering rods the problem is likely the
counterbalance valve. Replace with a
new counterbalance valve adjusted at
the factory. Do not attempt to adjust
this valve in the field.
8.1.2.3 Symptom: Main Line Winch Slipping and not Holding

the Rod Weight when the Main Line Hoist Lever is
Returned to Neutral Position
Spragg bearing in main line winch A. If the winch has just been repaired
incorrectly installed the sprag clutch may have been
improperly installed. To check this,
remove the mainline cable, turn the
drum into a position where a bar can
inserted into the cable retaining hole,
shut off the engine and try to rotate
the drum using the bar.
B. If the drum can be rotated

clockwise from the motor end in
the same direction that the winch is
powered to lower then the spragg
bearing is incorrectly installed.
Disassemble the winch and install the
spragg bearing properly.
Spragg bearing in main line winch The spragg bearing can be worn
worn from a long service life, use of the
incorrect type of oil that has anti-slip
properties, or in a relatively short
period of time if a drill continuously
opens the chuck without tensioning
the cable beforehand.
Brake disc in main line winch worn Replace the spragg clutch.
Brake discs in main line winch worn Replace the worn brake steel and
friction discs.
Pressurized oil is releasing the brake A faulty shuttle valve in the main line
winch manifold may lock pressure in
the brake circuit causing the winch
to not hold a load due to the brake
being released.
356
8.1.3 Wireline Winch
8.1.3.1 Symptom: Erratic Operation of the Wireline Winch

While Lowering Overshot
Incorrect setting of the V44-03 A. Insert the locking pin through
wireline winch load sense relief valve the flange of the wireline drum to
prevent the drum from rotating.
Engage the wireline control lever and
adjust the valve to 3000 psi using a
Sauer Danfoss adjustment tool (Ref.
#3549116).
Wrong counterbalance valves ratio

installed in wireline motor manifold.
Replace counterbalance valves.
8.1.3.2 Symptom: Wireline Winch will not Hold the Load

with the Control in the Neutral Position
Faulty V31 counterbalance valve in Replace the defective counterbalance
the motor manifold valve cartridge with a new factory
adjusted counterbalance valve. Do
not try to adjust in the field.NOTE:
It is normal for the wireline cable to
creep down under the weight of the
empty overshot or even a full tube.
This is due to internal leakage in
the motor. If the creeping becomes
excessive due to a long service life
the motor may have to be rebuilt or
replaced.
8.1.4 D03 Auxiliary Manifold
8.1.4.1 Symptom: None of the Functions Work on the D03

Auxiliary Manifold
Diverter valve V43 is not in the Engage diverter valve to correct
correct position position.
357

The restricted orifice disc between Replace the restricted orifice in
the V45 Rotation displacement the “P” port as shown in the parts
control and the V16 Brake valve has manual.
been intentionally removed or lost
during repairs
8.1.5 PQ Chuck
8.1.5.1 Symptom: PQ Chuck Does not Open or Close

Lack of proper pressure to the A2 Adjust the V15 chuck pressure
chuck cylinder reducing/relieving valve 1450 PSI.
If the pressure cannot be adjusted,
remove and cap the chuck hoses.
If the pressure can now be properly
adjusted, it means the chuck seals
are damaged and need replacing. If
the pressure still cannot be adjusted
the valve is defective.
8.1.5.2 Symptom: PQ Chuck Slipping on Rods

Gas spring discharged, worn jaw A. Inspect gas springs and replace
carbide inserts or jaw ramp any that have discharged (cylinder
rod not exposed or less than 1”
extended).
B. Remove and clean chuck jaws and

inspect carbide inserts. If carbides
are worn flat replace the jaws.

Opening Chuck
2 or more adjacent gas springs Replace gas springs.
discharged
358
8.1.5.4 Symptom: PQ Chuck Noisy when Rotated Slowly in

the Open Position
Ball thrust bearing damaged or Replace ball thrust and snap ring.
retaining snap ring dislodged from Hand pack bearing with High
groove Temperature EP-02 grease before
installing, ref. #3543876.
8.1.5.5 Symptom: Rotation Speed Control V45 does not

Function
Lack of pressure to head motor Turn rotary multi-gauge to V45
speed control rotation displacement control
pressure position and adjust V45
rotation control clockwise to see if
pressure increases to 200 psi. Using
a hand-held tachometer check the
head speed to verify it is changing
from low to high speed while the
valve is adjusted. If the pressure does
not increase the valve is defective. If
the pressure increases but the head
does not speed up, tee in a pressure
gauge at the motor displacement
control to verify that the signal
pressure is at the motor control. If the
pressure is seen at the motor control
and the head does not speed up the
problem may be with the min/max
displacement screw settings on the
motor. See PQ Head section for more
info.
8.1.6 Rod Clamp
8.1.6.1 Symptom: Rod Clamp does not Open or Close

Properly
Lack of pressure to V13 rod clamp Adjust V18 pressure reducing/
open/close control valve to A3 rod relieving to 750-850 psi and check
clamp cylinder operation of the rod clamp.
Defective or improperly connected Connect couplers properly or replace
quick disconnect couplers worn or defective couplers. Replace
all seals if cylinder is bypassing.
359
8.1.6.2 Symptom: Rod Clamp Slipping while Making or

Breaking Rod Joints
Operational problem - driller does Always close the rod clamp on rods
not close the clamp on rods while suspended by the main line hoist
suspended by the main line cable cable first to seat the slips.
NOTE: If the clamp is closed on
rods held in the chuck the slips will
not seat properly in the tapered rod
clamp bowl.
Rod clamp jaws or carbide inserts Clean or replace rod clamp slips.
dirty or worn
Rod clamp bowl slips and adapters Clean and lubricate rod clamp.
extremely dirty and not lubricated
Rod clamp jaw retaining pins bent Replace pins.
Guide element slips or rod clamp Replace guide weldment slips of rod
bowl worn clamp bowl.
NOTE: An indication of worn rod
clamp components is indicated by
the guide weldment alignment forks
actually contacting the top of the rod
clamp bowl/side plates when the rod
clamp is closed on a rod.
8.1.6.3 Symptom: Head Opener Not Working

Lack of pressure to V11 head swing Check P3 pump pressure is at 2000
cylinder A4 psi. Ensure that if there is a rod
through the chuck it is disconnected
from the rod string before operating
the side shift control.
8.1.6.4 Symptom: Mud Mixer Not Working Properly

Lack of pressure from V10 mud mixer Defective or improperly connected
on/off control to mud mixer motor M6 quick disconnect couplers, connect
couplers properly or replace.
Improper adjustment of V24 mud Connect test gauge to mud mixer
mixer sequence valve test port. Adjust sequence valve to
1800 psi as per operation and service
manual.
Mud mixer motor defective Replace mud mixer motor.
Mud mixer flow control V23 defective Replace mud mixer control valve.
360
8.1.6.5 Symptom: Rod Make/Break Head Float Not Working

Properly
Lack of pressure from V28 head Adjust V28 head float reducing/
float reducing/relieving valve to allow relieving valve as per operation and
the head to float up and down while service manual.
making or breaking rod joints
Feed carriage too tight on mast rails Use a feeler gauge to check the
to allow the head to float freely clearance between the carriage
nylatron wear bars and mast rails.
The clearance between the wear bars
and mast rail should be a minimum
of 0.010 or 0.25 mm on each inside
rail. The clearance between the front
and rear wear bars and the mast rail
should be 0.005 or 0.13 mm. Add or
remove shims as necessary.
Defective V28 head float pressure Install a new V28 valve.
reducing valve
Defective head float pilot operated To troubleshoot, interchange PO
V27 check valve check valves from front to back of
valve body to see if one is defective.
Replace with new PO check valve if
necessary .
8.1.6.6 Symptom: Rod Make Up Torque Problems

V35 rotation torque limiting valve not Refer to the operation and service
properly adjusted or defective manual for pressure adjustments and
operating procedure.
V34 torque control solenoid defective Solenoid not being energized during
or not energized rod thread making or is defective.
Check voltage and replace solenoid if
defective.
8.1.6.7 Symptom: PQ Head Rotation Problems

Rotation speed incorrect in minimum Refer to Chapter 5 in the Operation
displacement mode and Service Manual for motor
displacement adjustment settings.
Rotation speed incorrect in maximum Refer to Chapter 5 in the Operation
displacement mode and Service Manual for motor
displacement adjustment settings.
361

Rotation speeds incorrect in either A. Travel limiting adjustment screws
one or both of minimum and on the Sauer Danfoss main valve
maximum displacement modes V44-05 are improperly adjusted and
limiting the travel of the control lever
thereby limiting the flow to the head
motor M1.
Insufficient oil flow/pressure from the A. Adjust the pump high pressure
primary pump P1 compensator and standby
compensator as per operation and
service manual.
NOTE: It may be necessary to
adjust the standby compensator
to a maximum of 300 psi to get full
performance of the pump under load.
B. To test the pump, disconnect the

hydraulic hoses on the rotation motor
M1 and install a flow meter. With
the engine at 2200 rpm the pump
should produce 42 to 45 gpm at zero
pressure and 38 to 40 gpm when
loaded to 4500 psi.
Lack of rotation torque or power to A. Insufficient oil flow from the
turn rods in the hole primary pump P1, to test the pump,
disconnect the hydraulic hoses on the
rotation motor M1 and install a flow
meter. With the engine at 2200 rpm
the pump should produce 42 to 45
gpm at zero pressure and 38 to 40
gpm when loaded to 4500 psi.
B. Oil bypassing main relief valve

V46 in main control valve, adjust per
instructions in Chapter 5.
C. Vibration in the drill hole causing

a higher than normal drilling torque
or pressure for the depth of the hole.
Reduce rotation speed, condition the
drill hole, or grease the rod string in
harder formations to reduce torque.
D. Misalignment between the drill

hole collar and the rotating rods will
quickly cause the torque to increase.
Ensure the drill is properly aligned
with the hole collar.
E. Problems with excessive force

being applied to the diamond bit can
also increase the drilling torque.
362

Rotation unit appears to be A. Rotation unit overfilled. Refer to
overheating operation and service manual for
proper fill level.
B. Head lube pump P6 defective,

check flow.
C. Gear box endplay out of tolerance.

Refer to Chapter 6 in the Operations
and Service Manual.
D. Possible defective or failed

bearings.
E. Head cooler is plugged.

