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Operating manual &

Spare parts List



ORIGINAL DOCUMENT

DeltaBase 525/525RC

DB525RC Option with Trailer

DB525RC Option Percussion Drifter

Tth
This page is intentionally blank

Boart Longyear Sp. z o.o.


ul Popieluszki 30
55-080 Katy Wroclowskie
Poland
Tel.: +48 71 3630 264
Fax: +48 71 3630 201
This Operating Manual is valid for the following DELTABASE 525/DB525RC:

Machine No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

When making inquiries or ordering spare parts, be sure


to specify the following information:

Spare Part No.: . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine No.: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Descriptions and pictures are of general nature only and
may be modified in the course of technical development.
Service engineers and qualified fitters are always available to assist and advise, where required.
Please contact YOUR Service Section for details.

The Drill Rig number and


additional details can be
found on the nameplate of
the machine.
(Location shown on the
right)
The optional Trailer
number and additional
details can be found on the
nameplate of the Trailer.
(Location shown on the
right)

Important Note

DO NOT START or OPERATE THE DRILL until you have READ this manual
and UNDERSTAND the contents.
Non-authorised personnel MUST NOT under any circumstances attempt
to operate or repair the machine.
Safety Precautions listed in the manual are intended to alert the operator
and helpers to physical dangers inherant in various phases of operating and
maintaining mobile drilling equipment of this kind.
Safety First must always be the primary consideration of all personnel when
operating or maintaining the drill rig under normal, and espesially in unusual
conditions.
Since these Safety Precautions cannot cover every possible situation, everyone is expected to exercise good judgement and common sense while
working with, on or near the drill rig.
Hazard signal Words and Warnings
Hazard signal words are used throughout this manual. They appear in the
narrow lefthand column of several pages and, with their additional text description, are intended to alert the reader to the existance and relative degree
of hazard.
The signs DANGER, WARNING, CAUTION and NOTICE are defined
as follows :indicates an imminently hazardous situation which, if not avoided, will
result in serious injury.
indicates a potentially hazardous situation which, if not avoided, could
result in serious injury.
indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury.
is used to make people aware of situations, and gives hints for operation
and maintenance, which are important, but not hazard related. It generally
indicates an Operational Aid.

The optional Trailer


number and additional
details can be found on the
nameplate of the Trailer.
As shown below.

The machine number and


additional details can be
found on the nameplate of
the machine.
As shown on the right.

Table of Contents

Table of Contents
1-3

Standard Warranty Terms and Conditions for Boart


Longyear Equipment

Section 1 Introduction
1-4 Warnings
1-4

DELTABASE 525 Operating Manual


1-4

General Description

1-5

DELTABASE 525 Drill Equipment

1-5

General Description

1-7

Trailer option

1-8 Features

1-9

Technical Data
1-9

DIMENSIONS AND WEIGHTS *

1-9

CRAWLER CHASSIS STEEL TRACKS

1-10 PRIME MOVER


1-10 ROTARY HEAD DD52
1-10 Alternative ROTARY HEAD HY 79
1-10 Reverse Circulation flushing attachments (optional)
1-10 HYDRAULIC SYSTEM
1-10 DRILL MAST AND FEED SYSTEM WITH FEED CYLINDER
1-11 WINCH
1-11 ROD CLAMPS
1-11 OPTIONS
1-11 MUD/WATER PUMP
1-11 WATER PUMP System (Option)
1-11 REVERSE CIRCUATION System (Option)
1-11 TRAILER System (Option)
1-11 MAST EXTENSION
1-11 WIRELINE HOIST
1-11 ACCESSORIES
1-11 Crawler with rubber tracks
1-11 Crawler with rubber tracks and steel tips
1-11 Rod and break-out clamps - 220 mm

Table of Contents

1-11 Centraliser for 220 mm rod clamps


1-11 Drill pipe storage
1-11 Hand held tachometer
1-12 DRILLING SYSTEMS
1-12 STANDARD DRILLING SYSTEMS
1-12 OPTIONAL DRILLING PACKAGE
1-12 RECOMMENDED SPARES KITS

1-13 Transport Instructions


1-14 Offloading.
1-14 Transport Dimensions.
1-15 Top Lifting Points Location
1-15 Front Lifting Points Location

Section 2 Safety Considerations


2-3

Location of Warning Signage

2-4

Typical Drillheads - Location of


Warning Signage

2-5

Trailer (Option) Location of


Warning Signage

2-6

Personal Protective Equipment

2-7

Emergency STOPS

2-8

2-7

Guard Emergency Stop Switch

2-7

Control Panel Emergency Stop Switch

2-8

In the event of an Emergency Stop:

2-8

Mast/Drillhead Safety Guard

Safety Precautions
2-8 General
2-9

Specific Safety Instructions for Drilling

2-11 Safety Requirements


2-11 SAFETY VALVES
2-11 HYDRAULICS
2-11 REPLACEMENT OF WORN PARTS

Table of Contents

2-11 SAFETY DEVICES


2-11 STATIC COMPONENTS
2-11 DIRECTIVE OF APPLICATION
2-11 OPERATION

2-12 OPERATING INSTRUCTIONS


2-12 DANGER ZONE - 2.5 metres All round the Rig.
2-12 Danger Zone with Trailer (option)
2-12 SAFETY DISTANCE
2-12 TRANSPORT OF PERSONS
2-13 Fire Extinguisher Instructions
2-14 TRAMMING AND OPERATING CRAWLER DRILL RIGS
2-14 SAFE TRAMMING SET-UP (with Trailer option)
2-14 NOISE LEVELS
2-14 STABILITY
2-14 SECURING AGAINST FALL
2-15 SIGNALLING
2-15 UTILITY LINES
2-15 WORKING NEAR OVERHEAD LINES
2-15 OPERATIONAL INTERVALS

2-16 Extreme Environmental/Job Site Conditions


2-16 Extremely dusty Working Conditions.
2-16 Warm to Hot Ambient Air Temperature.
2-16 Extremely Cold Ambient Temperature.
2-16 Working At High Altitude (above sea level).
2-16 Working in Salty Atmosphere.

Section 3 Drill rig components


3-2

Drill Rig Complete


3-4

3-6

Optional Radio Control

Drilling Mast
3-10 General rules for Feed chains:
3-13 Drillhead Sideslide - DD52
3-14 Alternative Rotary Drill Head - HY79

Table of Contents

3-15 Drillhead Sideslide - HY79


3-16 Reverse Circulation Swivel (option)

3-17 Clamping and Breaking Device


3-18 Automatic SPT (option)
3-19 Oil Liner DTH Lube system (option)
3-22 High Pressure Water Pump (option)
3-23 Vice (Option)
3-24 Vandal Covers (option)
3-25 Main Hoist
3-26 Wireline Winch
3-27 Crawler Tracks
3-28 Trailer (option)
3-29 Water/Mud Pump
3-30 Air Compressor and reservoir (Option)
3-30 Reverse Circulation (Option) Air Hose Whip Check Connections
3-31 Hydraulic circuit
4-2

Section 4 Operations

4-3 Introduction
4-3

Equipment Description and Identification

4-4

Component Location
4-6

Diesel tank and Hydraulic tank location

4-7

Flushing Control valves

4-8

Flushing Control valves (circuit with RC option)

4-9

Auxiliary Controls

4-10 Main control panel description


4-10 Engine controls
4-11 Alignment controls
4-12 Swivel panel controls

Table of Contents

4-13 Fixed panel controls


4-14 Tramming Control Panel Description
4-15 Crown Block control description

4-16

Pre-start checks

4-16

Prior to Start-up

4-17

Initial Start-up

4-18

Tramming (Tracking)
4-18 Transport Support
4-18 Tramming control hoses
4-18 Mast in Tramming Position
4-18 Radio Control (Option)

4-19

Drilling Methods
4-19 Hints for Optimum Application

4-20 Drilling Operations


4-20 Calculating Bit Weight
4-21 Down Hole Drilling
4-22 Up Hole Drilling
4-23 Horizontal Drilling
4-24 Bit Weight Table

4-26 Flushing
4-26 Blow Down (option)
4-26 Reverse Circulation / Blow Down (Option) Air Hose
Whip Check Connections
4-27 Blow Down circuit (option)
4-28 Trailer (option)
Section 5 Care and Maintenance
5-3 Introduction

5-4

5-3

Operational Requirements

5-3

Safety Requirements

Tools and Equipment

Table of Contents

5-6

Recommended Tool Kit

5-7

Bolt Torques and Safe Loads

5-7

Preventive Maintenance
5-7

Repairs to Hydraulic Components

5-8

Tilt and Slide Support

5-9

Mast and Crowd Cylinder

5-10 Crown Block and Jib extend/slew


5-11 Holder clamp and Breakout clamp

5-12 DD52 Rotary Drillhead


5-13 DD52 Rotary Drillhead disassembly and assembly
5-14 DD52 Rotary Drillhead motor Gearbox assembly
5-16 DD52 Rotary Drillhead Gearbox assembly
5-17 DD52 Reducer Reference Parts List

5-21 Alternative HY79 Rotary Drillhead


5-22 HY79 Rotary Drillhead disassembly and assembly
5-23 HY79 Drillhead Exploded View
5-24 HY79 Rotary head - Reference Parts List

5-26 HY79 Rotary Drillhead with Reverse Circulation Swivel


and Blowdown (option)
5-27 Cyclone Sampler and Trailer (option)
5-28 SPT Option (Standard Penetration Tester)
5-29 Levelling Jacks
5-30 Main Frame Assembly
5-31 Changing the Hydraulic Oil

5-32 Lubrication, Maintenance, and Service Intervals


5-34 Recommended Oils and Lubricants
5-34 Selection of Hydraulic Oils
5-34 Selection & Application of Gearbox Oils and Grease
5-35 Gear Oil & Greasing Table