Rotation unit noisy A. Vibration in the drill hole causing
excessive backlash in the gears.
Condition the drill hole as required or
apply rod grease to the rod string to
reduce rotational torque.
B. Lack of oil in the rotation unit will

make the head appear noisy.
C. Chuck thrust bearing or retaining

ring damage allowing the bearing to
come in contact with the retaining
chuck bowl. Replace bearing and/or
retaining ring.
D. Chuck spindle bolts have become

loose. Clean, apply blue locktite to
bolts, and retighten to torque spec in
the parts manual.
E. Damaged bearings in the rotation

unit gear box or transmission. Repair
as necessary.
Upper or lower spindle seal leaking A. Seals have been over greased,
remove grease fitting and run head
for several hours to see if leak stops.
Replace fitting.
B. Damaged seals or sealing rings,

replace seals and seal rings as
necessary.
Water in rotation unit gear box or lube A. Damaged spindle upper seals or
system sealing ring allowing water to leak
into the rogation unit when pulling the
inner tube. Replace seals and seal
ring as necessary.
363
8.1.6.8 Symptom: Mud Pump Problems

Abnormal pulsation in water high A. Rock particles or debris preventing
pressures holes and fluctuating water ball from sealing on valves, remove
pressure gauge valve covers on FMC water chamber
to remove debris.
B. Blocked, partially obstructed,

frozen, or loose-suction hose on mud
pump.
C. Accumulator for mud pump in

control panel is discharged, replace
or recharge to 480 psi.
Lack of water pump speed A. Speed limit adjusting screw
on water pump speed control, V7
incorrectly adjusted.
B. Insufficient oil flow/pressure from

the secondary pump P2,.adjust the
pump high pressure compensator
and standby compensator per
operation and service manual.
C. Insufficient oil flow from the

secondary pump P2, to test the
pump, disconnect the hydraulic
hoses at the water pump motor M4
and install a flow meter. With the
engine at 2200 rpm the pump should
produce18-20 gpm at zero pressure
and 18 to 19 gpm when loaded to
3000 psi.
Water pump motor M4 will not Defective, worn, or disconnected
operate quick disconnect couplers on water
pump hoses.
8.1.6.9 Symptom: Auxiliary Set Up Valve V40 Problems

All auxiliary valve V40 functions do Diverter valve V43 not shifted to
not work proper position, shift valve to correct
position and try functions.
One function such as mast raising or A. Check for damage, binding, or
levelling jack does not work obstructions to movement before
proceeding.
B. Defective pilot-operated relief

or counterbalance valve, replace
defective valve.
364

Set up functions, mast raising, mast A. Check for binding or obstructions
dump, levelling jacks, etc. lack to movement before proceeding.
sufficient power or force
Relief valve V47 in V40 auxiliary
valve adjusted improperly, adjust
relief valve to 2300 psi per operation
and service manual.
8.1.6.10 Symptom: Tramming Problems (Optional Track

Mounted Drill)
Tracks do not operate A. 12 volt solenoid V43 operated
diverter valve not shifting when
selected, or 3 position selector switch
on the track drive control box is not
switched to Tram Mode.
B. Faulty remote-mounted shuttle

valve, refer to the hydraulic schematic
for troubleshooting. Inspect for
contamination and replace if needed.
C. Identify a remote for frequency

problems.
HBC Remotes - locate serial tag
decal (battery compartment) and
identify serial number. For example:
727-xxxxxxx (the last seven numbers
identify the transmitter to the receiver
as the digits need to be squential
for a matching pair). FCC Certified
- Canada, US, Mexico and the
Philippines. CE Certified - South
America and overseas countries.
This certification reference would be
visible on the model/serial tags.
Tracks do not operate E. Ensure the radio transmitter
battery is fully charged.To activate
the transmitter you need to twist
and pull the e-stop button on the
transmitter, push twice on the
transmitter start button to get a
flashing green light and push again
once after that. Refer to Chapter 4 in
the Operations and Service Manual
for Operating the Track Drive Control.
365
8.1.7 Engine
8.1.7.1 Symptom: Engine Will Not Start From OCP

Engine monitor does not turn on and A. Check if Master switch is turned
engine will not crank when ignition on, also check for dirty battery
switch is turned to start position. connections or battery could be
discharged.
B. Check all 3 automotive type blade

fuses located in the Cummins engine
wiring harness near the engine
starter. Remove fuses, replace burnt
fuses and clean contacts if required.
C. Check 31 pin Cummins harness is

properly connected to Engine panel
and harness extension connection at
master disconnect panel (also check
31 pin connectors for corrosion).
D. Check power 12vdc at key switch.
E. Check ground at key switch.

Engine monitor turns on, Engine A. Check if Rotation control lever is
does not crank when ignition key in neutral position, check for faulty
switch is turned to start position neutral switch
B. Check battery voltage, should be

12 volts or higher.
C. Check battery connections to

starter.
D. Faulty Starter.
366

Engine monitor turns on, Engine A. Emergency stop switch or trip
cranks but does not start when cable activated.
ignition key switch is turned to start
position
B. Check cable connections to
estops, track drive panel (if equipped)
and Engine Control Panel are hand
tight.
C. Check Fuel Level.
D. Fuel system air lock, the engine

ran out of fuel and pulled air into fuel
system, or engine has been sitting
for some time. Check the fuel filter,
it must be full of fuel for engine to
start. Crack open (Bleed) fuel lines at
the fuel pump header. Re-prime fuel
system using hand priming pump and
retry.
E. Check Fuel Filter, water separator,

low outdoor temperature -20 Deg C -
gelled fuel.
F. Check engine monitor for

Cummins Fault Code, Contact
Cummins Dealer.
Engine starts but shuts down after a A. High hydraulic oil temperature
few seconds switch activated, or low hydraulic oil
level switch activated. Check cable
connections. Check switches.
Alarm or fault code appears on A. Refer to the engine monitor section
engine monitor screen in the Operations and Service for
fault code explanation.
B. Fault 157- Fuel Pressure/ Delivery

Signal Issue. This fault may occur
when an E-stop has been activated
and disrupts voltage to the fuel
solenoid. Check E-stops. For
example, the clothesline emergency
stop out of adjustment because of
cable stretch.
Electrically operated functions do not Refer to the electrical schematic
work in the parts manual. Check for the
simple things first - dirty or loose
connections, damaged connectors
or wires, burnt fuses, bad grounds,
discharged battery, etc.
367
8.1.8 Hydraulic Oil
8.1.8.1 Symptom: Hydraulic Oil Overheating

Oil bypassing over main relief valve Adjust V46 per operation and service
V46 located in V44 main control valve manual. Oil passing over the main
relief valve will heat up the oil quickly.
Oil cooler fan M5 not working or Relief valve V48 setting in cooler
turning slowly circulation pump P4 adjusted
incorrectly. Refer to the operation and
service manual to adjust the relief
valve to 172 bar.
Oil cooler C1 bypassing oil internally Internal relief valve in cooler is
defective. Check cooler inlet and
outlet with temperature gun to
determine if oil is circulating through
the cooler.
Oil cooler C1 blocked or dirty Clean the fins of the oil cooler using
environmentally-friendly soap and
rinse with low pressure water hose.
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.
8.2 Engine - Monitor Fault Codes (J1939)

SPN PM 1 Description
28 3 % ACCEL POS3 VOLT ABOVE NORM OR SHORT HIGH
28 4 % ACCEL POS3 VOLT BELOW NORM OR SHORT LOW
29 3 % ACCEL POS2 VOLT ABOVE NORM OR SHORT HIGH
29 4 % ACCEL POS2 VOLT BELOW NORM OR SHORT LOW
91 3 ACCEL PEDAL POS VOLT ABOVE NORM OR SHORT HIGH
91 4 ACCEL PEDAL POS VOLT BELOW NORMAL OR SHORT LOW
91 9 ACCEL PEDAL POS VOLT BELOW NORMAL OR SHORT LOW
91 14 ACCEL PEDAL POS THROTTLE SIG VOLT OUT OF RANGE
94 1 FUEL DELIVERY PRESSURE VERY LOW
94 3 FUEL RAIL PRESSURE VOLTAGE OUT OF RANGE HIGH
368
94 4 FUEL RAIL PRESSURE VOLTAGE OUT OF RANGE LOW
94 10 FUEL DELIVERY PRESSURE DROPPING TOO FAST
94 13 FUEL DELIVERY PRESSURE OUT OF CALIBRATION
94 16 FUEL DELIVERY PRESSURE HIGH
94 17 NO RAIL FUEL PRESSURE
94 18 FUEL DELIVERY PRESSURE LOW
97 0 WATER IN FUEL DETECTED
97 3 WATER IN FUEL INDICATOR VOLTAGE OUT OF RANGE HIGH
97 4 WATER IN FUEL INDICATOR VOLTAGE OUT OF RANGE LOW
100 1 ENGINE OIL PRESSURE LOW
100 3 ENGINE OIL PRESS VOLT ABOVE NORM OR SHORT HIGH SOURCE
100 4 ENGINE OIL PRESS VOLT BELOW NORM OR SHORT LOW SOURCE
100 16 ENGINE OIL PRESSURE READING INCORRECT
100 18 ENGINE OIL PRESS LOW
105 0 INTAKE MAN1 AIR TEMP HIGH
105 3 INTAKE MAN1 TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
105 4 INTAKE MAN1 TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
105 16 INTAKE MAN1 AIR TEMP HIGH
107 0 AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED
107 31 AIR FILT DIFF PRESS PLUGGED AIR FILTER DETECTED
110 0 ENG COOL TEMP HIGH
110 3 ENG COOL TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
110 4 ENG COOL TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
111 1 LOW COOLANT LEVEL
158 2 KEY SWITCH INTERMITTENT
158 17 KEY SWITCH CIRCUIT PROBLEM
174 0 FUEL TEMP HIGH
174 3 FUEL TEMP VOLT ABOVE NORM OR SHORT HIGH SOURCE
174 4 FUEL TEMP VOLT BELOW NORM OR SHORT LOW SOURCE
174 31 FUEL TEMP VOLT OUT OF RANGE
189 31 ENG SPEED DERATE CONDITION EXISTS DUE TO FAULT
190 0 ENGINE OVERSPEED
190 2 ENG SPD DATA ERRATIC, INTERMITTENT OR INCORRECT
190 3 ENG SPD VOLT ABOVE NORMAL OR SHORT HIGH
190 4 ENG SPD VOLT BELOW NORMAL OR SHORT LOW
190 5 ENG SPD CIRCUIT IS OPEN
369
190 16 ENGINE OVER SPEED
611 3 INJ WIRING SHORTED TO BATTERY
611 4 INJ WIRING SHORTED TO GROUND
620 3 SENSOR VOLT1 (+5VDC) ABOVE NORMAL OR SHORT HIGH
620 4 SENSOR VOLT1 (+5VDC) BELOW NORMAL OR SHORT LOW
627 1 POWER SUPPLY LOW VOLT TO INJECTORS
627 4 POW ER SUPPLY INTERRUPTION
629 13 REPROGRAM CONTROLLER ECU PROBLEM
629 19 ECU NOT RECEIVING MSG FROM PUMP
632 2 FUEL SHUTOFF VALVE ERR DETECTED
632 5 FUEL SHUTOFF VALVE NON-FUNCTIONAL
632 11 FUEL SHUTOFF VALVE SOLENOID CKT OPEN OR SHORTED
636 2 ENG POS SENSOR TIMING SIGNAL ERROR
637 2 TIMING (CRANK) SENSOR TIMING SIGNAL ERROR
639 13 CAN BUS FAILURE
651 5 INJ CYLINDER1 CURRENT LESS THAN EXPECTED
651 6 INJ CYLINDER1 CURRENT INCREASES TOO RAPIDLY
651 7 INJ CYLINDER1 FUEL FLOW LOWER THAN EXPECTED
676 3 GLOW PLUG RELAY STUCK ON
676 5 GLOW PLUG RELAY WILL NOT TURN ON
729 3 INLET AIR HEATER DRIVER1 STUCK ON
729 5 INLET AIR HEATER DRIVER1 WILL NOT TURN ON
370
833 2 RACK POSITION SENSOR ERROR
833 3 RACK POSITION SENSOR VOLT ABOVE NORMAL
833 4 RACK POSITION SENSOR VOLT BELOW NORMAL
834 2 RACK ACTUATOR ERROR BLEED AIR IN FUEL SYSTEM
834 3 RACK ACTUATOR CKT VOLT ABOVE NORMAL
834 5 RACK ACTUATOR CKT OPEN
834 6 RACK ACTUATOR CKT GROUNDED
834 7 RACK ACTUATOR POSITION ERROR
970 2 EXT AUX ENG SHUTDOWN SWITCH INTERMITTENT
970 11 EXT ENG PROTECTION SHUTDOWN ACTIVE
970 31 EXT AUX ENG SHUTDOWN SW ITCH ACTIVE
971 31 ENG DERATE SWITCH ACTIVATED
1041 2 START SIGNAL MISSING
1041 3 START SIGNAL ALWAYS ACTIVE
1076 0 FUEL INJ PUMP CONT VALVE ERROR
1077 7 FUEL INJ PUMP ERROR
1077 11 FUEL INJ PUMP CONT VP44 INPUT VOLT OUT OF RANGE
1077 12 FUEL INJ PUMP CONT VP44 SELF TEST ERROR
1077 19 FUEL INJ PUMP CONT VP44 DETECTED CAN BUS FAILURE
1077 31 FUEL INJ PUMP CONT POWER DERATED
1078 7 FUEL INJ PUMP SPD/POS SENSOR ERROR
1078 11 FUEL INJ PUMP SPD/POS SENSOR ERROR
1078 31 FUEL INJ PUMP SPD/POS VP44 UNABLE TO ACHIEVE TIMING
1079 3 SENSOR VOLT1 (+5VDC) ABOVE NORM OR SHORT HIGH
1079 4 SENSOR VOLT1 (+5VDC) BELOW NORM OR SHORT LOW
1080 3 SENSOR VOLT2 (+5VDC) ABOVE NORM OR SHORT HIGH
1080 4 SENSOR VOLT2 (+5VDC) BELOW NORM OR SHORT LOW
1109 31 ENG PROT SYSTEM APPROACHING SHUTDOWN
1110 31 ENG PROT SYSTEM SHUT ENG DOWN
1347 5 FUEL PUMP ASSY 1 CKT OPEN,SHORTED GROUND OR OVERLOAD
1347 7 FUEL PUMP ASSY 1 RAIL PRESSURE CONT MISMATCH
1347 10 FUEL PUMP ASSY 1 LOW FUEL FLOW
1348 5 FUEL PUMP ASSY 2 CKT OPEN,SHORTED GROUND OR OVERLOAD
1348 10 FUEL PUMP ASSY 2 LOW FUEL FLOW
371
1485 2 ECU MAIN RELAY PUMP POWER RELAY FAULT
1569 31 ENG PROT TORQ FUEL DERATE LIMIT CONDITION EXIST
2000 6 FUEL INJECTION PUMP CONT VALVE ERROR
2000 13 SECURITY VIOLATION PROPER CONT NOT INSTALLED
Table 8–1: Engine Fault Codes
372
A-1
A-2
A-3
A-4
A-5
A-6
Please refer to the following location for the LF230 Electrical