Table of Contents

Section 6 Fault finding tables


6-2

No Pressure

6-2

Flow Low or Pressure Fluctuating

6-2

Valves not operating properly

6-2

Hydraulic oil temperature too high

6-3

Noises from Pumps - no oil supply

6-3

Leakage from Drillhead

6-3

Engine Stalling

Section 7 Authorised Service & Repair Agents


7-2

Boart Longyear Distributers

Section 8 Main Hoist


8-2

Main Hoist

Section 9 Wireline Winch


9-2

Wireline winch

Section 10 Crawler tracks


10-2 Crawler Tracks

Section 11 Accessories
11-2 Accessories

Section 12 Water Pump


12-2 Water Pump

Section 13 Parts Lists


13-2 Parts Lists

Section 14 Spares kit


14-2 Spares kit

Section 15 Trailer Option


15-2 Introduction

SECTION 1

Table of Contents
1-3

Section 1 Introduction

1-3

Standard Warranty - Boart Longyear Equipment

1-4 Warnings
1-4

DELTABASE 525 Operating Manual


1-4

General Description

1-5

DELTABASE 525 Drill Equipment

1-5

General Description

1-7

Trailer option

1-8

Percussion Drifter option

1-9 Features

1-10 Technical Data


1-10 Dimensions And Weights
1-10 Crawler Chassis Steel Tracks
1-11 Prime Mover
1-11 Rotary Head Dd52
1-11 Alternative Rotary Head Hy 79
1-11 Percussive Drifter (Option)
1-11 Hydraulic System
1-11 Drill Mast And Feed System With Feed Cylinder
1-12 Winch
1-12 Winch (Option)
1-12 Rod Clamps
1-12 Rod Clamps - (Option For Percussive Application).
1-12 Mud/Water Pump
1-12 Water Pump System (Option)
1-12 Reverse Circulation System (Option)
1-12 Trailer System (Option)
1-12 Mast Extension
1-12 Wireline Hoist
1-13 Accessories
1-13 Rod and break-out clamps - 220 mm

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525_20081002D

2012 Boart Longyear

Introduction

1-13 Centraliser For 220 Mm Rod Clamps


1-13 Drill Pipe Storage
1-13 Hand Held Tachometer
1-13 Petol Tongue - Breakout Key
1-13 Tool Box
1-13 Drilling Systems
1-13 Standard Drilling Systems
1-13 Optional Drilling Package
1-13 Recommended Spares Kits

1-14 Transport Instructions


1-15 Offloading.
1-15 Transport Dimensions.
1-16 Top Lifting Points Location
1-16 Front Lifting Points Location

DB525_OM_20081002D

1-2

Section 1 Introduction
Introduction

1-3

Standard Warranty Terms and Conditions for Boart Longyear Equipment


Limited Warranty
a. Consumables. Boart Longyear warrants for a period of
one (1) year after the date of shipment of the consumable
products manufactured by it, or the performance
of related services, under the Contract, that such
consumable products are free from defects in materials
and workmanship and such services are performed in a
professional and workmanlike manner; provided, however,
with respect to consumable products purchased through an
authorized Boart Longyear distributor, the warranty period
shall commence on the date of purchase by the end-user.
b. Capital Equipment. Boart Longyear warrants that the
capital equipment manufactured by it is free from defects in
materials and workmanship for a period equal to the lesser
of (i) one (1) year after the date of shipment, or (ii) the
initial 1,000 operating hours. Boart Longyear warrants for
a period of six (6) months after the performance of related
services that such services are performed in a professional
and workmanlike manner.
c. General Terms. Boart Longyear further warrants that,
to the extent applicable, as of the date of shipment or
performance, all goods manufactured by it and services
performed shall conform to the written specifications
agreed between the parties. THIS IS BOART
LONGYEARS 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 Longyears warranty obligations,
Purchaser must: (i) contact Boart Longyear and request
authorization to return any goods claimed to be defective
promptly upon Purchasers 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 Purchasers 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
Longyears obligations hereunder for breach of warranty,
Purchaser shall offer its reasonable cooperation and
assist Boart Longyear in the course of Boart Longyears
review of any warranty claim. If requested by Purchaser,
Boart Longyear will promptly repair or replace, at Boart
Longyears expense, goods that are confirmed to be non-

conforming as a result of Boart Longyears examination


and according to Boart Longyears warranty as set forth
herein. All removal and installation of goods shall be at
Purchasers expense; provided, however, Boart Longyear
will reimburse the Customer for an amount equal to the
reasonable expenses incurred by the Customer and
attributable to the removal and shipment of any defective
goods. Boart Longyear reserves the right to reimburse
Purchaser for an amount equal to the purchase price
of any defective goods in lieu of providing repaired
or replacement goods. Anything contained herein to
the contrary notwithstanding, in no event shall Boart
Longyear be liable for breach of warranty or otherwise in
any manner whatsoever for:(i) normal wear and tear; (ii)
corrosion, abrasion or erosion; (iii) any goods, components,
parts, software or services which, following delivery or
performance by Boart Longyear, has been subjected to
accident, abuse, misapplication, modification, improper
repair, alteration, improper installation or maintenance,
neglect, or excessive operating conditions; (iv) defects
resulting from Purchasers 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 Purchasers 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 Purchasers 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

DB525_OM_20081002D

Introduction

1-4

Warnings
1
2

This manual is a general description of the operation and maintenance


requirements of DELTABASE 525 heavy duty Drill Rigs with the optional
Reverse Circulation DB525RC drillhead and Trailer system.
Pictures, descriptions and technical data may therefore not match your
drill rig in every aspect.

3 REMEMBER!
4
You are the one who is responsible for your personal safety when
operating the DB525 / DB525RCdrill rig.
5
This manual is only a general guide to essential operating procedures,
safety precautions, etc.
6
The procedures described in this manual do not relieve you of your
responsibility to exercise caution and common sense.
7
You must comply with all safe working procedures and instructions
relevant to your drill site at all times!

DELTABASE 525 Operating Manual


General Description
1

This manual describes the BOART LONGYEAR DELTABASE 525


series drill and outlines its operational and maintenance procedures .
It also includes a number of procedural hints.

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.

DB525_OM_20081002D

Introduction

1-5

DELTABASE 525 Drill Equipment

DRILL MAST

DRILLHEAD

GUARD

CONTROL
PANEL
BREAK
CLAMP
AND
HOLD
CLAMP

General Description
The Deltabase 525 is a compact, lightweight multi-purpose drill rig especially
designed for :
Wireline and conventional coring

Undisturbed sampling and testing

Geological and geophysical work

Ground consolidation drilling

Water well drilling

Auger drilling

Reverse Circulation drilling
Apart from a compressor or water supply (for flushing purposes) the
DELTABASE 525 drill rigs are designed to operate fully
independently, and are therefore suited to all types of drilling
applications, in a variety of ground conditions.
The mast can be positioned horizontally as well as vertically. This
feature, in combination with two articulating swivel joints (option),
allows for perfect alignment of the drill, even in areas of restricted
access.
DB525_OM_20081002D

Introduction

1-6

Hydraulic oil
Cooler

Winch
Tramming
Control
Panel

Lube-oil Filler
(behind)

Water/Mud Pump

Fu e l - o i l f i l l e r
(behind)

Engine Speed
Control

Stabilisers
- one each
corner

Fire Extinguisher

Stabiliser Control
Panel

Main Control
Panel

DB525_OM_20081002D

Auxiliary Control
Panel

Introduction


Spare Wheel

Towing Hitch

1-7

Trailer option
Storage Compartment

Stabilser Wheel
Jack

Centrifuge(RC Cyclone) and


Sample collector (RC Splitter)

Trailer
Cyclone Door
Open/Close

Water Reservoir

Air and Oil connections

Cyclone lift and


slew controls
Stabilser Jacks
DB525_OM_20081002D

Introduction

1-8

Percussion Drifter option

Control Panel for


Percussive Drifter

Rod Clamp/Breaker for


Percussive Drifter
small diameter Rods
Option

DB525_OM_20081002D

Introduction

1-9

The main power source is an air-cooled diesel engine, which drives the
open-centre hydraulic circuit. (Maximum operating pressure: 250 bar). The
hydraulics power all operating functions, tramming, set-up, and drilling.
The drill mast carries a DELTABASE series drill head, together with the
entire drill string. The drill mast is attached to the mast carrier by means of
adjustable guide Slippers.
Holding and thread breaking clamps allow for rapid rod changes.
All control and monitoring elements of the fully hydraulic crawler drill
DELTABASE 525 are conveniently positioned. Self-explanatory graphic
symbols are used to indicate control functions.
The crawlers are operated remotely from the Radio Remote or from the
control pendant. Both options have two levers (left and right track sections)
to activate and steer the crawler undercarriage.
The control pendant is stowed at the rear of the machine and the Radio
Remote is kept in the rig storage box.
On the right-hand side of the machine are the control levers for positioning,
setting-up and alignment of drill mast.
The drilling control panel is mounted on a slewable arm on the right hand
side of the machine. All of the control and monitoring elements for drilling
functions are mounted on this panel.
During transport and tramming the control panel is stowed parallel to the
base frame of the rig and within the width of the machine. During drilling,
the control panel is swung out, then angled and positioned to afford the
driller optimum visual observation of the bore.
Emergency STOP switches are fitted on the control panel, inside the mesh
guard (see next paragraph), on the Front Left Hydraulic Jack and on the
Radio remote tramming panel.
The operator is protected from the rotating drilling elements by a wire mesh
guard with an emergency stop interlock which fully encloses the accesible
area. If local regulations permit; a lanyard pull-wire can be fitted along the
length of the mast in place of the wire mesh guard. Activating any of these
switches immediately stops all drilling and tracking functions.
The diesel engine can be fitted with an optional soundproof cover when
operating in areas with stringent noise regulations.
The drill rigs electrics are 12V DC.

Features

Mast with feed cylinder and extension to enable 6m rod pull

Rod holding and thread break-out clamp with adjustable



clamping force
Rotary head side shift
New generation diesel engine power supply
Integrated control panel mounted on swinging arm
Hydraulic mast raising with mast dump compensates for
uneven drill site conditions

DB525_OM_20081002D

Introduction

Technical Data

DIMENSIONS AND WEIGHTS *

Crawler Mounted Drill Rig Weight:


Standard 6 500 kg (RC option 7500 kg)
Consists of:
4DEUTZ BF4L914 Power Unit Grp. -4.3 litre
4 cylinder (D914L04 as option)
Hydraulic Module
Main Hoist c/w Cable
Hydraulic Mast Raising (independant)
Lower Mast Assembly
Rotation Unit Group
Crawler Frame
Battery
Levelling Jacks (hydraulic) - 4
Operator Controls
Holding Clamp and Breaking Clamp

CRAWLER CHASSIS STEEL TRACKS

Axis distance 1715 mm


Length 1900 mm
Width of track shoes 300 mm
Max. ground pressure 0.053 MPa
Weight 1035 kg
Max. Driving speed 1.5 km/h
Max.Climbing ability 60% (30deg)

* Dimensions and weights may vary depending


on options and should be checked before crating
or lifting

DB525_OM_20081002D

1-10

Introduction

1-11

PRIME MOVER

Standard
Swept volume
Power maximum
Rated rpm
Specific Fuel consumption

DEUTZ BF4L914 air cooled Diesel



4.31 l
72.4 kW
2300 rpm

225 g/kWh
ROTARY HEAD DD52 2 Gear with variable displacement motor
RPM
Torque (Nm)
1st Gear

48 to 250
4890 to 977
2nd Gear

140 to 740
1859 to 371
Rotation Motor Danfoss hydraulic motor (variable/reversible - remote pilot)
Mechanical Transmission (2 Speed)
Ratio
1st Gear
7.68:1
2nd Gear
2.92:1
Bore inside dia.
62 mm
Floating Spindle inside dia.

30 mm
Floating Spindle stroke

60 mm
Drive Flange

2 3/8A.P.I.
Side shift
500 mm stroke hydraulic
Note - The hydraulic motor ratings are at max. and min. displacement, prime
mover at 2200 rpm.

Alternative ROTARY HEAD HY 79

Max torque and RPM low gear



Max torque and RPM high gear

Rotation motors
Top drive flange

Adaptor
Gear ratio

Distance from drilling line to chain

6500/40 Nm/rpm
300/800 Nm/rpm
DANFOSS TMT 315 +Parker 80
3 1/2 API IF .Box
2 3/8 API REG Pin
4.05:1
435 mm

Reverse Circulation flushing attachments (optional)


Percussive Drifter (option) 2 Gear manual and 2 Electric

Torque (Nm)
RPM
M1
296 daNm
n1 = 87 min
M2
148 daNm
n2 = 174 min
M3
72 daNm
n3 = 360 min
M4
36 daNm
n4 = 720 min
Percussion unit type 10
Frequency (f) = 3000 min
We = ... 180 Nm
Shank: R38 female and H66 (RH) male thread

HYDRAULIC SYSTEM

Primary Pump Parker bent axis - fixed displacement


Max flow
66 lpm @ 2200 rpm
Max pressure

25 MPa
Secondary pump - Casappa gear pump
Max flow (1st)

59 lpm @ 2200 rpm
Max flow (2nd)

48 lpm @ 2200 rpm
Max pressure (1st)

17.5 MPa
Max pressure (2nd)

17.5 MPa

DRILL MAST AND FEED SYSTEM WITH FEED CYLINDER

Total Length

6.30 m
Feed stroke
4m
Feed speed -Up

12.5 m/min
- Down
18 m/min
Fast Feed speed - Up
31 m/min

- Down
51 m/min
Pull down force

34 kN
Pull back force
55 kN
Drilling Inclination
45 deg below horizontal to 90 deg vertically down
DB525_OM_20081002D

Introduction

1-12

WINCH

Main Hoist Type Braden BG 6


Line pull - Bare Drum

- Full Drum
Rope speed @ 60 l/min
- Bare Drum


- Full Drum
For Cable Dia14 mm

31.1 kN
23.1 kN
29 m/min
36 m/min
35 m

WINCH (option)

Main Hoist Type SH220


Line pull
Rope speed @ 50 l/min
For Cable 12 mm

20000 N
44 m/min

ROD CLAMPS

Max. clamping diameter


Max. clamping capacity
Max. breaking torque

220 mm
175 kN
20.5 kNm

ROD CLAMPS - (option for Percussive application).

Max. clamping diameter


Capable of handling down to 44mm diameter

140 mm

OPTIONS
MUD/WATER PUMP

Type DELTAPUMP - 200 with hydraulic motor


Working pressure
Continuous delivery

45 bar
200 l/min

WATER PUMP System (Option)

Type Dynaset -
HPW 200/30-45
Water pressure (max) -
200 bar
Suction head (max) 3 metre
Suction connection - BSP 3/4
Complete with - Unloader valve, change-over valve for optional 150 litre reservoir
or external water supply and quick connectors for Water Gun.

REVERSE CIRCULATION System (Option)

Dual Swivel


Automatic Blow Down
Deflector Box
Driver Sub
Saver Sub -
3 1/2 Remet

3 1/2 Metzke
4 Remet
4 Metzke
4 Matrix

TRAILER System (Option)

RC Cyclone

750 cfm
1100 cfm
RC Splitter 3-Tier Splitter
Cone Splitter

MAST EXTENSION

Length of rods
Total weight
Fitted onto standard mast to pull 6 m rod lengths

WIRELINE HOIST

Line pull
Rope speed @ 59 l/min
For Cable Dia 6 mm
Optional Cable Dia 5,0 mm
DB525_OM_20081002D

2x3m
140 kg

6500 N
100 m/min
250 m
350 m

Introduction

1-13

ACCESSORIES

Crawler with rubber tracks, Crawler with rubber tracks and steel tips
Rod and break-out clamps - 220 mm
Centraliser for 220 mm rod clamps
Drill pipe storage
Hand held tachometer
Petol Tongue - breakout key
Night lights
Down the hole in-line oiler
Spring shock absorbers on floating spindle for use with DTH
Connecting flange 2 7/8 API thread
Connecting flange HQ thread
Connecting flange NQ thread
Connecting flange NWY thread
Jaw plates for BW casing
Jaw plates for NW casing
Jaw plates for HWT casing
Tool box

DRILLING SYSTEMS

The figures in these tables have been calculated, based on field experiences,
and may be reasonably expected. Actual drilling capacity will depend on in-hole
tools and conditions, drilling techniques and equipment used.

STANDARD DRILLING SYSTEMS

Core drilling

Core barrel:
NQ/NQ2/NV/NV/2
HQ/HV

PQ/PV

SQ
Reverse Circulation drilling

Rotary Drilling (Tricone)
Hole Dia - 216 mm (8.5)
Auger Drilling
Hole Dia - 150 mm

Hole depth (metres)

Hole depth (feet)

310 m
220 m
145 m
90 m
140 m
160 m

1000 ft
710 ft
480 ft
290 ft
4 RC pipe
3 1/2 RC pipe

175 m

570 ft

15-20 m

49-65 ft

OPTIONAL DRILLING PACKAGE

SPT (Standard Penetration Test) Auto Hammer


Impact rate
1-30 bpm
Length of Travel
762 mm
Hammer Weight
63 kg
Total Weight
180 kg
DTH Drilling package
Max.size DTH Hammer:
98mm
3 7/8
Air requirement:
17,2m3/min @ 24bar max.
Depth capacity:
290m max.
950 ft
Hole size - recommended: 115 mm
4 1/2
Hole size - max:
127mm
5
Recommended rod size:
76,1 mm
3
Note - The air compressor must be selected according to the hammer in use.
In-line oiler and shock absorber are required for DTH drilling

RECOMMENDED SPARES KITS

Basic kit (S)


Large kit (L)
Super kit (XL)
More details are given in the description of each kit.
DB525_OM_20081002D

Introduction

1-14

Transport Instructions

The height of the Mast support is adjustable for Shipping or Tramming


positions. When stowed in the lowest height for shipping the mast Slide
cylinder must be fully retracted (in) or the Engine cowling will be damaged.

Mast Support in Shipping


position with mast Slide
cylinder fully retracted (in)

DB525_OM_20081002D

Mast Support in
normal tramming
position

Introduction

1-15

Offloading.

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


depending on the transporter. Check that all transport bindings are
removed.

Offloading by Lifting the rig.


Ensure that the lifting appliance is capable of carrying


the weight of the rig - 7000kg, plus any drilling tools.
All lifting points are highlighted in red, see diagrams
below.

Offloading by driving the rig.

Before attempting to operate the rig for off-loading, read and understand the instructions given in Sections 2 and 4 of this manual.
The Crawler mounted DB 525 Drill Rig is an off -road vehicle and
therefore should not be driven on public roads
except for access to site. Always consult local laws.

Transport Dimensions.
Length:
Width:
Height:
Weight:

6500 mm
1900 mm
2310 mm
7000 kg (RC option 7500 kg)

Tow Pin
Tow Pin

Lifting Points
Elevation

Lifting Points
Plan View

DB525_OM_20081002D

Introduction

1-16

Top Lifting Points


Location

Front Lifting Points


Location

Rear Lifting Points


Location
Front Towing
Pin Location

Rear Towing Pin


Location

DB525_OM_20081002D

SECTION 2

Table of Contents
2-3

Section 2 Safety Considerations

2-3

Location of Warning Signage

2-4

Typical Drillheads - Location of Warning Signage

2-5

Trailer (Option) Location of Warning Signage

2-6

Personal Protective Equipment


2-7 Jack-leg
2-7 Emergency
2-7

2-7

2-8

Stop Switch

Emergency STOPS
2-7

Guard Emergency Stop Switch

2-7

Control Panel Emergency Stop Switch

2-8

In the event of an Emergency Stop:

2-8

Mast/Drillhead Safety Guard

Safety Precautions
2-8 General
2-10 TRAILER (OPTION) SAFE SETTING-UP
2-10 Specific Safety Instructions for Drilling

2-12 Safety Requirements


2-12 SAFETY VALVES
2-12 HYDRAULICS
2-12 REPLACEMENT OF WORN PARTS
2-12 SAFETY DEVICES
2-12 STATIC COMPONENTS
2-12 DIRECTIVE OF APPLICATION
2-12 OPERATION

2-12 OPERATING INSTRUCTIONS


2-13 DANGER ZONE - 2.5 metres All round the Rig.
2-13 Danger Zone with Trailer (option)
2-13 SAFETY DISTANCE
2-13 TRANSPORT OF PERSONS
2-13 NOISE LEVELS
Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Safety Considerations

2-14 Fire Extinguisher Instructions


2-15 STABILITY
2-15 SECURING AGAINST FALL
2-15 TRAMMING AND OPERATING CRAWLER DRILL RIGS
2-15 SAFE TRAMMING SET-UP (with Trailer option)
2-16 SIGNALLING
2-16 UTILITY LINES
2-16 WORKING NEAR OVERHEAD LINES
2-16 OPERATIONAL INTERVALS

2-17 Extreme Environmental/Job Site Conditions


2-17 Extremely dusty Working Conditions.
2-17 Warm to Hot Ambient Air Temperature.
2-17 Extremely Cold Ambient Temperature.
2-17 Working At High Altitude (above sea level).
2-17 Working in Salty Atmosphere.