Schematics:
LF230 Electrical Schematic: #5003500
B-1
B-2
Contents
C.2 Technical Specifications........................................................................ C-3
C-1
C-2
C.3 Technical Specifications
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
C-11
C-12
C-13
C-14
Installation, Maintenance and Service
Manual
D-1
D-2
BRADEN
RW300A
INSTALLATION, MAINTENANCE AND SERVICE MANUAL
PACR WINCH DIVISION

P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
LIT2231 R1 PHONE (918) 251-8511 FAX (918) 259-1575
5/2005 Copyright 2005 PACCAR Winch Division.
Printed in U.S.A. All rights reserved. www.paccarwinch.com
D-3
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL SAFETY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WINCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
RECOMMENDED FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
WIRE ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
RECOMMENDED PLANETARY HOIST GEAR OIL . . . . . . . . . . . . . . . . . . . . .11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
DISASSEMBLY OF WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
BRAKE CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
BRAKE CLUTCH ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
PLANET CARRIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
WINCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
CROSS-SECTION DRAWING AND PARTS KEY . . . . . . . . . . . . . . . . . . . . . .26
METRIC CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
D-4
FOREWORD
Read this entire publication and retain it for future reference.
The minimum service intervals specified are for operating hours of the prime mover.
The following service instructions have been prepared to provide assembly, disassembly and maintenance infor-
mation for the Braden Model RW300A. It is suggested that before doing any work on this unit, all assembly and
disassembly instructions should be read and understood.
Some illustrations in this manual may show details or attachments that are different from your winch. Also, some
components have been removed for illustrative purposes.
Whenever a question arises regarding your winch or this manual, please contact the Braden Technical Support
Department via phone at (918)-251-8511, from 08:00 to 16:30 hours, CT, Monday through Friday, via fax at (918)-
259-1575, or via email at winch.service@paccar.com, for the latest available information.
Model Number
Serial Number OIL LEVEL
SIGHT GLASS
The winch serial number and model number are

stamped into a data plate located on the drum
bearing support end bracket. The serial number
is steel stamped into the top of the motor end
support plate. Always refer to the serial number
and model number when requesting information
or service parts.
VENT LOWERING PORT

SAE -12 ORB
(1 1/16-12 THRD)
EXPLANATION OF MODEL NUMBER
RW 300 A - 69 - V 086/050 - B S
WINCH MAX DESIGN GEAR PISTON MOTOR BRAKE OPTION
RATING MODEL RATIO MOTOR SIZE
RW REDUCER DRIVE / WINCH

300 DESIGNATES APPROXIMATE PEAK TORQUE X 1000 lb.-in.
A DESIGNATES DESIGN SERIES
69 DESIGNATES GEAR REDUCTION RATIO :1
V DESIGNATES PISTON MOTOR VARIABLE DISPLACEMENT
086/050 DESIGNATES MOTOR DISPLACEMENT IN CUBIC INCH/REVOLUTION; LOW RANGE/HIGH RANGE
B DESIGNATES UNIT EQUIPPED WITH INTERNAL BRAKE
S DESIGNATES SPECIAL
D-5
GENERAL SAFETY RECOMMENDATIONS

Safety and informational callouts used in this manual include:
CAUTION
WARNING – This emblem is used to warn against CAUTION – This emblem is used to warn against
hazards and unsafe practice which COULD result in potential or unsafe practices which COULD result in
severe personal injury or death if proper procedures personal injury and product or property damage if
are not followed. proper procedures are not followed.
Safety for operators and ground personnel is of prime concern. Always take the necessary precautions to ensure
safety to others as well as yourself. To ensure safety, the prime mover and winch must be operated with care and
concern by the operator for the equipment and a thorough knowledge of the machine’s performance capabilities.
The following recommendations are offered as a general safety guide. Local rules and regulations will also apply.
1. Be certain equipment (boom, mast, sheave blocks, 14. Keep hydraulic system clean and free from contam-
pendants, etc.) is either lowered to the ground or ination at all times.
blocked securely before servicing, adjusting, or 15. Use correct anchor method for wire rope and pock-
repairing winch. et in drum. Do not use knots to secure or attach
2. Be sure personnel are clear of work area BEFORE wire rope. For additional safety, ALWAYS maintain
operating winch. a minimum of five (5) wraps of wire rope on the
3. Read all warning and caution tag information provid- drum.
ed for safe operation and service of winch. 16. Never attempt to clean, oil or perform any mainte-
4. Inspect rigging and winch at the beginning of each nance on a machine with the engine or prime mover
work shift. Defects should be corrected immediately. running, unless instructed to do so in this manual.
5. Keep equipment in good operating condition. 17. Never operate winch controls unless you are prop-
Perform scheduled servicing and adjustments listed erly positioned at the operators station and you are
in the “Preventive Maintenance” section of this man- sure personnel are clear of the work area.
ual. 18. Assure that personnel who are responsible for hand
6. An equipment warm-up procedure is recommended signals are clearly visible and that the signals to be
for all start-ups and essential at ambient tempera- used are thoroughly understood by everyone.
tures below +40°F (4°C). Refer to “Warm-up 19. Ground personnel should stay in view of the opera-
Procedure” listed in the “Preventive Maintenance” tor and clear of winch drum. Do not allow ground
section of this manual. personnel near winch line under tension.
7. Operate winch line speeds to match job conditions. 20. Do not exceed the maximum pressure, PSI (kPa), or
8. Leather gloves should be used when handling wire flow, GPM (LPM), stated in the winch specifications.
rope. 21. Install guarding to prevent personnel from getting
9. Never attempt to handle wire rope when the hook any part of body or clothing caught at a point where
end is not free. Keep all parts of body and clothing the cable is wrapped onto the drum or drawn
clear of cable rollers, cable entry area of fairleads, through guide rollers.
sheaves and winch drum. 22. “Deadman” controls, which automatically shut off
10. When winding wire rope on the winch drum, never power to the winch whenever the operator leaves
attempt to maintain tension by allowing wire rope to his station, should be installed whenever practica-
slip through hands. Always use “Hand-Over-Hand” ble.
technique. 23. Never allow anyone to stand under a suspended
11. Never use wire rope with broken strands. Replace load.
wire rope. 24. Avoid sudden “shock” loads or attempting to “jerk”
12. Do not weld on any part of the winch. load free. This type of operation may cause heavy
loads, in excess of rated capacity, which may result
13. Use recommended hydraulic oil and gear lubricant. in failure of cable and winch.
D-6
THEORY OF OPERATION
DESCRIPTION OF WINCH The static brake system has three operating compo-
The winch has four basic component parts: nents:
1. Winch base 1. Spring Applied, Multiple Friction Disc Static Brake
2. Hydraulic motor and brake valve 2. Brake Clutch Assembly
3. Brake cylinder and motor support 3. Hydraulic Piston and Cylinder
4. Drum assembly Figure 2
The drum assembly consists of four basic assemblies:
1. Drum with integral ring gear Static Motor
2. Output planetary gear set Brake
3. Secondary planetary gear set
4. Primary planetary gear set To
Brake
The hydraulic motor is bolted to the brake cylinder and Tank
Valve
the base. The motor end of the drum, running on dual
tapered bearings, is supported by the brake cylinder.
The other end of the drum runs on a spherical bearing Pump
on the support bolted to the base. The ring gear for the
planetary sets is machined into the drum’s inside sur-
face.
Control
WINCH OPERATION Valve
The hydraulic motor drives the sun gear of the primary Low Pressure Medium Pressure High Pressure
planetary gear set through the splined inner race of the
brake clutch. When driven by the sun gear, the primary
planet gears walk around the ring gear in the drum and Figure 3
drive the primary planet carrier. Static Motor
Brake
The primary planet carrier drives the secondary sun
gear. The secondary planet gears drive the secondary
planet carrier, which drives the output sun gear. The To
Brake Tank
output planet carrier is splined to the brake cylinder and Valve
cannot rotate. Therefore, as the output planet gears are
driven by the sun gear, they will drive the ring
gear/drum. Pump
DUAL BRAKE SYSTEM – DESCRIPTION

The dual brake system consists of a dynamic brake sys- Control
tem and a static brake system. Valve
The dynamic brake system has two operating compo- Low Pressure Medium Pressure High Pressure
nents:
1. Brake valve assembly
Figure 4
2. Hydraulic motor
The brake valve is basically a counterbalance valve. It Static Motor
contains a check valve to allow free flow of oil to the Brake
motor in the hoisting direction and a pilot operated,
spring-loaded spool valve that blocks the flow of oil out
To
of the motor when the control valve is placed in neutral. Brake
Tank
When the control valve is placed in the lowering posi- Valve
tion, the spool valve remains closed until sufficient pilot
pressure is applied to the end of the spool to shift it
against spring pressure and open a passage. After the Pump
spool valve cracks open, the pilot pressure becomes
flow-dependent and modulates the spool valve opening
which controls the lowering speed. Control
Valve
Figures 2, 3 & 4 show a simplified version of the brake
valve for illustrative purposes. Low Pressure Medium Pressure High Pressure
D-7
The static brake is released by the brake valve pilot Figure 5 Static Friction Brake Applied
pressure at a pressure lower than that required to open
the pilot operated spool valve. This sequence assures
that dynamic braking takes place in the brake valve and Sprag
that little, if any, heat is absorbed by the friction brake. Cams
The friction brake is a load holding brake only and has

nothing to do with dynamic braking or rate of descent of
a load.
Hoisting
The brake clutch is splined to the primary sun gear shaft
between the motor and the primary sun gear. It will
allow this shaft to turn freely in the direction to raise a
load and lock up to force the brake discs to turn with the
shaft in the direction to lower a load. Figures 5 and 6.
The hydraulic cylinder, when pressurized, will release Permits free

the spring pressure on the brake discs, allowing the shaft rotation
brake discs to turn freely. while hoisting
DUAL BRAKE SYSTEM – OPERATION

When hoisting a load, the brake clutch which connects Figure 6
the motor shaft to the primary sun gear, allows free rota- Static Friction Brake Applied
tion. The sprag cams lay over and permit the inner race
Sprag
to turn free of the outer race. Figure 5. The friction brake
Cams
remains fully engaged. The winch, in raising a load, is
not affected by any braking action. Figure 2.
When the lifting operation is stopped, the load attempts

to turn the primary sun gear in the opposite direction.
This reversed input causes the sprag cams to instantly
roll upward and firmly lock the shaft to the fully engaged Stopped,
friction brake. Figure 6. Holding
Load
When the winch is powered in reverse, to lower the
load, the motor cannot rotate until sufficient pilot pres-
sure is present to open the brake valve. Figures 3 & 4.
The friction brake within the winch will completely
release at a pressure lower than that required to open
the brake valve. The extent to which the brake valve
opens will determine the amount of oil that can flow
through it and the speed at which the load will be low- Load attempts to rotate shaft in opposite direction.
ered. Increasing the flow of oil to the winch motor will Brake clutch locks sun gear shaft to friction brake.
cause the pressure to rise and the opening in the brake
valve to enlarge, speeding up the descent of the load.
Decreasing this flow causes the pressure to lower and
the opening in the brake valve to decrease thus slowing
the descent of the load.
When the control valve is shifted to neutral, the pres-

sure will drop and the brake valve will close, stopping
the load. The friction brake will engage and hold the
load after the brake valve has closed.
The friction brake receives very little wear in the lower-

ing operation. All of the heat generated by the lowering
and stopping of a load is absorbed by the hydraulic oil
where it can be readily dissipated.
D-8
WINCH INSTALLATION
WINCH ASSEMBLY
W/BRAKE VALVE
& STATIC BRAKE
BRAKE
VALVE
WINCH BRAKE
BR
19° 19°
CASE
DRAIN
CONTROL
VALVE
1. The winch must be mounted with the centerline of
the drum in a horizontal position. Due to the design
of the winch base group, the cable departure angle
must only be in the shaded area as shown. When
PUMP
mounting the winch, use all four mounting holes with
1.25 in. grade 8 capscrews, hardened washers and
nuts tightened to recommended torque.
2. The winch must be mounted to a flat, rigid surface

that will not flex when the winch is in use, causing 6. The winch directional control valve must be a three
binding in the gear train. Binding in the winch gear position, four way valve with a motor spool such that
train will result in accelerated wear of internal com- when the valve is in the center position, both work
ponents, reduced hoisting capacity and heat. If nec- ports are open to tank (often called open center,
essary, use shim stock under the winch mounting open port).
pads to ensure the surface is flat within 0.020 in. (0.5
mm). 7. High quality hydraulic oil is essential for satisfactory
performance and long hydraulic component life.
3. The vent plug, installed in the brake cylinder, must Make certain the hydraulic oil used is the proper vis-
always be located above the horizontal centerline. If cosity for your starting ambient temperature.
the winch is mounted on a pivoting surface, be sure Typically, the maximum cold weather start-up viscos-
the vent plug remains above centerline. ity should not exceed 5000 SUS with a pour point
20°F (11°C) lower than the minimum anticipated
4. Hydraulic lines and components that operate the temperature.
winch should be of sufficient size to assure minimum Under continuous operating conditions, the oil tem-
back pressure at the winch. The motor must be perature should not exceed 180°F (82°C). Optimum
externally drained directly to the reservoir to avoid oil temperature is 120-140°F (49-60°C). Unless oth-
motor shaft seal failure. erwise specified by the vehicle manufacturer, the
hydraulic oil filter should have a 10 micron rating.
a
b
First sheave
or load
5. The winch must be mounted perpendicular to an

imaginary line from the center of the winch to the first
sheave to ensure even spooling. Make certain the
fleet angle is between ½ and 1 ½ degrees.
D-9
SPECIFICATIONS
Unit weight without wire rope, approximate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1370 lb. (621 kg)
Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69:1
Cable Drum Dimensions:

Barrel Diameter 15.25 in. (387 mm)
Flange Diameter 20.0 in. (508 mm)
Barrel Length 13.5 in. (343 mm)
Cable Storage Capacity

Layer 1 2
7/8 in. (22 mm) 65 ft. (19.8 m) 137 ft. (41.8 m)
Gear Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 pints (7.1 liters)
RECOMMENDED FASTENER TORQUE
Higher and lower torque values for special applications will be specified; such as the use of spanner nuts, nuts
on shaft ends, jam nuts and where distortion of parts or gaskets is critical.
Lubricated torque values based on use of SAE 30wt engine oil applied to threads and face of bolt or nut.
Avoid using thread lubricants as the applied torque may vary by 10-40% depending upon product used.
Q
Torque (LB-FT) Torque (LB-FT)
Bolt Dia. Thds Per Grade 5 Grade 8 Bolt Dia. Thds Per Grade 5 Grade 8
Inches Inch Dry Lubed Dry Lubed Inches Inch Dry Lubed Dry Lubed
20 10
1/4 8 6 12 9 3/4 265 200 380 280
28 16
18 9
5/16 17 13 24 18 7/8 420 325 600 450
24 14
16 8
3/8 31 23 45 35 1 640 485 910 680
24 14
14 7
7/16 50 35 70 50 1 1/8 790 590 1290 970
20 12
13 7
1/2 75 55 110 80 1 1/4 1120 835 1820 1360
20 12
12 6
9/16 110 80 150 110 1 3/8 1460 1095 2385 1790
18 12
11 6
5/8 150 115 210 160 1 1/2 1940 1460 3160 2370
18 12
To convert lb. ft. to kg-m, multiply lb. ft. value by 0.1383.
D-10
WIRE ROPE INSTALLATION

Prepare the end of the wire rope as recommended by
the wire rope manufacturer. Insert the free end of the
wire rope through the opening in the drum flange. Push
the wire rope into the anchor pocket until the end of the The clamp plate wire rope anchor system is not capa-
wire rope is even with the outer edge of the pocket. ble of supporting the rated load. Always MAINTAIN a
Install the clamp plate onto the drum flange with the thin minimum of five wraps of wire rope on the cable
end of the clamp wedge toward the dead end of the wire drum. If the wire rope is fully reeled out, the wire rope
rope. Apply a light load of approximately 500 lb. (227 may slip out of the drum causing a loss of load con-
kg) to the wire rope as the new wire rope is wound onto trol which may result in property damage, injury or
the cable drum. death. We suggest that the last 5-6 wraps of wire
rope be painted bright red to serve as a visual warn-
The anchor system is designed for use only with 7/8 in. ing.
(22mm) wire rope.
D-11
PREVENTIVE MAINTENANCE
A regular program of preventive maintenance for your Inspection procedures for hoists are divided into five
planetary hoist is strongly recommended to minimize general categories based upon the hoist usage or duty
the need for emergency servicing and promote safe, cycle, which in turn determines different, appropriate
reliable hoist operation. The user of Braden products is intervals for inspections. The usage categories must be
responsible for hoist inspection, testing and mainte- assigned by the hoist user/owner on a consistent unit-
nance with frequency dependent upon the severity of by-unit basis. The five hoist usage categories are as fol-
the hoist duty cycle and thoroughness of the preventive lows:
maintenance program in effect.
Idled: - The hoist has not been used for three months.
Infrequent Usage - The hoist is used less than ten
hours per month based on a three month average.
Any time a hoist exhibits erratic operation and/or Moderate Usage - Hoist used 10-50 hours per month
unusual noise, the hoist must be taken out of service based on a three month average.
until it is inspected and serviced by a qualified techni- Heavy Usage - Hoist used 50-200 hours per month.
cian. Continued operation of a hoist with a defect in a Severe Duty - Hoist is operated more than 200 hours
critical component may lead to loss of load control, per month OR where 50% of the lifts exceed 75% of the
property damage, injury or death. Braden rated capacity for the hoist.
A record of written, dated and signed inspections, load
The following chart lists the inspections that are
tests, maintenance and repairs or modifications must be
required for each type of usage category.
kept readily available in an appropriate location for a
minimum of five years.
INSPECTION
PRE-USE SEMI-ANNUAL ANNUAL TEAR-DOWN
DAILY INSPECTION INSPECTION INSPECTION
USAGE INSPECTION
CATEGORY
REQUIRED IF
IDLED REQUIRED REQUIRED MAINTENANCE
Not used for BEFORE PLACED BEFORE PLACED -- & REPAIR
3 months IN SERVICE IN SERVICE HISTORY
UNKNOWN
5 YEARS
INFREQUENT 3 YEARS IF NOT
USAGE REQUIRED REQUIRED REQUIRED SUBJECT TO
less than ten hours FULL INSPECTION
per month PROGRAM
4 YEARS
MODERATE 2 YEARS IF NOT
USAGE REQUIRED REQUIRED REQUIRED SUBJECT TO
10-50 hours per FULL INSPECTION
month PROGRAM
3 YEARS
HEAVY USAGE 1.5 YEARS IF NOT
50-200 hours per
REQUIRED
REQUIRED REQUIRED SUBJECT TO
month SEMI-ANNUALLY
FULL INSPECTION
(6 months)
PROGRAM
SEVERE USAGE
200+ hours per month REQUIRED REQUIRED 1 YEAR
REQUIRED
or 50% of lifts exceed QUARTERLY SEMI-ANNUALLY
75% rated capacity (3 months) (6 months)
D-12
Pre-Use or Daily Inspection: Semi-Annual Inspection

Must include but is not limited to the following inspec- (every six months):
tions that will be performed prior to placing the hoist into Must include but is not limited to the following inspec-
service and then as necessary during extended operations performed by a qualified technician.
tion. This inspection must be performed by a qualified
technician. 1. Perform the Pre-Use inspection.
HOIST
2. Take a lubricant sample as described later in this
section and analyze it for wear metals content, cor-
rect viscosity, lubricant deterioration, moisture and
other contaminants. If the oil sample contains a high
OIL FILL & DRAIN
SAE -8 ORB
CABLE POCKET AND amount of metallic particles, the hoist must be taken
ANCHOR TO ACCEPT
(3/4-16 THRD) 7/8 WIRE ROPE out of service to undergo a tear-down inspection.
Note: Oil analysis cannot detect nor warn against a
fatigue failure.
OIL FILL
OIL FILL/DRAIN
ACCESS
MODEL NO.
SERIAL NO.
3. Perform a brake test as described later in this sec-
ACCESS HOLE
HOLE
tion.
4. Inspect/tighten all hoist mounting fasteners to rec-

1. Check for external oil leaks and repair as necessary. ommended torque.
This is extremely important due to the accelerated
wear that will result from insufficient lubricating oil in 5. Service the hydraulic system oil and filters as recom-
the hoist. Check the oil level monthly if no external mended by the vehicle manufacturer.
oil leaks are detected.
Annual Inspection:
2. Check the hydraulic fittings and hoses for leaks,
chaffing, deterioration or excessive corrosion and Must include but not limited to the following inspections
repair as required. that must be performed by a qualified technician.
3. Visually inspect for corroded, loose or missing fas- 1. Perform the Pre-Use and Semi-Annual inspections.
teners and tighten or replace as required.
2. Change hoist gear cavity lubricating oil after an oil
4. Inspect the entire length of wire rope and rigging as sample has been taken as described later in this
recommended by the wire rope and rigging manu- section. Refill the hoist to the proper level with rec-
facturer. ommended lubricant. Refer to "Recommended
Planetary Hoist Gear Oil" later in this section for
5. Inspect all safety devices such as anti-two-blocking more information.
switches and limit switches and repair as required.
On new hoists, change gear oil after the first 50
6. A warm-up procedure is recommended at each start- operating hours then every 500-1000 operating
up and is essential at ambient temperatures below hours or annually depending upon hoist usage as
40°F (4°C). The engine should be run at low RPM shown on Page 9.
with the hoist control valve in neutral allowing suffi-
cient time to warm up the hydraulic system. The
hoist should then be operated without a load, at low
speeds, raise then lower several times to prime all
lines with warm hydraulic oil and to circulate gear
lubricant through the planetary gear train.
Failure to properly warm up the hoist, particularly

under low ambient conditions, may result in tempo-
rary brake slippage due to thick gear oil in the brake
clutch assembly or hydraulic system back-pressure
attempting to release the brake, which could result in
property damage, injury or death.
10
D-13
Oil change instructions: 1. The fill/drain plug is located on the end of the drum
flange, away from the motor. Rotate drum barrel to
place the fill/drain plug at the bottom, 6 o'clock posi-
Oil Fill/Drain Plug tion. Remove the plug and capture the gear oil in a
suitable container. Recycle or dispose of used oil in
an environmentally responsible manner. While the
oil is draining, collect oil from mid-stream for oil
analysis.
2. Rotate drum to place the drain/fill plug at the 3

o'clock position. Fill winch to the level plug with rec-
ommended oil. Oil fill capacity is 15 pints (7.1 liters).
Install plug securely after refilling gear cavity.
3. Remove the vent relief plug located in the brake

cylinder above the motor. Clean the vent relief plug
in solvent and reinstall. Do not paint over the plug.
Drum seal leaks will result if the relief vent hole is
restricted.
RECOMMENDED PLANETARY HOIST GEAR OIL
Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slip-
page which could result in property damage, severe personal injury or death. Some gear lubricants contain large
amounts of EP (extreme pressure) and anti-friction additives which may contribute to brake clutch slippage or
damage to brake friction discs or seals. Oil viscosity with regard to ambient temperature is also critical to reliable
brake clutch operation. Our tests indicate that excessively heavy or thick gear oil may contribute to intermittent
brake clutch slippage. Make certain that the gear oil viscosity used in your hoist is correct for your prevailing
ambient temperature.
PREVAILING AMBIENT TEMPERATURE

oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF
EXXON SPARTAN EP220 OR EQUIVALENT
AGMA 5 EP, ISO VG 220
EXXON SPARTAN EP150 OR EQUIVALENT