DB525_OM_20081002D

2-2

Section 2 Safety Considerations


Safety Considerations

2-3

Location of Warning Signage

Maintenance note - To ensure that all personnel are continually aware


of the dangers of the rig, examine all signs during routine maintenance
and replace as required.

Mast Support adjust

DB525_OM_20081002D

Safety Considerations

2-4

Typical Drillheads - Location of Warning Signage

Maintenance note - To ensure that all personnel are continually aware


of the dangers of the rig, examine all signs during routine maintenance
and replace as required.

DB525_OM_20081002D

Safety Considerations

Trailer (Option) Location of Warning Signage

2-5

Maintenance note - To ensure that all personnel are continually aware


of the dangers of the rig, examine all signs during routine maintenance
and replace as required.

DB525_OM_20081002D

Safety Considerations

2-6

Personal Protective Equipment

DANGER ZONE

Approved Hard Hat

Safety Boots

Working Gloves not Operator

Hearing Protection

Respiratory Protection *

Safety Glasses *

* Especially on applications creating dust, or when using compressed air for flushing!

This list must be amended to meet YOUR on site requirements.

DB525_OM_20081002D

Safety Considerations

2-7

Emergency STOPS
DELTABASE rigs are fitted with various Emergency STOP switches.
Familiarize yourself with the position and operation of all the Emergency
STOP switches.Check the operation of the stop switches DAILY.

Guard Emergency Stop Switch

Jack-leg
Emergency
Stop Switch

Green Button
Control Panel Emergency Stop Switch

DB525_OM_20081002D

Safety Considerations

2-8

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.
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 section 4-12 to 4-13).

Mast/Drillhead Safety Guard

This is a guard which covers the Mast and Drillhead over the area within
reach of the operator. A special hinge on the guard is interlocked with the
operation of the Drillhead so that when it is opened the drill rotation and feed
stop immediately, low speed rotation at low torque is obtained by pressing the
Green button on the main control panel. Closing the Guard restores normal
drilling settings. This green button also functions to energise the hydraulics
after initial start-up.

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. 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, drifters, shank adapters,
couplings, drill steels, casing, bits, and crowns with
your bare hands during drilling. These parts usually get hot
and a severe burn may result. Be sure to wear work gloves when you
are handling any of these components.
5 Dry Nitrogen is the only gas used to charge accumulators on drifters and
rotary heads. Never use Oxygen to charge accumulators because a
mixture of Oxygen and Oil may ignite to produce an
explosion.
DB525_OM_20081002D

Safety Considerations

2-9

6 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.
7 When pressurised, damaged accumulators could burst,
scattering metal fragments throughout the area, and severely
injuring personnel.
8 Be sure to bleed the accumulator before attempting to disassemble it,
and only replace with accumulators that have been tested and approved.
9 Always operate the drill rig from the operators position.
10 Make sure all other persons are clear of the drill rig
before moving or starting any drilling operation.
11 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.
12 Use extreme caution when tramming or setting up on
uneven ground.
13 Always ensure that the stability of the rig is not impaired.
14 Drills have many moving components. Keep yourself and all
other persons clear of moving drill heads, feed
mechanisms, drill strings, and moving tools.
15 Know where you are drilling! Make sure you do not drill into
any utilities, such as buried electric cables, gas, or
water mains.
16 Use only purpose-made craneage lugs and/or lifting holders when
lifting the rig.
17 Do not remove or disable protective guards and safety
devices under any circumstances.
18 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.
19 Exhaust fumes from internal combustion engines are deadly. Be sure
to only operate the drill rig in well ventilated areas.
20 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.
21 Noise and Vibration levels The A weighted sound power level at the operating position is 104dB.
Appropriate hearing protection is required while operating
the Rig.

DB525_OM_20081002D

Safety Considerations

2-10

TRAILER (OPTION) SAFE SETTING-UP

The Trailer Stabiliser Jacks must always be applied on stable ground before
raising the Cyclone Bracket. Additionally - during transport the Cyclone must
be in the transport position and the Sample hose must be secured by the
Blockades (see pictures below)

Sample Hose

Blockade secure

Sample Hose

Blockade secure

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 tramming the Rig do not walk alongside, even for short
distances. You could tram the Rig over your own feet.
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
DB525_OM_20081002D

Safety Considerations

2-11

rake, 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 very heavy (especially Duplex Strings).
6 Always ensure there are adequate foot holds (mud-sludge).
7 Special care is required when placing Duplex Drill String Sections
(casing and inner rods) on the drill mast. The inner string threads must
be connected first.
8 Keep the casing section firmly secured to prevent it from sliding
down and squashing fingers during this process.
9 Care must be taken when flushing with compressed air
because pressurised air can drive cuttings with extreme force
and great velocity.
Reverse Circulation 0ption - this high volume compressed air
system is supplied with Whip-checks and anchors; these must
always be applied and maintained.
10 Ensure that all persons are at a safe distance and that
whip-checks are applied before opening air to the drill string.
11 Always relieve the pressure on the flushing medium in the drill string
during steel changes (i.e. extending the drill string and tripping-out the
hole).
12 When using DHD drill tubes (API, etc.) always ensure that clamps
are placed directly alongside couplings (joints).
13 DHD tubing is manufactured using relatively thin-walled tubes, which may
deform or be damaged by hydraulic pressure.
14 When using spanners to break and uncouple threaded
joints on drill strings, always comply with the following:
a) Note the direction of rotation to break joints
b) Select the correct size spanner to suit the flats
c) Place the spanner securely on the flats
d) The spanner must rest against the drill mast in the direction
of rotation required to break the joints
e) Do not hold the spanner by hand
f) Keep the spanner in position with a safety rope
g) Stand behind the drill mast.
15 Never stand beneath drill bits when inspecting for wear and
removing plugs when flushing holes.
16 Plugs may be forced out by flushing pressure, or the bit
may drop out causing severe injury.
17 Use a mirror for inspection if the bit cannot be removed for checking.
18 Do not hit drill bits with a hammer when cleaning strings of concrete
residue. Carbide inserts may break and cause severe
injury.
19 Remember that some cleaning solvents used for removal of oil and grease
develop dangerous fumes when they vapourise. Be sure to use
solvents only in well-ventilated areas.
20 The operator must never leave the control panel while drilling
is in progress.
21 The rig must be secured against inadvertent and unauthorised
movement prior to each operational interval.
22To avoid inadvertent or unauthorised start up once the engine is stopped,
ensure the starter key taken out of the ignition lock and all covers, doors
and lids are locked and secured.
23 If the drill rig is parked on a slope or incline, the crawler tracks must be
DB525_OM_20081002D

Safety Considerations

2-12

secured using wedges, in addition to engaging the hydraulic brakes.

Safety Requirements

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.

SAFETY VALVES

Settings for pressure limiting valves in the hydraulic circuits of the crawler
drill rig must only be changed by Boart Longyear approved personnel

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.

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 centre.

SAFETY DEVICES

The safety devices on the drill rig must only be changed by or with the permission of Boart longyear approved personnel.

STATIC COMPONENTS

Welding of static and bearing components on the drill rig is only to be carried
out by the manufacturer or by Boart Longyear approved personnel.

Safety devices and protective equipment incorporated within


moving machine components must only be opened, removed,
or disabled with the rigs engine stopped and secured against
inadvertent or unauthorised start up. (Safety devices include
engine covers, lids, caps, doors, gratings and panels.) All safety
devices and protective equipment must be reinstalled after
completing maintenance service and repairs.
DIRECTIVE OF APPLICATION

Boart Longyear drill rigs must be used only as directed and described in the
Operating Manual. The drill rig must not be used for :- Towing other machines, lifting parts other than for the the drilling duties, carrying passengers
or materials other than drilling tools, or for clearing debris from the drill site.

OPERATION

The rig functions must be activated only from the control panel.

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.
DB525_OM_20081002D

Safety Considerations

2-13

DANGER ZONE - 2.5 metres All round 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 slewing the
rig or moving any of its operational components.
The operator can work the rig only if no-one is within the Danger Zone. If
someone enters the Danger Zone the operator must immediately give appropriate warning signals. These are usually made with 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.

Danger Zone with Trailer (option)

SAFETY DISTANCE

A safety clearance of 0.5 metres must be kept from buildings, scaffolding,


and other equipment to prevent the danger of being squashed.
At all times keep in mind the rigs slewing requirements.
If the safety distance can not be complied with the area must be cordoned
off.

TRANSPORT OF PERSONS

Using the rig to transport persons is strictly forbidden.

NOISE LEVELS

The Maximum noise level measurements are:


Lwa = 104db
Lpa = 85db
Ear defenders must be worn

DB525_OM_20081002D

Safety Considerations

Fire Extinguisher Instructions

In case of a fire of solid substances, extinguish by short pulses

DB525_OM_20081002D

2-14

Safety Considerations

2-15

TRAMMING AND OPERATING CRAWLER DRILL RIGS

Independent and unassisted operation and maintenance of the crawler drill


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

SAFE TRAMMING SET-UP (with Trailer option)


Mast Stowed

Cyclone Stowed

STABILITY

The crawler drill rig must only be operated when it is in a stable position. The
rigs stability may be impaired by:
- Excessive load
- High Winds
- Unsecured ground
- Incorrect drill mast position
- Jerky acceleration and stopping during tramming,
- Slewing movements, and
- Operating on slopes and inclines.
The maximum allowable Gradients are:Parking
Drilling with jacks down

- 20deg
- Lateral 19deg
- Longitudinal 11deg
Tramming with Mast level - Lateral 19deg
- Longitudinal 10deg
The operator is responsible at all times for the rigs operation and must modify
procedures to allow for any likely instability and ensure a safe work area.