AGMA 4 EP, ISO VG 150
MOBILGEAR SHC 150 or 220

SYNTHETIC OR EQUIVALENT
oC -40 -30 -20 -10 0 10 20 30 40 50 oC
i
NOTE: SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE
CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.
Texaco Meropa 150, previously used as factory fill, may no longer be widely available due to current market conditions. As of
mid-year 2002, planetary hoists are factory filled with Exxon Spartan EP150, or equivalent. The chart below relates the Texaco
products to 4 currently available oils. Consult your oil supplier for other equivalent oils if required.
Texaco Exxon Mobil Shell Chevron

Meropa 150 Spartan EP 150 Mobilgear 629 Omala 150 Gear Compounds EP 150
Meropa 220 Spartan EP 220 Mobilgear 630 Omala 220 Gear Compounds EP 220
9/2002
11
D-14
SPECIAL TOOLS
2 each ½-13NC eye bolt
2 each ¾-10NC eye bolt:
NOTE: The first two items below are required only if NOTE: If a press is available (with at least 5
the motor support is separated from the ring inches of travel), only part (A) shown
gear. The other tools are required to service below is required (center hole not
the brake assembly. required). If a press is not available,
all parts shown and listed below are
3 each 7/8 - 9NC x 6 inch long capscrews required.
A ratcheting internal snap ring pliers capable 1 each 1 - 8 NC threaded rod, 14 inches long
of handling an N5000 700 snap ring. 1 each 1 - 8 NC nuts
1 each 1 inch plain washer
All units use a single coil spring to apply the
internal brake. The following spring compres-
sor must be fabricated and is strongly recom-
mended.
6.00
2.00 5.37
0.50 1.06
2.00
1.06
0.38
0.75
9.50
1.00
2.00 WELD
14.00
8.50
10.00
0.75
4.00 WELD
12
D-15
TROUBLESHOOTING
If a hoist ever exhibits any sign of erratic operation, or load control difficulties (load creeping down or chatter-
ing) appropriate troubleshooting tests and repairs must be performed immediately. Continued operation of a
hoist with a defect may result in property damage, injury or death.
TROUBLE PROBABLE CAUSE REMEDY

A
The hoist will not lower the 1. The problem could be a plugged internal Remove the counter-balance cartridge from
load or not lower the load orifice or leaking cartridge body seal ring the valve body and inspect condition of body
smoothly. on the counter-balance valve. If a small seal rings. Disassemble valve body and flush
piece of contamination entered the count- with clean solvent to remove contamination.
er-balance (CB) valve cartridge, it may be Assemble valve using new seal rings on CB
restricting the hydraulic signal to open the valve cartridge. Install an accurate 0-1000
valve. The pressure may be going too high PSI (0-6900 kPa) test gauge in the brake
or the smooth action of the CB valve may release hose. With no load on the hoist, slow-
be impaired. ly move the control lever into the lowering
position and record the pressure when the
If the cartridge body seals are leaking, the drum begins to turn in the lowering direction.
pilot signal pressure may be lost or the oil The static brake will release at approximate-
flow that the CB valve is modulating is ly 300 PSI (2070 kPa) and the CB valve
able to return to tank without the proper should open at approximately 1050 PSI
control allowing the load to lower too early (7240 kPa).
or too quickly.
2. The friction brake may not be releasing as Check brake cylinder seal as follows:
a result of a defective brake cylinder seal.
A. Disconnect the swivel tee from the brake
NOTE: If the brake cylinder seal is defec- release port. Connect a hand pump with
tive you will usually find oil leaking from the accurate 0-2000 psi gauge and shut-off valve
winch vent plug. to the –4 J.I.C. fitting in the brake release port.
B. Apply 1000 psi to the brake. Close shut-off

valve and let stand for five (5) minutes.
C. If there is any loss of pressure in five (5)

minutes, the brake cylinder should be disas-
sembled for inspection of the sealing surfaces
and replacement of the seals. Refer to “Motor
Support-Brake Cylinder Service”.
3. Friction brake will not release as a result of Disassemble brake to inspect brake discs.
damaged brake discs. Check stack-up height as described in “Motor
Support-Brake Cylinder Service”.
B
Oil leaks from vent plug. 1. Same as A2. Same as A2.
2. Motor seal may be defective as a result Motor case drain back pressure must not
of high back pressure or contaminated exceed 40 psi (275 kPa). Inspect hydraulic
oil. system for a restriction in the return line to
the reservoir. Be sure plumbing is properly
sized to winch motor.
Oil analysis may indicate contamination has

worn motor shaft and seal. Thoroughly flush
entire hydraulic system and install new filters
and oil. Install new motor seal.
13
D-16

C
The brake will not hold a 1. Excessive system back pressure acting on System back-pressure must not exceed 100
load with the control lever the brake release port. psi (690 kPa). Inspect hydraulic system for
in neutral. restriction in the circuit from the motor to the
reservoir.
2. Friction brake will not hold due to worn or Same as Remedy 3 of Trouble A3.
damaged brake discs.
3. Brake clutch is slipping. Improper planetary gear oil may cause the
brake clutch to slip. Drain old gear oil and
flush winch with solvent. Thoroughly drain
solvent and refill winch with recommended
planetary gear oil listed in “Preventive
Maintenance”.
Brake clutch may be damaged or worn.

Disassemble and inspect brake clutch as
described in “Brake Clutch Service”.
D
The winch will not hoist the 1. The winch may be mounted on an uneven Reinforce mounting surface.
rated load. or flexible surface which causes distortion
of the winch base and binding of the gear If necessary, use shim stock to level winch.
train. Binding in the gear train will absorb Refer to “Winch Installation”.
horsepower needed to hoist the rated load
and cause heat. First loosen, then evenly retighten all winch
mounting bolts to recommended torque.
2. System relief valve may be set too low. Check relief pressure as follows:
Relief valve needs adjustment or repair.
A. Install an accurate gauge into the inlet
port of the brake valve.
B. Apply a stall pull load on the winch while

monitoring pressure.
C. Compare gauge reading to winch specifi-

cations. Adjust relief valve as required.
NOTE: If pressure does not increase in pro-

portion to adjustment, relief valve may be
contaminated or worn out. In either case, the
relief valve may require disassembly or
replacement.
3. Be certain hydraulic system temperature Same as remedies for Trouble D1 & D2.
is not more than 180°F (82°C). Excessive
hydraulic oil temperatures increase motor Same as remedies for Trouble E2.
and pump internal leakage and reduce
performance.
4. Winch line pull rating is based on 1st layer Refer to winch performance charts for addi-
of wire rope. tional information.
5. Rigging and sheaves not operating effi- Perform rigging service as recommended by
ciently. rig manufacturer.
14
D-17

E
The winch runs hot. 1. Same as D1. Same as remedies for Trouble D1.
2. Be certain that the hydraulic system tem-

perature is not more than 180°F (82°C).
Excessive hydraulic oil temperatures may
be caused by:
A. Plugged heat exchanger. Thoroughly clean exterior and flush interior.
B. Too low or too high oil level in hydraulic Fill/drain to proper level.
reservoir.
C. Same as D2. Same as remedies for Trouble D2.
D. Hydraulic pump not operating efficiently. Engine low on horsepower or R.P.M.

Tune/adjust prime mover.
Check suction line for damage.
Pump worn. Replace pump.
3. Excessively worn or damaged internal Disassemble winch to inspect/replace worn

winch parts. parts.
F
Winch “chatters” while 1. Same as D2. Same as remedies for Trouble D2.
raising rated load. 2. Hydraulic oil flow to motor may be too low. Same as remedies for Trouble E2.
3. Controls being operated too quickly. Conduct operator training as required.
G
The wire rope does not 1. The winch may be mounted too close to Check mounting distance and fleet angle.
spool smoothly on the the main sheave, causing the fleet angle Reposition winch as required.
drum. to be more than 1-1/2 degrees.
2. The winch may not be mounted perpendi- Refer to “Winch Installation”.

cular to an imaginary line between the
center of the cable drum and the first
sheave.
3. Could possibly be using the wrong lay Consult wire rope manufacturer for recom-
rope. There is a distinct advantage in mendation of wire rope that best suits your
applying rope of the proper direction of lay. application.
When the load is slacked off, the several
coils on the drum will stay closer together
and maintain an even layer. If rope of
improper lay is used, the coils will spread
apart each time the load is removed.
Then, when winding is resumed, the rope
has a tendency to criss-cross and overlap
on the drum. The result is apt to be a flat-
tened and crushed rope.
4. The winch may have been overloaded, Replace wire rope and conduct operator/rig-
causing permanent set in the wire rope. ger training as required.
15
D-18
DISASSEMBLY OF WINCH
See cross-section illustration on page 26 and parts key 6. Remove the brake release hose adapter from the
for reference. brake release port to prevent damage. Remove the
motor pilot adapter (40) from the brake cylinder.
1. Remove the wire rope from the cable drum and
rotate the drum until the fill/drain plug is at the bot- 7. With a suitable hoist, turn the hoist over with the
tom, six o'clock position. Remove the drain plug and motor end down. Remove the capscrews and lock-
capture the gear oil in a suitable container. Recycle washers (99,100) that retain the tie-plates (101) to
or dispose of used oil in an environmentally respon- the end-brackets (96, 97). Remove the drum bear-
sible manner. Install the drain plug. ing support and end-bracket assembly from the
cable drum.
2. Label the hydraulic hoses as they are removed from
the hoist motor. Install plugs in the open hoses and 8. Remove the 16 socket head capscrews and lock-
motor ports to reduce entrainment of dirt in the open washers (12, 13) from the drum flange end (5). With
port. a plastic face mallet, unseat the drum flange end (5)
from the drum ring gear (60). Remove the drum
flange end from the drum ring gear.
CAUTION
The RW300 hoist weighs approximately 1370 lbs.
(621 kg). Use adequate lifting equipment.
3. Remove the hoist mounting fasteners and lift the

hoist from the mount. Begin disassembly by placing
the hoist on a stable work surface with the motor
end facing up. Secure the hoist in this position to
prevent it from falling and causing injury.
4. Remove the hose that connects the brake valve to

the brake release port. Remove the fasteners secur-
ing the motor to the brake cylinder assembly. Lift the
motor straight up to disengage the motor shaft from 9. Remove the primary sun gear (2) from the primary
the brake clutch assembly. planet carrier assembly (71).
5. Remove the brake clutch assembly/brake hub (42)