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 contractors 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.
DB525_OM_20081002D

Safety Considerations

2-16

SIGNALLING

If the operators vision is impaired during tramming and working, someone


must give signals for assistants or the tramming/working area must be cordoned off.
Only reliable persons should be designated to give signals. They must receive
instruction and be aware of this responsibility.
Communication must be co-ordinated and exclusively used between the
operator and the signaller.
The signallers attention must not be diverted by any additional tasks.

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.

WORKING NEAR OVERHEAD LINES

Unless local or national stipulations require otherwise, the following minimal


safety distances must be complied with.

Rated Voltage

Proximity
If working near overhead power lines:

Up to 1000V

1 metre

Above 1KV

3 metres

Above 110KV

4 metres

Above 220KV

5 metres

If rated voltage unknown
5 metres
For overhead tram lines:

Up to 1000 V AC / 1500 V DC
1 metre

Above 1000 V AC / 1500 V DC
1.5 metres

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 unauthorised
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 O 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 crawler tracks must be
secured with wedges in addition to the failsafe hydraulic 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.
Proir to re-starting the rig check that the mast and drillhead alignment are
as required.

DB525_OM_20081002D

Safety Considerations

2-17

Extreme Environmental/Job Site Conditions


Extremely dusty Working Conditions.

In order to extend the service life of the standard air filter for the Deutz 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 outside the sound proof enclosure and 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

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 the installation of a larger
dimensioned hydraulic oil cooler, otherwise the machine will overheat. In
addition to a larger cooler, the hydraulic oil viscosity could be changed. Further
more the cooling performance of the diesel engine must be inspected.
Please contact Boart Longyear regarding a Desert version engine capable
of operationg to +60 C, 5000m Above sea level

Extremely Cold Ambient Temperature.

If the drill rig is required to operate for extended periods in an ambient temperature below 0 degrees C, and/or occasionally under 10 degrees C, then
we recommend the installation of heating systems for the powerpack.
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.
Futhermore the hydraulic oil can be warmed up by an oil heater integrated
into the tank.
Also the hydraulic oil may be changed to HLP46(-5 to 10 degrees C) or
HLP30(-10 to 0 degrees C).
Please contact Boart Longyear

Working At High Altitude (above sea level).

For any operation at high altitude the hydraulic tank must be modified and an
inspection and check on the power of the diesel engine is necessary.
The standard air filter unit must be inspected and eventually replaced with a
filtration system under charging pressure.
Please contact Boart Longyear

Working in Salty Atmosphere.

When working in a salty atmosphere the hydraulic cylinder rods in particular


must be protacted. Furthemore the machine, especially the chassis. must be
coated with a defensive laquer against corrosion. The hydraulic oil radiator
must also be provided with a protective laquer finish, and in extremely salty
environments (offshore for instance) the radiator must be replaced with a
stainless steel model.
Please contact Boart Longyear
See also the Prime Mover manual.

DB525_OM_20081002D

SECTION 3

Table of Contents
3-2

Section 3 Drill rig components

3-2

Drill Rig Complete


3-4

3-6

Optional Radio Control

Drilling Mast
3-10 General rules for Feed chains:
3-13 Drillhead Sideslide - DD52
3-14 Alternative Rotary Drill Head - HY79
3-15 Drillhead Sideslide - HY79
3-16 Reverse Circulation Swivel (option)
3-17 Percussive Drifter (option)

3-18 Clamping and Breaking Device


3-19 Clamping and Breaking Device (option)
3-20 Automatic SPT (option)
3-21 Oil Liner DTH Lube system (option)
3-24 High Pressure Water Pump (option)
3-25 Vice (Option)
3-26 Vandal Covers (option)
3-27 Main Hoist
3-28 Wireline Winch
3-29 Crawler Tracks
3-30 Trailer (option)
3-31 Water/Mud Pump
3-32 Air Compressor and reservoir (Option)
3-32 Reverse Circulation (Option) Air Hose
3-32 Whip Check Connections
3-33 Hydraulic circuit

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 3 Drill rig components


Drill Rig Components

3-2

Drill Rig Complete


Hold clamp and
Breakout clamp

Rotary Drill Head

Drill Mast

Guard

Water Pump

Oil cooler

Engine
compartment

Engine Control D r i l l e r C o n t r o l Set-up Control Levelling Jacks


at each corner
Panel
Panel
Panel
DB525_OM_20081002D

Drill Rig Components

3-3

Drill Rig Complete


Engine control Alignment functions
panel
panel

Set-up functions
fixed panel

Drilling functions
swivelling panel
(open for use)

Drilling functions
swivelling panel
(Open for use)

DB525_OM_20081002D

Drill Rig Components

3-4

Drill Rig Complete


Read all instructions prior to tramming the rig.

Pendant Tramming controls


(stowed)
Speed selector

Emergency Stop

Optional Radio Control

Radio Remote
Tramming
Control

Radio Remote
Receiver
Driving Start
Button

Driving Stop Button


DB525_OM_20081002D

Drill Rig Components

3-5

Drill Rig Complete

Wireline Winch

Main Hoist

DB525_OM_20081002D

Drill Rig Components

3-6

Drilling Mast
The frame of the drill mast is fabricated from rolled steel section,
and is capable of drilling from vertical to horizontally forwards.
The travel of the rotary head is infinitely variable in forward
drilling mode and features fast feed and return. The drillhead
rotational speed is manually adjustable for low and high speeds
and is infinitly variable in both ranges.
The drillhead assembly, complete with side shift, is traversed
up and down the mast by a hydraulic cylinder acting through a
leaf-chain and pulley system. All pulleywheels are roller bearing
mounted. All chains and pulley wheels are made from high grade
steel.
The drill mast is raised and lowered by hydraulic cylinders
equipped with load control valves.
The drill mast is designed to handle full strings of casing and drill
pipes.
The hydraulically controlled feed system allows full control of the
drilling speed and bit weight.
The drillmast has a facility to advance towards the ground to
position the break-out device on the drill string.
The mast is locked in the upright position by clevis pins.

Safety Guard

Rotary Drill Head

Rod Clamps

Mast Assembly

DB525_OM_20081002D

Drill Rig Components

Drilling Mast
The rotary head is held onto
the drill mast with low friction
sliders. Lateral alignment of
the rotary head is controlled
by four rollers with eccentric
shafts (Lateral alignment rollers on the photo below).
The up and down movement
of the Rotary Head is controlled from the swing-out panel
(see section 4), by activating
the hydraulic cylinder chain
and pulley system.

Low Friction
Sliders

Lateral alignment
rollers

DB525_OM_20081002D

3-7

Drill Rig Components

3-8

Locking pins
(one each side

Finger trap hazard,


do not enter danger
zone until mast is
fully raised, the
mast must be static
when the pin is
inserted.

The Mast is raised to vertical by two Lift cylinders which are complete with over centre counter balance valves to lock the cylinders
in the event of hose failure. There are two manually inserted locking pins which maintain the mast in the vertical position during long
working cycles.

DB525_OM_20081002D

Drill Rig Components

3-9

Drilling Mast

Chain adjuster Bolts


The speed of feeding the drill head and also the Fast Feed facility
are regulated from the swivelling panel (see section 4).

DB525_OM_20081002D

Drill Rig Components

3-10

General rules for Feed chains:


The chain pulleys are mounted on roller bearings.
Feed chains have to be checked daily for cracks and fissures.
Pins and links with wear marks and grooves or mechanical
deformations must be replaced. Feed chains have to be checked
weekly for elongation.
Excessive lengthening of the chains should be avoided. They
should be adjusted by tightening the adjuster bolts at the end of
the mast assembly. As a general rule, the useful life of chain is
when the percentage extension reaches 2 per cent (160mm on
each piece of chain), then the chain should be replaced.
Elongation test procedure:
The gauge distance must consider at least 17 double-links in the
working range of the chain and should be done as follows:
Fix the total length of 17 double-links of a new chain within the
pitch distance (roller to roller / link to link)
The test procedure compares the total length of the new chain
and the used chain and if the used chain shows increased
lengths of 161/2 double-link gauge, the chain must be
replaced.
Nominal length values of chains:
(For example) Type 24 B-2 1 double link 38,1 mm
17 double links 647,7 mm

DB525_OM_20081002D

Drill Rig Components

3-11

Drilling Mast
The load applied to the drill head is proportionally regulated from
the Swivelling Panel
The maximum thrust is 34 kN.
The maximum pull back is 55 kN.
A special valve in the hydraulic system automatically balances
the load applied to the up and down movement of drill head.

Chain adjuster Bolts

Retract Chain

Drillhead

Feed Chain

DB525_OM_20081002D

Drill Rig Components

3-12

The high torque / high speed rotary head is equipped with a


hollow drive shaft mounted between conical roller bearings and
ball bearings.
The rotary head has two speed ranges, manually selected at the
Drillhead gearbox (position 1 below).
The Drillhead is powered by a high torque - variable displacement
hydraulic motor which is hydraulically controlled from the
swivelling control panel.

Gear selector
(position1)

Water swivel
(position2)

Floating
spindle
(position3)

The head output speed and torque are infinitely variable being
controlled from the swivelling control panel.
The head is equipped with a water swivel (position2)and a top
sub shaft extension adaptor for connection to the drill pipes.
The head has lateral side shift to allow passage of drill string and
for wireline extraction.
For easy coupling of the drill pipe the rotary head is equipped
with a floating spindle (position3)allowing axial movement.
Drill tools are manually connected to the rotary head.
The floating spindle is a thread saver and is important during
making up and breaking out drill pipe connections (i.e. when
screwing and unscrewing).

DB525_OM_20081002D

Drill Rig Components

3-13

IMPORTANT NOTE

STop first and only switch the gear stages at stop.
SERIOUS
MALFUNCTION
or even
considerable
damage WILL BE
caused IF this
warning IS NOT
ADHERED TO

Drillhead Sideslide - DD52


The drillhead can be moved sideways 500 mm to clear the way
for rod extraction/insertion and wireline operations.