from the brake cylinder. The input sun gear (2) can
not be removed at this time. 10. Remove the primary planet carrier (71) and second-
ary sun gear assembly from the drum ring gear. If
the thrust washer (70) between the primary and
DO NOT attempt to remove the large retaining ring secondary planet carriers stayed on the secondary
at this time. It is holding the static brake spring in planet carrier, remove it and set it aside with the pri-
compression. Removing this retaining ring at this mary planet carrier.
time could result in property damage, personal injury
or death.
16
D-19
11. Remove the secondary planet carrier assembly (68) 14. Remove the twelve capscrews and lockwashers
from the drum ring gear. The output sun gear (64) (82, 83) that secure the motor end-bracket (96) to
will come out with the secondary sun gear. If the the brake cylinder (34). Install three 7/8 - 9 jack-
thrust washer (66) stayed on the output planet car- screws, 6 inches long, evenly spaced into the end-
rier remove it and set aside with the secondary plan- bracket mounting bolt holes. Apply general purpose
et carrier. grease to the threads to reduce friction. Evenly
tighten the jack-screws against the drum ring gear
flange to push the brake cylinder out of the drum
ring gear and separate the bearings. When the two
pieces have separated, you will hear the bearing
cone drop off the brake cylinder journal onto the pile
of shop towels.
15. Install two ¾ - 10 eye bolts into the brake cylinder

motor mounting holes and lift the brake cylinder out
of the drum ring gear. Be very careful to avoid dam-
aging the drum seals. One half of the lapped metal
surface seal is installed on the brake cylinder; the
other half is on the drum ring gear. This seal is very
durable and will last many years and may often be
reused if the mating surfaces are still smooth with
12. Install two ½-13 thread eyebolts into the two tapped no scoring.
holes in the output planet carrier (63). The output
planet carrier weighs approximately 125 lb. (57 kg). 16. Inspect the ring gear teeth for pitting and wear. If the
With a hoist, lift the output planet carrier out of the wear is greater than .015 in. (.4 mm) when com-
drum ring gear. pared to the unworn area of teeth, the ring gear
should be replaced. Inspect the thrust washers for
13. Use a long pry bar or chisel to separate the ends of scoring and wear. Replace the thrust washers if
the split ring (65) then remove both halves from the scoring appears excessive.
brake cylinder. The bearing cone (57) is a snug fit
on the brake cylinder and will have to be pressed
off. Place a stack of shop towels onto the work
bench to provide padding when the bearing drops
off of the brake cylinder. Turn the drum ring gear
assembly over with the motor end up and centered
over the stack of shop towels.
17
D-20
BRAKE CYLINDER SERVICE

Fabricate the spring compressor tool as illustrated in
the “Tools” section of this manual.
DISASSEMBLY
4. Remove the brake piston (59). Remove and discard

both sets of piston O-rings and backup rings (27, 28,
30, 31).
1. Install the spring compressor tool as show. If a

hydraulic press is available, only part "A" of the tool
is required. Tighten the nut above part "A" or apply
hydraulic pressure to slightly compress the spring
and relieve load on the retaining ring (53). Carefully
remove the retaining ring.
5. Turn the assembly over to access the brake plates.

Remove the retaining ring (62). Remove the spacer
plate (61), steel separator discs and friction discs
(25, 26).
Thoroughly clean and inspect all parts, paying close

attention to the sealing surfaces of the brake piston.
Place each friction disc on a flat surface and check
2. Slowly and carefully unscrew the nut above part "A" for distortion with a straight edge. Friction material
until spring pressure is completely released (spring should appear even across the entire surface and
travel is approximately 4 inches [10 cm]). Remove the groove pattern should be visible. Replace fric-
the compressor tool. tion discs if splines are worn to a point, disc is dis-
torted, friction material is worn unevenly or groove
pattern is no longer visible. Place each steel brake
plate on a flat surface and check for distortion with a
straight edge. Check surface for signs of material
transfer or heat. Replace steel discs if splines are
worn to a point, disc is distorted or heat discolored.
Check the brake release passage to be sure it is

clean and completely open.
Inspect both sets of large tapered roller bearings

(35, 36, 56, 57) for signs of damage or excessive
3. Remove the spring stop (52), spring (55) and piston wear. The bearing rollers should not exhibit any
stop (32) from the brake cylinder.
18
D-21
irregularities. If the rollers show any sign of spalling, 3. Install the spacer plate (61) on top of the last friction
corrosion, discoloration, material displacement or disc.
abnormal wear, the bearing should be replaced.
Likewise, the cage should be inspected for wear or
deformation. If there is any damage that would
impair the cage's ability to separate, retain and guide
the rollers properly, the bearing should be replaced.
Carefully inspect both halves of the metal face seal

between the motor support/brake cylinder and the
ring gear. If the metal contact faces show signs of
excessive wear or mechanical damage, or the rub-
ber rings are brittle or damaged, the seal should be
replaced. 4. Install the retaining ring (62). Turn the assembly over
with the motor end up and be sure all brake plates
ASSEMBLY are stacked squarely against the spacer plate.
BACKUP RING
O-RING
BACKUP RING
5. Install new O-rings and backup rings (27, 28, 30, 31)
1. Set the motor support/brake cylinder on a bench with into the brake cylinder as shown. It is VERY impor-
the motor end down. tant to position the O-rings and backup rings as
shown above to prevent brake cylinder leakage.
2. Starting with a steel disc, alternately install a steel

then a friction disc until eight (8) of each type disc 6. Lightly lubricate the sealing surfaces of the brake pis-
have been installed (ending with a friction disc). It is ton (59) and install it into the brake cylinder until it
advisable to lightly lubricate the brake discs with oil touches the brake discs.
that will be used in the winch prior to assembly.
7. Install the piston stop (32) and the brake spring (55).
19
D-22
Brake Cylinder Pressure Test
1. Connect a hydraulic hand pump with an accurate

gauge and shut-off valve to the brake release port of
the motor support. Apply 500 psi (3,450 kPa) to the
brake. Close the shut-off valve and let stand for five
(5) minutes. If there is any loss of pressure, the
brake cylinder should be disassembled for inspec-
tion of the sealing surfaces and O-rings.
WHILE PRESSURE IS APPLIED AND THE BRAKE

8. Set the spring stop (52) on the spring and install the IS RELEASED, install the brake clutch assembly/
spring compressor tool, or move the assembly to a brake hub. Rotate the clutch back and forth to align
press. Be sure the step on the compressor tool is the splines in all brake discs. When the brake clutch
squarely seated on the spring stop. has engaged all the discs, release the pressure on
the brake cylinder and remove the brake clutch.
CAUTION
The brake spring must be compressed approximate-
ly 4 inches (10 cm) and has a compressed force of
approximately 1,500 lb (680 kg). Extreme care
should be observed while completing this step to
avoid sudden release of the spring. DO NOT stand
directly in front of the spring while it is being com-
pressed.
9. Slowly compress the spring until the spring stop is

slightly below the retaining ring groove in the brake
cylinder. Install the retaining ring (57). NOTE: The
holes in the ends of the retaining ring are slightly
tapered. The smaller end of the hole MUST be
installed away from the spring stop, or toward the
motor, to prevent the ring from slipping off the pliers
when installed or removed. Be sure the retaining
ring is completely seated in its groove, and slowly
release the spring compressor until the force of the
spring is held by the retaining ring. Remove the
spring compressor tool.
20
D-23
BRAKE CLUTCH ASSEMBLY SERVICE

Before disassembling the brake clutch, make note of 3. Apply a light coat of winch lubricant to all compo-
the freewheeling direction of the inner brake race (50). nents as they are assembled. Install the roller bear-
Hold the outer race (42) and try to turn the inner race in ing (58) into the outer race (42). Install spacer (47)
both directions. It should turn free of the outer race in on top of roller bearing. Install the sprag clutch
one direction only. If the inner race will not turn freely in assembly (46). NOTE: The sprag assembly con-
either direction, or turns freely in both directions, the sists of three parts; two u-shaped bronze spacers
sprag clutch assembly has been damaged and must be and a cam assembly. The bronze spacers are
replaced. installed with their open end toward the cam assem-
bly, one spacer on each side. Rotate the cam
assembly while gently pushing it into the outer race.
Before installing the inner race (50), be sure the

internal retaining ring (49) is installed and fully seat-
ed. Slide the inner race through the sprag clutch
(the race will have to be rotated in the freewheeling
direction to start it into the clutch). Be sure the inner
race turns freely in the same direction determined
before the unit was disassembled. If it turns freely
in the opposite direction, the sprag clutch has been
installed backwards and must be reversed. Install
1. Remove the retaining ring (43). All other internal parts spacers (44, 45), and retaining ring (43).
can now be removed, including the sprag assembly
(46) and the roller bearing (58).
2. Thoroughly clean all parts in solvent and inspect for

signs of wear and/or damage. Inspect the sprag
clutch and roller bearing closely for abnormal wear,
cracks, pitting or corrosion. Check small clips for
breakage or bright spots; the signs of excessive
wear.
The polished surfaces of the inner and outer races

must be perfectly smooth to insure positive engage-
ment of the clutch. The slightest defect may reduce
sprag clutch effectiveness, which could result in
property damage, personal injury or death. The
entire sprag clutch assembly must be replaced if any
component is defective.
21
D-24
PLANET CARRIER SERVICE

OUTPUT PLANET CARRIER 5. Install a retaining ring (21) in the bore of a planet
gear. Be sure it is completely seated in the groove.
1. The preferred method of removing the planet pin
(18), is to first remove the roll pin (24). This can usu-
ally be done by using a punch or small pry bar to
drive or push the roll pin out of the planet carrier
(63). Access to the roll pin is gained through a
drilled hole in the end of the planet pin. If this
method is not successful, the roll pin must be
sheared by driving or pressing the planet pin out of
the carrier. A piece of pipe or tubing long enough to
hold the planet pin may be used to support the car-
rier while each pin is removed. Adequately support
the assembly and drive or press out one planet pin,
shearing the roll pin. 6. Install a bearing spacer (20) into the bore of the
planet gear. Be sure the step on the spacer is
toward the retaining ring.
7. Install a bearing cup (22) into each end of the gear.

The cups should firmly contact the spacer.
8. Repeat steps 5, 6 and 7 for each planet gear.
2. Slide the planet gear (19) out of the carrier and

remove the bearing cones. Clean and inspect the
bearing cups in each end of the gear. If they are
determined to be in serviceable condition, no further
disassembly is required. 9. Install a bearing cone (23) into each end of a planet
gear and slide the gear and bearings into the planet
3. If the bearings need to be replaced, remove the carrier, aligning the bearing bores with the planet pin
bearing cups, spacer and internal retaining ring from bore.
the bore of the planet gear.
4. Repeat steps 1, 2 and 3 for each planet gear.
Thoroughly clean all parts and inspect for damage

and wear. The bearings should be examined for
any signs of spalling, corrosion, discoloration, mate-
rial displacement or abnormal wear. The bearing
cages should be inspected for wear or deformation.
If any of these conditions are found, the bearing
should be replaced. Gears should be inspected for
abnormal wear or pitting and replaced as necessary.
Inspect all machined surfaces and bearing bores for 10. Install a planet pin through the planet carrier and
signs of damage or excessive wear. bearings, aligning the hole in the pin with the roll pin
hole in the carrier. Drive a new roll pin (24) into
NOTE: Steps 5 through 8 are necessary only if the place in the carrier.
planet gear bearings are being replaced.
NOTE: Always use NEW roll pins.
22
D-25
Thoroughly clean all parts and inspect for damage

and wear. The bearing rollers should be examined
for any signs of spalling, corrosion, discoloration,
material displacement or abnormal wear. If any of
these conditions are found, the rollers should be
replaced. Gears should be inspected for abnormal
wear or pitting and replaced as necessary. Inspect
all machined surfaces and bearing bores for signs of
damage or excessive wear.
5. Engage the sun gear with the splines on the planet

carrier and install the retaining onto the sun gear.
6. Liberally coat the bore of a planet gear with a good