Drillhead moved
sideways 500 mm

DB525_OM_20081002D

Drill Rig Components

Alternative Rotary Drill Head - HY79


The high torque high/low speed rotary head is equipped with a
hollow drive shaft mounted between conical roller bearings and
ball bearings. The head is powered by one high torque - variable
displacement hydraulic motor and one fixed displacement motor.
The head output speed is manually set to High or Low rotation
and is infinitely variable in either High setting or Low setting.
Control is from the pivoting panel.

Water swivel

Gear selector

Oil Level

The head is equipped with a water swivel and a top sub shaft
extension adaptor for connection to the drill pipes. For easy
coupling of the drill pipe the rotary head can float 50mm axially
The floating facility is a thread saver and is important during
making up and breaking out drill pipe connections (i.e. when
screwing and unscrewing).
Drill tools are manually connected to the rotary head.

The correct oil level is 3/4


full showing on the level
glass on the rotation gear
box, with the rotary head in
the drilling position.

DB525_OM_20081002D

3-14

Drill Rig Components

3-15

The HY79 drillhead has a manual change two


speed facility for changing from higher to lower
speed drilling operations. It is important to follow
the steps below to change gears.
1 - STOP the engine.
2 - Turn the Gear Change Stick

Changing from Low to High - 1 turn ccw.

Changing from High to Low - 1 turn cw.
3 - Rotate the Drill Spindle until engagement is
felt through the Gear Change Stick.
4. IMPORTANT - If the Gear Change Stick is not
turned one full turn, return to original position,
rotate the Drill Spindle through a small angle,
then try again.
Gear selector
Do not start the engine to rotate by the hydraulic motors until the
Gear Change Stick is turned fully in or fully out.
Serious damage will be caused.
If it is not possible to align the teeth manually:
Reengage the original gear and rotate with the hydraulics, then
repeat the process.
Drillhead Sideslide - HY79
The drillhead can be moved sideways 500 mm to clear the way
for rod extraction/insertion and wireline operations.

Drillhead moved
sideways 500 mm

DB525_OM_20081002D

Drill Rig Components

3-16

Reverse Circulation Swivel (option)


The HY 79 Rotary Head is fitted with a special Water/Air Swivel
arrangement when Reverse Circulation is required.
RC Outlet
Wear plate access
Blow-down system
Blowdown
air inlet

Drilling air
inlet

DB525_OM_20081002D

SECTION 3

Percussive Drifter (option)


The Eurodrill H1006 Rotary/Percussive Drifter is fitted as an
option.

H1006 Percussive
Drifer

Manual Rotation
speed change

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Drill Rig Components

Clamping and Breaking Device

3-18

This device is for holding, making up and breaking out the drill
pipes, core barrels and casing tubes. It includes:1. Holding Clamp - for holding the drill string during thread making
or breaking.
2. Breakout device - with a clamp for gripping the upper drill pipe
then a breakout cylinder for breaking the thread by rotating up to
30degrees.
Standard clamps have a capacity of 50-133mm Dia. Optional size
capacity of 60-220mm Dia can be supplied.
Both holding and unscrewing clamps can be open front type so
as to facilitate installing and extracting rods, core barrels and
casings.If the clamps are closed front type (with pinned gate), to
free the area remove the pin on one side and open the gate.

Breakout
Clamp
(position2)
HoldingClamp
(position1)

DB525_OM_20081002D

Drill Rig Components

Clamping and Breaking Device


(option)

3-19

This device is for holding, making up and breaking out small


diameter drill rods generally applies when usig a Rotary/
Percussive Drifter.

Breakout
Clamp
(position2)
HoldingClamp
(position1)

DB525_OM_20081002D

Drill Rig Components

Automatic SPT (option)

3-20

The rig is equipped with automatic, hydraulically operated SPT


(Standard Penetration Test). The weight of the drop hammer is
63Kg, and the free fall height is 75 cm.
Sideslide activated

SPT in working
position

DB525_OM_20081002D

Drill Rig Components

3-21

Oil Liner DTH Lube system (option)


A reservoir and electric control for the automatic lubrication of
DTH.

Isolation Valve

Oil Liner
reservoir
(DTH Lube)
Oil Liner Control
Panel (DTH Lube)
On/Off/Auto
Selector Switch
Green Light (see next
page for function)
Red Light (see next
page for function)

DB525_OM_20081002D

Drill Rig Components

3-22

AIR lINE OIl lUbRICATION SYSTEM MANUAl


The Air Line Lubrication System functions in two operating modes selected by means of S1
switch (ON-MANUAL / OFF / ON-AUTOMATIC). When the MANUAL mode is selected the red H20
LED is on indicating the E3 electrovalve (lubrication pump) is energized all the time. When AUTO
mode is selected the green H10 LED is on and the red H20 LED is turning on and off periodically as
the E3 electrovalve gets energized and disenergized.

S1

H10

H20

The H20 flashing frequency (corresponding to the periods the lubrication valve E3 is with or
without electric power supply) can be adjusted by means of the two timer relays (K10, K20) fitted
inside the control panel of the Lubrication System. Use the dial on the top of the K10 and K20 relays to
adjust respectively the delay time and the time for the E3 electrovalve to be energized (working time).
If the time scale of the timers needs be changed use the first three dip switches from left and set them
according to the below given time scales diagram.

Both the timers time scales are set to 0,510s by default.

DB525_OM_20081002D

Drill Rig Components

Delay time
relay

3-23

Working
time relay

A lED diode
b Time adjustment dial
C Time scale / function selection

DB525_OM_20081002D

Drill Rig Components

3-24

High Pressure Water Pump (option)


External
water suction
connection
High pressure
Lance
connector
or to Dust Deflector (RC option)

Optional Water tank


- 150 litres

Water level indicators

Water pump/PTO Change over valve

Water/Mist Pump
Valve positioning
details.
Position of 3-Way Valve

Flow to Gun and Dust Deflector


(RC option)
Dust Deflector (RC option)
DB525_OM_20081002D

Flow to Collector

Position of 3-Way Valve

Drill Rig Components

Vice (Option)

DB525_OM_20081002D

3-25

Drill Rig Components

Vandal Covers (option)

3-26

Lockablle covers to prevent damage to controls by vandals.

Lift off Control panel


Vandal cover

Tramming Control Vandal cover


(closed)

Tramming Control Vandal cover


(open)

DB525_OM_20081002D

Drill Rig Components

3-27

Main Hoist

The main hoist is used for handling the rods and pulling the drill
string during conventional coring operations.
Main Hoist Type Braden BG 6
Line pull - Bare Drum
31.1 kN

- Full Drum
23.1 kN
Rope speed @ 140 l/min
- Bare Drum

30 m/min

- Full Drum
40 m/min
For Cable Dia13 mm

30 m
Brake
- Failsafe with overcentre valve capable of withstanding 1.3

times the winch capacity

Fitted with a limit switch to prevent reeling off of the rope, this
cuts out the rig hydraulics which must be re-set with the green reset button on the fixed control panel.
See Main Hoist section for full specification and Parts list.

DB525_OM_20081002D

Drill Rig Components

3-28

Wireline Winch

The Wireline winch is used for retracting the core barrels from the
hole.
Wireline Winch
Line pull
Rope speed @ 59 l/min
For Cable Dia 6 mm
Optional Cable Dia 5,0 mm
Brake

6500 N
100 m/min
250 m
350 m

- Failsafe with overcentre valve capable of withstanding 1.3


times the winch capacity

See Wireline Winch section for full specification and Parts list.

DB525_OM_20081002D

Drill Rig Components

3-29

Crawler Tracks
The rig is equipped with a hydraulically powered TrackOne
Crawler Tracks type 070221. These comprise of a Left and Right
hand pair. See section 10 at the back of this manual.

Crawler Tracks

DB525_OM_20081002D

Drill Rig Components

3-30

Trailer (option)
The rig may be coupled to a trailer for Reverse Circulation
operations
Manual Stabiliser Jacks
at each corner

Cyclone and Sampler

Storage
Water Reservoir
compartment

Hose stowage
Brackets

DB525_OM_20081002D

Cyclone door operator

Hydraulic and air


Cyclone Slew and
Lift positioner valves connectors

Drill Rig Components

Water/Mud Pump

3-31

The Water/Mud pump is a hydraulically driven triplex mud pump. It is deck


mounted and driven from the hydraulic system which is powered by the
diesel engine.
The pump is supplied complete with all accessories.
All controls are positioned close to the operator.
Maximum pressure:
50 bar
Maximum working pressure: 35 bar
Maximum flow:
90 litres/min
The output flow of the pump is variable to suit site conditions.

Accumulator

Pressure Regulator
(manual re-set)

DB525_OM_20081002D

Pump

Drill Rig Components

3-32

Air Compressor and reservoir (Option)


The rig is equipped with an engine mounted Air Compressor with
an Air receiver mounted at the rear of the rig.

Air Reservoir

Reverse Circulation (Option) Air Hose


Whip Check Connections
When the Rig is equipped for Reverse Circulation duties involving
high volume Compressed air, the hose system is protected by the
application of Whip checks and anchors. These safety items must
always be utilised and must be monitored regularly for wear and
damage - replace any item that shows signs of wear or damage.
Typical Whip Checks and Anchors

DB525_OM_20081002D

Drill Rig Components

3-33

Hydraulic circuit

The pumps are mounted directly on the diesel engine.


In the complete version of the drilling rig there are 2 pumps.
A bent axis fixed displacement pump powers the crawler tracks, the
drillhead and main hoist

A 2 stage gear pump actuates all auxiliary movements and feed.


All pumps are protected against excessive pressure by safety
valves mounted before the distribution valves. The fixed pressure
rating must not be changed.
The Oil Tank is fitted with the following:1. Oil level and temperature sensor which shuts down the system
if the temperature exceeds 80 degrees
2. Oil filter with electric signal device, which lights a warning lamp
positioned on the engine instrumental panel. When this
happens, the filter cartridge must be replaced.
The filter grade is 10 micron. We recommend using 17/15/13
class oil (ISO 4406).
ATTENTION!!
During cold weather starting (when the temperature of the
oil is low and therefore the viscosity is high), the lamp may
light due to the high resistance the oil meets when flowing
through the filter element. This does not necessarily mean
that the filter is clogged.
After the oil has circulated for a certain time and become
fluid, if the lamp does not extinguish then the filter cartridge
should be renewed.
3. A filling tap with breather and pre-filter.
4. Three ball-valves to close the oil circuit in case of a shutdown
or repair, avoiding the loss of oil.
5. One heat exchanger incorporated in the return circuit and
fitted with one electric fan that is automatically actuated by a
thermostat in the oil tank when the oil temperature has risen to
the value indicated. A lamp on the engine control panel lights
when the fan is running.
The thermostat is set to 60 degrees C.
All the control and monitoring elements of the drill are assembled
in the control panels.

DB525_OM_20081002D

SECTION 4

Table of Contents
4-2

Section 4 Operations

4-3 Introduction
4-3

Equipment Description and Identification

4-4

Component Location
4-6

Diesel tank and Hydraulic tank location

4-7

Flushing Control valves

4-8

Flushing Control valves (circuit with RC option)

4-9

Auxiliary Controls

4-10 Main control panel description


4-10 Engine controls
4-11 Alignment controls
4-12 Swivel panel controls
4-13 Fixed panel controls
4-14 Tramming Control Panel Description
4-15 Crown Block control description

4-16

Pre-start checks

4-16

Prior to Start-up

4-17

Initial Start-up

4-18

Tramming (Tracking)
4-18 Transport Support
4-18 Tramming control hoses
4-18 Mast in Tramming Position
4-18 Radio Control (Option)

4-19

Drilling Methods
4-19 Hints for Optimum Application

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 4 Operations
SECTION 4

4-20 Drilling Operations


4-20 Calculating Bit Weight
4-21 Down Hole Drilling
4-22 Up Hole Drilling
4-23 Horizontal Drilling
4-24 Bit Weight Table

4-26 Flushing
4-26 Blow Down (option)
4-26 Reverse Circulation / Blow Down (Option) Air Hose
Whip Check Connections
4-27 Blow Down circuit (option)
4-28 Trailer (option)

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

Prepared by TSG - Printed in Poland - Issue level DB525 20081002C

2010 BoartLongyear Sz o.o.

Operations

4-3

Introduction
The DELTABASE 525 is configured for:




DTH drilling of holes from 4 to 61/2


Geothermal wells
Water wells
Drilling with casing
Reverse Circulation (Option)

Important - The personnel responsible for operating the DB525 must be


sufficiently trained and be aware of all the safety rules in this manual.
If there is anything you are not sure about, contact the Boart Longyear,
Technical Support Group.
Contact information :- European Service Manager
T.S.G.(Technical Support Group)

BOART LONGYEAR

Arrowmax Buildings
Langwith Road
Langwith Junction



Mansfield

Notts NG20 9RN

England Tel: +44(0) 1623 747898

Equipment Description and Identification


Filler Pump (hydraulic reservoir) - this pump is used to pump hydraulic
fluid into the reservoir and is permanently connected through the main
return line filter.
Main Frame Enclosure - contains the main hydraulic directional control
valves and circuitry.
Circuit Testing- Pressure gauges monitor the system by measuring main
pressures at any time while the machine is running.
Hydraulic Reservoir - has a total oil capacity of 200 litres, and is fitted with
an indicator to show hydraulic oil level and temperature.
Lifting Eyes - assist with lifting and slinging the Drill Rig.
Oil Cooler - provides cooling of hydraulic oil by electric driven fan blowing
air across Heat Exchanger.
Hydraulic Filters - maintain continual particle filtration through 10 micron,
beta-rated elements. A visual clogging indicator is fitted, which changes
colour to warn of an element servicing requirement, the Return filter has
an electrical connection to a warning light on the insrument panel.
Electric Starter - refer to section 4-13 to 4-14 for further details starting
procedure.
Fuel Tank - has a capacity of 60 litres, and is fitted with a fuel gauge on the
Starter panel. The tank is filled via a
fillercap on the mid left side of the rig.
Engine and Pump - The diesel engine and close coupled Hydraulic Pump
are situated in the Engine Compartment. The speed of the diesel engine
is controlled by accelerator lever mounted to the right of the main control
panel.
The pictures on the following pages locate the main components of the DB
525.
Note: The hydraulic reservoir can be filled with a wide range of oils. See the
Oil Selection Chart in section 5 to determine the oil most suited to your
conditions.
DB525_OM_20081002D

Operations

4-4

Component Location
Hold clamp and
Breakout clamp

Drill Mast

Rotary Drill Head

Water Pump

Battery compartment

DB525_OM_20081002D

Safety
Guard

Oil cooler

Engine compartment

Control panels

Levelling Jacks at
each corner

Operations

Alignment functions Set-up functions


panel
fixed panel
Engine control
panel

4-5

Engine speed
control

Rotation to Zero Standard


Rotation speed
speed control
control
RC only

Drilling functions High/Low speed Hydraulics Actiswivelling panel Tram selector vate button
(Open for use)

DB525_OM_20081002D

Drilling functions
swivelling panel
(Stowed)

Operations

4-6

Diesel tank and Hydraulic tank location

Diesel tank
filler

DB525_OM_20081002D

Hydraulic
tank filler

Operations

Flushing Control valves

Flushing
Control
valves

Reverse circulation
Dust deflector
injection water
(option)
Flow control.
Open/Close control
(see circuit on next
page for set-up)

DB525_OM_20081002D

4-7

Operations

Flushing Control valves (circuit with RC option)

DB525_OM_20081002D

4-8

Operations

Auxiliary Controls

High Pressure
water Pump - up
Trailer PTO - down

Compressed Air
connection

Auxiliary Hydraulic
PTO

DB525_OM_20081002D

4-9

Operations

4-10

Main control panel description


Engine controls

Filter clogged light

Fan belt light


Hydraulic oil light

Cooling fan light


Hydraulic oil
light

Engine oil light


Engine Temperature
light
Battery charge
light
Pre-heat Glow plug
(D914 Engine only)
Engine start/stop
switch

Engine Pressure
Working Lights
Engine Revs
DB525_OM_20081002D

Engine Temperature

Fuel Level

Operations

4-11

Alignment controls

Tram speed selector


High-down
Low-up

Set-up Spirit level

There is a potential
for causing injury
when these levers
are moved. Ensure
the danger area
around the rig is
clear of people before
operating.

Levelling Jack
Right rear

Levelling Jack
Left front

Levelling Jack
Left rear
DB525_OM_20081002D

Mast raise

Levelling Jack
Right front

4-12

Operations

Swivel panel controls

Drillhead
side-shift
Breakout
clamp

Mast slide
Clamp

Breakout
cylinder

Tip-out or
Crown
block slew

There is a potential for


causing injury when
these levers are moved.
Ensure the danger area
around the rig is clear of
people before operating.

Safety Guard Bar


shown stowed for
clarity - Must be raised
during operation

Clamp adjustment
Crown
Drillhead
block
Rotation
extend
Wire line

Pressure
Rotation/
Winch

winch

Main winch

Pressure
Feed
Drillhead
feed

Emergency Stop
Air Valve
Blow Down Holdback Feed Speed
Control
Control
Pressure Control
(RC option) (RC option)
DB525_OM_20081002D

Feed
Pressure
Control

Operations

4-13

Swivel panel for Rotary/Percussive Drifter (option)


The extra controls are shown for the optional Percussive Drifter.

Percussion Pressure
Rotation

Main Winch

Percussion

Drifter Feed

Warning Light for High


speed engaged

Rotation Speed Control


Up- Fast
Down - Slow
Note - The 2 other speeds are
manually controlled on the Drifter
DB525_OM_20081002D

Operations

4-14

Fixed panel controls

Selector
Drill/Drive
Pressure Pressure
Pilot circuit Clamp/
Cylinders

Selector
Auger/Core
Drilling

Pressure
Pump/SPT

Drillhead
Rotation speed
control to Zero
(RC only)

Standard
Drillhead
Rotation
speed control

There is a potential for


causing injury when
these levers are moved.
Ensure the danger area
around the rig is clear of
people before operating.

Pressure
Selector
control
Up-SPT on.
Pilot circuit Down- Water
pump on.

DB525_OM_20081002D

Fast Feed
select - Down

SPT Counter

Green
Hydraulics
activation
Button

Operations

Tramming Control Panel Description

There is a potential
for causing injury
when these levers
are moved. Ensure
the danger area
around the rig is
clear of people before
operating.

Tramming Left
Crawler

DB525_OM_20081002D

Tramming Right
Crawler

4-15

Operations

Crown Block control description

Crown Block
Jib Extend

DB525_OM_20081002D

Crown Block
Slew

4-16

Operations

4-17

Pre-start checks
Power Unit
Check that the main pump has been primed. If not, prime by
removing the case drain hose and adding Hydraulic oil until
case is full. Refit hose.
Check that the diesel engine levels of coolant, engine oil and
diesel fuel are correct.
Coolant Type of coolant
.....................................
Freezing point
Oil Type of engine oil:
....................................
Viscosity
Fuel Check that there is sufficient for the job.
Check that the hydraulic oil tank is full to the top of the sight
glass, fill by Hand Pump if necessary
Type of hydraulic oil:
Viscosity:
Check that the rotary head gearbox is full to the sight glass.....
Type of oil:
.....................................
Viscosity:
Check that the top winch is full
....................................
Type of oil:
.....................................
Viscosity:
Check that the crawler track planetary gear boxes have been
primed.
.
Type of oil:
.....................................
Viscosity:
Check that the tension of the crawler tracks is set correctly......

See section 10
Check that panels are fitted correctly (tramming control,
swivelling panel and diesel engine panel).

Prior to Start-up
Be sure to check that all control elements (levers) are in the
neutral O position.
The Emergency STOP switches must not be activated
Release any activated switches by rotating them slightly.
Check that the Safety Guard Door is closed and latched.
All stopcocks for pump suction lines must be open.
Hydraulic hoses and lines must be securely connected and
tightened. Check for oil leaks.
Check oil levels in the engine, gearboxes, and hydraulic oil
tank.
Check the diesel fuel level in the fuel tank.
For further information see the Engine Manual (DEUTZ)
DB525_OM_20081002D

Operations

4-18

Initial Start-up
Set the accelerator control to approx. 1/4 engine rpm.
Switch the main switch on (battery isolator)
Insert the starter key and turn right to position I.