11. The roll pin should be slightly recessed in the carri- grade of oil soluble grease.
er when properly installed. Use a punch to stake the
carrier next to the pin hole so the pin will not back 7. Set a thrust washer on a clean flat work surface.
out when the unit is in operation. Set the planet gear on the thrust washer with the
bore in the gear centered over the washer. Install a
12. Repeat steps 9, 10 and 11 for each planet gear. row of loose rollers around the bore of the gear,
using additional grease as required to hold them in
place.
PRIMARY AND SECOND STAGE
PLANET CARRIERS 8. Set another thrust washer on top of the rollers and
slide the gear and bearing assembly into place in
1. The preferred method of removing the planet pin, is the planet carrier. Align the gear with one of the
to first remove the roll pin. This can usually be done planet pin bores in the carrier and install a planet
by using a punch or small pry bar to drive or push pin. Align the hole in the pin with the hole in the car-
the roll pin out of the planet carrier. Access to the rier and install a new roll pin.
roll pin is gained through a drilled hole in the end of
the planet pin. If this method is not successful, the NOTE: Always use NEW pins.
roll pin must be sheared by driving or pressing the
planet pin out of the carrier. A piece of pipe or tub- 9. The roll pin should be slightly recessed in the carri-
ing long enough to hold the planet pin may be used er when properly installed. Use a punch to stake the
to support the carrier while each pin is removed. carrier next to the pin hole so the pin will not back
Adequately support the assembly and drive or press out when the unit is in operation.
out one planet pin, shearing the roll pin.
10. Repeat steps 5 through 9 for the remaining planet
2. Slide the planet gear out of the carrier and remove gears.
the thrust washers and loose roller bearings.
3. Repeat steps 1 and 2 for each planet gear.
4. Remove the retaining ring holding the sun gear in

the planet carrier and remove the sun gear.
23
D-26
WINCH ASSEMBLY
The following procedure should be used to assemble er-bore in the output planet carrier holds the split
the complete winch. It assumes all the sub-assemblies rings in the groove. The split rings must be centered
have been properly serviced as described earlier in this for the planet carrier to install over the brake cylin-
manual. der splines.
1. Install the motor end-bracket (96) onto the fully 5. Install two ½-13 eye bolts into the output planet car-
assembled brake cylinder. Install the 12 capscrews rier. With a hoist, install the output planet carrier into
and lockwashers (82, 83) only snug at this time. the drum ring gear. Rotate each gear to align the
They will be tightened to recommended torque after teeth as you lower the carrier. Rotate the carrier to
both end-brackets have been installed. If the lapped align the carrier with the brake cylinder splines.
metal face seal assembly (33) is being replaced, When aligned, the carrier will drop down onto the
install one half of the seal in the brake cylinder and splines and capture the split rings.
the other half in the drum ring gear. The old seal is
simply pried out of position. Thoroughly clean the 6. Install thrust washer (66), onto the second stage
seal seat areas. planet assembly (with output sun gear). A light coat
of oil soluble grease should be used to hold it in
Note: Handle the new seals with great care. The place during assembly. Slide the planet assembly
smooth metal contact surfaces must remain perfect- into the ring gear and engage the output sun gear
ly flat and free of dents or nicks for the seal to oper- with the output planet gears. The second stage
ate leak free. Alcohol acts as a lubricant for rubber. planet gears should now be at least 1/8 inch (3 mm)
If alcohol in not available, a light coating of oil may below the top of the teeth cut into the drum ring
be used. gear. If they are above the ring gear teeth, the unit
is not properly assembled to this point. Either the
Apply denatured alcohol to the large o-rings and thrust washer (66) is improperly positioned, or the
place them in the seal seat in the housings. Apply output planet carrier is not fully engaged onto the
denatured alcohol to the o-ring again and evenly brake cylinder (possibly caused by the split ring not
push the lapped metal face seal into the o-ring. You being fully seated). Remove the second stage plan-
may need the assistance of another technician to et assembly and/or the output planet assembly to
help push the metal face seal into place. Do not use determine and correct the cause of the problem
punches or metal tools directly on the seal surface before proceeding.
as the lapped surface is easily damaged.
7. Install thrust washer (70) onto the primary planet
2. Install bearing cone (36) onto the brake cylinder and assembly (with second stage sun gear). A light coat
new bearing cups (35, 56) into the drum ring gear. of oil soluble grease should be used to hold it in
Place the brake cylinder on the workbench with the place during assembly. Install the primary planet
motor side down. Apply a light coat of oil to the assembly onto the second stage planet assembly,
metal face seals and to the bearing cones and cups. engaging the second stage sun gear with the sec-
Place the drum ring gear onto the brake cylinder. ond stage planet gears. Visually check to be sure
The face seals will hold the two components slight- the thrust washer is properly positioned.
ly apart.
8. Install the primary sun gear (2) through the center of
3. Install bearing cone (57) onto the brake cylinder. the primary planet assembly.
Use a brass punch to gently start the bearing onto
the brake cylinder journal. 9. Press a new bearing (88) if required, into the drum
flange. Use a flat steel plate that is slightly smaller
Note: Fabricate the bearing compression tool OD than the drum bearing as a pressure plate to
shown in the “Tools” section of this manual. press the new drum bearing into the drum flange
bore until it is fully seated at the bottom. Apply non-
4. Using the bearing compression tool, or large frame hardening sealant to the outside diameter of a new
hydraulic press, press the bearing cone down into drum seal then install the new seal into the drum
the bearing cup. Make certain the bearing cone is flange. Use a flat steel plate as a driver and press
fully seated in the cup. Remove any burs or nicks the new seal into the drum flange until it is even with
from the split rings and install the split rings into the the outside edge of the drum flange.
groove in the brake cylinder. The two halves of the
split ring must be centered in the groove. The count-
24
D-27
CAUTION 16. Install new o-rings onto the motor pilot adapter (39,
40, 41) and install the adapter into the brake cylin-
In the following step, the drum flange/primary ring der. Install the motor sub-assembly onto the winch.
gear may suddenly drop onto the drum ring gear Install and tighten capscrews and lockwashers (78,
when all primary planet gear teeth are aligned with 79) to 380 lb.-ft. (515 N-m) torque. Install the brake
those in the flange. DO NOT work with your fingers release signal hose from the lowering port of the
between the drum flange and the drum ring gear. motor to the brake release port on the brake cylin-
der.
10. Carefully set the drum flange (5) onto the drum ring
gear, engaging the primary planet gears with the 17. Fill winch to the oil level port or the centerline of the
ring gear teeth machined into the inside surface. assembly with recommended gear oil. Refer to
Turn the drum flange to align the bolt holes with "Recommended Gear Oil" in the "Specifications"
those in the drum ring gear and install the 16 cap- section of this manual.
screws and lockwashers (12, 13). Tighten the cap-
screws (12) to 210 lb.-ft. (285 N-m) torque in an Note: Whenever a winch has been repaired, it should
alternating cross-over pattern. be tested on a test tower or tested on the original equip-
ment. The following test procedure is offered as a sug-
11. Install the drum bearing support/end-bracket gestion only; equipment specifications will dictate the
assembly onto the drum assembly. For added safe- test required.
ty, remove two of the drum bearing support cap-
screws (89) and replace them with two 5/8 - 11 eye 1. Install the winch as recommended in the
bolts so that a hoist may be used to lift the drum "Installation" section of this manual.
flange. After the end-bracket is installed, remove the
eye bolts and install the drum bearing support cap- 2. Install wire rope as recommended by the wire rope
screws (89) snugly at this time. supplier. If unknown, make certain first layer, the
most important, is tightly packed onto the cable
12. Install the tie plates (101) onto the end-brackets with drum and maintain approximately 500 lb. (226 kg)
capscrews and lockwashers (99, 100). Only hand tension load on all layers of wire rope.
tighten the capscrews at this time.
3. Rope off a secure test area for test lift. Make certain
13. Place assembled winch onto a flat surface and no personnel will be under a suspended load. Lift a
evenly tighten the tie plate capscrews (99) to 105 test load of approximately 2500 pounds (1134 kg)
lb.-ft. (142 N-m) torque. Tighten the motor end- approximately 3 feet (1 meter) and return the con-
bracket capscrews (82) to 600 lb.-ft. (814 N-m) trols to neutral/hold. If the load is held firmly, raise
torque in an alternating cross-over pattern. Tighten then lower the test load the full height of the
the drum bearing support capscrews (89) to 210 lb.- boom/mast as available. Increase the load and
ft. (285 N-m) torque. repeat the test. If no problems are found, the winch
may be placed into service. If any malfunction is
14. Turn the winch up on end with the motor end up. detected, the winch must be removed from service
Secure the winch in this position so that it does not until the problem is corrected and the winch passes
fall over. Install the brake release hose adapter into the lift tests. Make a permanent record of the winch
the brake release port. Attach a hand-pump to the repairs that include the date of repair, what was
adapter and apply approximately 500 PSI (3450 wrong before the repair, what was done, what parts
kPa) to release the brake. were used, the test performed and the name of the
technician(s).
15. Install the brake clutch assembly/brake hub into the
brake cylinder. You must align all of the brake discs
and the input sun gear splines. The brake clutch
assembly should bottom out with the input sun gear
against the snap ring in the inside diameter of the
inner brake race. After the brake clutch assembly is
fully seated, release the pressure from the hand-
pump then remove the hand pump.
25
D-28
RW300A COMPONENTS
100
101
99
74
110
44
29
39
40
41
43
45
78
79
52
53
54
55
42
29
82
83
32
46
49
47
50
34
58
96
33
36
31
35
30
38
28
95
27
94
85
56
98
57
26
59
25
65
24
72
23
61
22
62
21
60
20
2
19
63
18
64
11
66
17
67
14
3
16
68
15
70
11
69
67
8
71
9
10
12
13
6
73
97
7
93
92
91
90
89
88
87
81
80
5
26
D-29
RW300A (04893, 05051 & 05435) PARTS KEY
Item Description Qty. Item Description Qty.

1 WASHER, THRUST 1 70 WASHER, THRUST 1
2 GEAR, PRIMARY SUN 1 71 CARRIER, PRIMARY PLANET 1
3 GEAR, SECONDARY SUN 1 72 BEARING 1
4 WASHER, THRUST 1 73 ANCHOR, CABLE 1
5 FLANGE, PRIMARY RING 1 74 SIGHT GAUGE 1
6 PIN, PRIMARY PLANET 3 78 LOCKWASHER (3/4 Z) 4
7 PLUG 1 79 CAPSCREW (3/4 NC X 2 G8 Z) 4
8 WASHER, THRUST 6 80 NAMEPLATE 1
9 ROLLER 51 81 DRIVE SCREW 4
10 GEAR, PRIMARY PLANET 3 82 CAPSCREW (7/8 NC X 2-1/4 G8 Z) 12
11 SPIROL PIN 6 83 LOCKWASHER (7/8 Z) 12
12 CAPSCREW 16 85 O-RING 1
13 LOCKWASHER, H1-COLLAR 16 87 SUPPORT, BEARING 1
14 PIN, SECONDARY PLANET 3 88 SPH ROLLER BRG 1
15 GEAR, SECONDARY PLANET 3 89 CAPSCREW (5/8 NC X 1-1/4 G8 Z) 8
16 ROLLER 42 90 LOCKWASHER (5/8 Z) 8
17 WASHER, THRUST 6 91 OILSEAL 1
18 PIN, PLANET 3 92 LOCKWASHER (3/8 HI COLLAR Z) 4
19 GEAR, FINAL PLANET 3 93 CAPSCREW (3/8 NC X 1-1/4 G8) 4
20 BEARING SPACER 3 94 LOCKWASHER (1/2 HI COLLAR Z) 16
21 RING, INTERNAL RETAINING 3 95 CAPSCREW (1/2 NC X 2-3/4 G8) 16
22 BEARING, CUP 6 96 SIDE PLATE, MOTOR 1
23 BEARING, CONE 6 97 SIDE PLATE, SUPPORT 1
24 ROLLPIN 3 98 TENSION ROLLER ASSY (04893 WINCH) 1
25 FRICTION DISC THIS PAGE
9 INTENTIONALLY
99 LEFT(1/2
CAPSCREW BLANK
X 1-1/2 G8 SPECIAL) 16
26 BRAKE DISC 9 100 LOCKWASHER (1/2) 16
27 BACK-UP RING 1 101 TIE PLATE 2
28 O-RING 1
29 PIPE PLUG 3
30 O-RING 1
31 BACK-UP, O-RING 1 HYDRAULIC MOTOR SUB-ASSEMBLY
110
32 PISTON STOP 1 (FOR WINCH ASSEMBLY 04893 & 05051)
33 SEAL 1 MOTOR, HYDRAULIC (05051 WINCH)
111 1
34 SUPPORT, MOTOR 1 MOTOR, HYDRAULIC (04893 WINCH)
35 BEARING, CUP 1 112 BRAKE VALVE 1
36 BEARING, CONE 1 113 MANIFOLD 1
38 FLANGE, BEARING CARRIER 1 114 O-RING 1
39 O-RING 1 115 CAPSCREW (7/16 NC X 1-1/2 SOC HD) 4
40 ADAPTER, MOTOR 1 116 CAPSCREW (7/16 NC X 3-3/4 SOC HD) 4
41 O-RING 1 117 HOSE ASSY (-4 JIC X 20 IN.) 05051 WINCH 1
o
42 BRAKE RACE, OUTER 1 118 ELBOW (45 ORB TO JIC -4/-4) 2
43 RING, INTERNAL RETAINING 1 ADAPTER (-4 JIC / -4 ORB) 04893 WINCH 1
119
44 SPACER 1 ELBOW (-4 JIC / -4 ORB) 05051 WINCH 1
o
45 SPACER 1 120 SWIVEL NUT ELBOW (90 ) 1
46 51729 SPRAG ASSEMBLY 1 121 HOSE ASSEMBLY (-4 JIC X 14 IN.) 1
47 SPACER 1 122 ADAPTER (JIC TO ORB -4/-6) 1
49 RING, INTERNAL RETAINING 1 123 PLUG (-4 ORB) 1
50 BRAKE RACE, INNER 1
52 SPRING, STOP 1
53 RING, INTERNAL RETAINING 1
54 RELIEF VALVE 1
55 SPRING 1
56 BEARING, CUP 1
57 BEARING, CONE 1
58 BEARING, ROLLER 1
59 PISTON 1
60 GEAR, RING 1
61 RETAINER, BRAKE 1
62 RING, INTERNAL RETAINING 1
63 CARRIER, FINAL PLANET 1
64 GEAR, FINAL SUN 1
65 RING, SPLIT 1
66 WASHER, THRUST 1
67 RING, EXTERNAL RETAINING 2
68 CARRIER, SECONDARY PLANET 1
69 O-RING 1
27
D-30
HYDRAULIC MOTOR SUB-ASSEMBLY

110
(FOR WINCH ASSEMBLY 05435)
1 MOTOR, HYDRAULIC (05051 WINCH) 1
2 BRAKE VALVE 1
3 ADAPTER 2
4 O-RING 2
5 CAPSCREW (1/2 NC X 1-1/2 G8 Z) 6
6 CAPSCREW (1/2 NC X 4-1/2 G8 Z) 2
7 HOSE ASSEMBLY (-4 JIC X 17 IN.) 1
8 NEEDLE VALVE 1
9 HOSE ASSEMBLY (-4 JIC X 20 IN.) 1
10 TEE, MALE BRANCH 1
11 CAP NUT 1
12 PLUG (-4 ORB) 1
14 CAPSCREW (1/2 NC X 5-1/2 G8) 2
15 ADAPTER 1
16 TEE, MALE BRANCH 1
17 ELBOW FITTING 1
18 PLUG 1
21 NIPPLE 1
22 ELBOW 2
28
D-31
MODEL NO.
SERIAL NO.
TENSION ROLLER ASSEMBLY

98 (04893 WINCH ONLY) 1
(NOT ALL PARTS ARE SHOWN)
1 TENSION ROLLER ARM 2
2 TENSION SPRING 1
3 TENSION ROLLER SHAFT 1
4 TENSION ARM SHAFT 1
5 SETSCREW 2
6 WASHER (1 INCH) 8
7 ROLLER BUSHING 2
8 SPRING ANCHOR 1
9 ROLLER ROD END 1
10 HEX NUT (5/16) 2
11 LOCKWASHER (5/16) 4
12 CAPSCREW (5/16 NC X 3/4 G5) 2
13 ROLLPIN 3
14 RETAINING RING 2
15 THRUST WASHER 2
16 ROLLER 3
17 ROLLPIN 2
18 LEVER ARM 1
19 COLLAR 1
29
D-32
METRIC CONVERSION TABLE

English to Metric Metric to English
LINEAR
inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.3937 = inches (in.)
feet (ft.) X 0.3048 = meters (m) meters (m) X 3.281 = feet (ft.)
miles (mi.) X 1.6093 = kilometers (km) kilometers (km) X 0.6214 = miles (mi.)
AREA
2 2 2
inches (sq.in.) X 645.15 = millimeters (mm ) millimeters 2 (mm 2) X 0.000155 = inches2 (sq.in.)
feet2 (sq.ft.) X 0.0929 = meters2 (m 2) meters2 (m 2) X 10.764 = feet 2 (sq.ft.)
VOLUME
3
inches (cu.in.) X 0.01639 = liters (l) liters (l) X 61.024 = inches3 (cu.in.)
quarts (qts.) X 0.94635 = liters (l) liters (l) X 1.0567 = quarts (qts.)
gallons (gal.) X 3.7854 = liters (l) liters (l) X 0.2642 = gallon (gal.)
inches3 (cu.in.) X 16.39 = centimeters3 (cc) centimeters3 (cc) X 0.06102 = inches3 (cu.in.)
feet3 (cu.ft.) X 28.317 = liters (l) liters (l) X 0.03531 = feet 3 (cu.ft.)
feet3 (cu.ft.) X 0.02832 = meters3 (m 3) meters3 (m3) X 35.315 = feet 3 (cu.ft.)
fluid ounce (fl.oz.) X 29.57 = millileters (ml) milliliters (ml) X 0.03381 = fluid ounce (fl.oz.)
MASS
ounces (oz.) X 28.35 = grams (g) grams (g) X 0.03527 = ounces (oz.)
pounds (lbs.) X 0.4536 = kilograms (kg) kilograms (kg) X 2.2046 = pounds (lbs.)
tons (2000 lbs.) X 907.18 = kilograms (kg) kilograms (kg) X 0.001102 = tons (2000 lbs.)
tons (2000 lbs.) X 0.90718 = metric tons (t) metric tons (t) X 1.1023 = tons (2000 lbs.)
tons (long) (2240 lbs.) X 1013.05 = kilograms (kg) kilograms (kg) X 0.000984 = tons (long) (2240 lbs.)
PRESSURE
o
inches Hg (60 F) X 3600 = kilopascals (kPa) kilopascals (kPa) X 0.2961 = inches Hg (60oF)
pounds/sq.in. (PSI) X 6.895 = kilopascals (kPa) kilopascals (kPa) X 0.145 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.0703 = kilograms/sq.cm. (kg/cm 2) kilograms/sq.cm. (kg/cm2) X 14.22 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.069 = bars bars X 14.5 = pounds/sq.in. (PSI)
o o
inches H2O (60 F) X 0.2488 = kilopascals (kPa) kilopascals (kPa) X 4.0193 = inches H2O (60 F)
bars X 100 = kilopascals (kPa) kilopascals (kPa) X 0.01 = bars
POWER
horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)
ft.-lbs./min. X 0.0226 = watts (W) watts (W) X 44.25 = ft.-lbs./min.
TORQUE
pound-inches (in.-lbs.) X 0.11298 = newton-meters (N-m) newton-meters (N-m) X 8.851 = pound-inches (in.lbs.)
pound-feet (ft.-lbs.) X 1.3558 = newton-meters (N-m) newton-meters (N-m) X 0.7376 = pound-feet (ft.-lbs.)
pound-feet (ft.-lbs.) X .1383 = kilograms/meter (kg-m) kilogram/meter (kg-m) X 7.233 = pound-feet (ft.-lbs.)
VELOCITY
miles/hour (m/h) X 0.11298 = kilometers/hour (km/hr) kilometers/hour (km/hr) X 0.6214 = miles/hour (m/h)
feet/second (ft./sec.) X 0.3048 = meter/second (m/s) meters/second (m/s) X 3.281 = feet/second (ft./sec.)
feet/minute (ft./min.) X 0.3048 = meter/minute (m/min) meters/minute (m/min) X 3.281 = feet/minute (ft./min.)
TEMPERATURE
o
Celsius = 0.556 (oF - 32) o
Fahrenheit = (1.8 X oC) + 32
COMMON METRIC PREFIXES

mega (M) = 1,000,000 or 106 deci (d) = 0.1 or 10-1
kilo (k) = 1,000 or 103 centi (c) = 0.01 or 10-2
hecto (h) = 100 or 102 milli (m) = 0.001 or 10-3
deka (da) = 10 or 101 micro (m) = 0.000.001 or 10-6
30
D-33
D-34
www.boartlongyear.com
Copyright © 2010 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.

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GLOBAL DRILLING PRODUCTS

Copyright © 2016 Boart Longyear. All rights reserved.

LF230 DIAMOND CORE DRILL

1.6.5.10 Transport of Persons............................................................ 25

Chapter 3: Component Description

3.4.1 Drill Head....................................................................................... 52

3.12.1 Engine Control Panel (ECP) Tier 4i Model.................................... 90

4.7 Raising The Mast..................................................................................... 124

4.23.5.2 Fire...................................................................................... 151

Chapter 5: Hydraulic System

5.5.1 C1 Main Hydraulic Cooler........................................................... 188

Chapter 6: Electrical System

7.6.1 Wireline Rope Installation............................................................ 238

8.1.8 Hydraulic Oil................................................................................ 368

Appendix A: Hydraulic Schematic

Appendix B: Electrical Schematics

Appendix C: Technical Specifications

Appendix D: Braden RW300

1.6.5.10 Transport of Persons............................................................ 25

1.1 Important Safety Information

1.1.1 Hazard Signal Indicators

“Danger” indicates an imminently hazardous situation which, if not

“Warning” indicates a potentially hazardous situation which, if not

“Caution” indicates a potentially hazardous situation which, if not

“Notice” is used to draw attention to detailed instructions. These notes

1.1.2 Safety Guidelines

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

●● Keep clear of rotating equipment. Wear proper clothing. Loose or

●● Do not adjust the hydraulic system before consulting a Boart

1.1.3 Safety Labels

When ordering parts or requesting information, you will always be asked

Figure 1–1: Machine Name Plate

Figure 1–2: Warning Decal: Interference with Draw Works

DO NOT operate this machine without reading and understanding the

Figure 1–3: Danger Decal: Read the Manual

DO NOT position mast within 100m of power transmission lines.

Figure 1–4: Danger Decal: Electrical Shock

ONLY use this outlet for a 12 VDC 40 AMP circuit.

Figure 1–5: Caution Decal: Electrical Circuit Outlet

Figure 1–6: Warning Decal: Winch Cable

DO NOT operate this machine without rotation barrier in place. Operator

Figure 1–7: Warning Decal: Rotating Parts

The continuous sound pressure level, during normal coring operations,

Figure 1–8: Warning Decal: Sound Levels

Moving parts of the machine have the potential to crush or pinch.

Figure 1–9: Warning Decal: Crush/Pinch Point

Figure 1–10: Warning Decal: Opening the Head

ALWAYS ensure head lock-down bolts are in place before operating.

Figure 1–11: Warning Decal: Head Lock-Down

DO NOT adjust the manifold without consulting field service first.

Figure 1–12: Warning Decal: Manifold Setting

Figure 1–13: Warning Decal: Moving the Drill

ALWAYS use an appropriate lifting device at the designated lifting

Figure 1–14: Decal: Lift Point

1.1.3.1 Personal Protective Equipment (PPE)

Figure 1–15: Decal: Personal Protective Equipment

Always use Lockout/Tagout procedures before working on or near any

Figure 1–16: Decal: Lockout/Tagout

Always wear fall protection when working on elevated areas of the

Figure 1–17: Decal: Safety Harness

1.1.4 Inspect Safety Decals/Labels

1.2 Personal Protective Equipment

Figure 1–18: Approved Hard Hat Required