There is a potential
that the engine can
stall causing injury
if the rig is operated
before the red ignition
light is extinguished.

The oil pressure warning lamp and battery control


(ignition) lamp must light up.
Flick start/stop to position II several times to allow the pumps
to prime.
Turn the starter key to position II and release it as soon as
the engine is running smoothly.
Raise the engine revs to approximately1200 RPM until the
red ignition light is extinguished (2 to 3 minutes).

The oil-pressure warning lamp and battery control


(ignition) lamp must switch off.
For low temperature starting; if necessary; the key can be
left in position II for no more than 40 seconds to pre-heat
the engine (glow plugs).
With out exception, the engine must be turned off immediately

if any of the warning lamps on the engine starter panel

light up.
The engine is turned off by turning the ignition key to the O
position, or by activating the Emergency STOP switch.
During the start-up procedure, the key should not be kept in
position II for more than 10 seconds.
If the engine does not start, wait for approximately 1 minute
before repeating the above procedure.
Press the Green Hydraulics Activtion button.
Check for leaks, and rectify before proceeding.
Slowly activate all cylinders (to fill with oil)
Re-check the hydraulic oil tank and top up if necessary.

DB525_OM_20081002D

Operations

4-19

Tramming (Tracking)
Never tram the Drill rig with the Drill Mast in a raised position (or
the Trailer cyclone in the raised position). The Drill Mast must
always be in the Stowed position and resting in the transport
support shoe when tramming the rig. Check that the 4 Levelling
Jacks are fully retracted. The rig can be trammed by Radio remote (Option) or by Hydraulic Pendant.
Transport Support
Mast in Tramming Position

Radio Control (Option)

Never operate the


Radio control if the
Rig is out of sight

Tramming control hoses


Prior to tramming, be sure to check that you have adequate
clearance, that the tramming area is clear and free from
obstructions, and that no persons are near the drill rig.
The drill rig must be trammed only by using the special
Tramming controls.
When using the Pendant controls ensure the control hoses,
are free from danger of trapping.
When using the Radio remote always keep the Rig in full
view, never leave the Control panel when the side activate
button is applied and always engage the flashing light and
beeper before moving the rig.
Activate the control levers in the direction required.
The tracks are steered by counter-activating control levers.
Brakes automatically apply when control levers are centred.
To avoid acceleration instability, operate the levers
slowly.
Always apply both Joystick controls levers to turn and steer the
rig.
Do not attempt to turn the rig on the spot in muddy or boggy
conditions.
Apply both levers to slowly tram to and fro, while turning at the
same time.
DB525_OM_20081002D

Operations

4-20

Drilling Methods
Hints for Optimum Application
Do not place excessive feed pressure on the drill because
this causes several problems:
The drill rig will be lifted off the ground and become
unstable. Increased wear of accessory components, drill
string, hydraulic drill, and rotary head will result.
Always keep thread connections clean and well lubricated.
When tripping out of the hole, the time spent on this
procedure is regained many times over through faster
penetration.
Make sure that all casing joints are screwed together.
Always maintain perfect alignment of all drill string
parts and if necessary re-adjust both during drilling and
retracting.
Store all drill string components, e.g. casing, drill steels,
augers etc., on a set of saw horses to keep them out of the
dirt and to make lifting and handling easier.
Clean all threads with a wire brush and grease them with a
high quality thread compound.
Pay close attention to hydraulic pressure gauges at all
times during drilling.
Monitoring the pressure in the rotation circuit indicates how
much torque is being applied to the drill string.
If you notice that the pressure is reaching the set limit, you
may be getting stuck.
Stop advancing and retract the drill string slightly.
Shut off the hammer (if mounted) and allow the drill string
to rotate with the flushing flowing until the torque pressure
drops back down.
Then proceed further.
Also watch your feed pressure gauge, as this will help to
establish an idea of how much force is on the bit.
Pay close attention to flushing pressure. A rise in pressure
indicates that either the bit is getting clogged or the
annulus is collaring.
Take corrective action before it is completely clogged or
collared.
Also, make sure that everyone is clear of the rig, as
sometimes the plug opens with considerable force and
cuttings come up the annulus at great speed.

DB525_OM_20081002D

Operations

4-21

Drilling Operations
Calculating Bit Weight
The Drills Remote Control Panel has two control valves that
together or individually are utilised to control the fine feeding
operation. The feed pressure control valve regulates the amount
of oil pressure being directed into the feed cylinder. The feed flow
control regulates the oil flow exiting the cylinder.
The feed pressure gauge (P1) and the hold back pressure gauge
(P2) do not display actual weight on the drilling bit. Actual bit
weight needs to taken from the Bit Weight Chart verses the
change in hold back pressure at the end of this chapter.

Safety Guard Bar


shown stowed for
clarity - Must be raised
during operation

Pressure
gauge P1
Feed

Pressure
gauge P2
Holdback

The following method uses the change in hold back pressure


which occurs when the feed flow control is adjusted, to determine
the load on the bit. A slightly different technique is required for
uphole drilling to down hole drilling but the principle remains the
same.
DB525_OM_20081002D

Operations

4-22

Down Hole Drilling


1 With the rod string connected to the Drillhead and the drilling bit
approximately 150 mm off the bottom of the hole, set the feed
speed control to zero.
2 Rotate the drill string and then increase the setting of the feed
pressure control to a level sufficient for drilling. The amount of
pressure required will vary significantly due to types of rock and
drilling bits used. Also as hole depth increases, the feed pressure
requirement is potentially less due to greater rod weight acting
on the face of the bit.

P2 Hold Back pressure


will rise in accordance
with amount of rod
weight and feed
pressure.
P1 Feed pressure will
rise in proportion to
setting of feed pressure
control.

3 To commence feeding, gradually active the feed speed control


which will be accompanied by a drop in the hold back pressure
on the gauge.

P2 Hold Back pressure


falls.
P1 Feed pressure
remains constant.

4 In a true vertical hole the level of visible drop may be minimal.


5 Register the indicator reading on the hold back pressure gauge
at this point whilst the bit is advancing downward but not yet
contacting the hole bottom.
6 As the drilling bit touches the bottom of the hole, a further reduction
in pressure will be noted. The change in hold back pressure from
the point in para 4, to th pressure indication now is the amount
of weight being applied to the bit (lined area on P2)

DB525_OM_20081002D

Operations

4-23

7 If the indicator on P2 drops to zero, it is likely that there is insufficient feed pressure to provide sufficient bit force. To counteract
this, the feed pressure setting should be increased.
8 To approximate the bit weight, first determine the change in pressure (MPa) on P2 in para 6. For example, if the drop off is 6 MPa,
locate 6 MPa on the bit weight chart at the end of this chapter
and its corresponding bit weight value in kN.
Up Hole Drilling

1 With the rod string connected to the drillhead and the drilling bit approximately 500 mm off hole bottom, set the feed pressure control to zero and
activate the feed flow control.
2 Rotate the rod string, move the feed control lever forward and then
adjust the feed pressure control so that the rod string slowly moves upward
into the hole.
3 Note the indicator reading on the feed pressure gauge which approximates
the weight of the rod string and drill head. The deeper the hole, the higher
the pressure will be.

4 Set the feed speed control to zero and then increase the feed pressure
further to supply sufficient cutting force onto the bit to suit the type of rock
being cut.

5 Slowly increase the feed speed control to commence fine feeding. The
resultant change in hold back pressure from the point in para 4, to the
pressure indication now is the amount of weight being applied to the bit
(lined area on P2).

DB525_OM_20081002D

Operations

4-24

6 If the indicator on P2 drops to zero it is likely that there is insufficient feed


pressure to provide sufficient bit force. Feed pressure will need to be periodically increased to compensate for the additional rod weight as the hole
depth increases.
7 To approximate the bit weight, first determine the change in pressure (MPa)
on P2 in para 5. For example, if the drop off is 6 MPa, locate 6 MPa on the
bit weight chart at the end of this chapter and its corresponding bit weight
value in kN.

Horizontal Drilling
1 With the rod string connected to the drillhaead and the drilling bit
approximately 500 mm off hole bottom, set the feed pressure control
to zero and activate the feed speed control valve.
2 Rotate the rod string, move the feed speed control lever forwards and
then adjust the feed pressure control so that the rod string slowly
moves into the hole.
3 Note the indicator reading on the feed pressure gauge, which is the
pressure required to overcome the friction of the rods lying in a flat
hole.

4 Set the feed speed control to zero and then increase the feed pressure further to supply sufficient cutting force onto the bit to suit the
type of rock being cut. Rod weight should have no influence on
horizontal holes.
5 lowly activate the feed speed control to commence fine feeding. The
resultant change in hold back pressure from the point in para 4, to
the pressure indication now is the amount of weight being applied
onto the bit (the lined area P2).

DB525_OM_20081002D

Operations

4-25

6 If the indicator on P2 drops to zero, it is likely that there is insufficient


bit force. Increase the value of P1 by increasing the fine feed pressure to remedy this.

7 To approximate the bit weight, first determine the change in pressure (MPa) on P2 in para 5. For example, if the drop off is 6 MPa,
locate 6 MPa on the bit weight chart at the end of this chapter and
its corresponding bit weight value in kN or Ibf.
Bit Weight Table
Change in Hold Back Pressure
(P2) MPa
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DB525_OM_20081002D

Resultant Bit Force


kN
3.3
6. 5
9.8
12.0
16.2
19.5
22.7
25.0
29.2
32.5
35.7
38.9
42.2
45.4
48.7

Operations

4-26

Under some deep hole applications the Hold Back pressure and
Feed pressure tend to reach a balance point due to the weight of
the drill string. Decreasing Feed speed will slow down the
pentration rate and will overcome this balance point. Beyond this
balance point it will become necessary to operate the feed control
in reverse, i.e. to apply sufficient retract preesure to allow the
weight of the drill string to apply the weight to the bit.
When drilling, Boart Longyear recommends that you always start
with a low torque setting, so that there will be sufficient in
reserve.
Our aim is to ensure your rig is operating as efficiently as
possible.To help you achieve maximum productivity with
minimum of down-time, we offer the following guide to reduce lost
time during start up. The most important aspect of efficient drilling
is having the correct system of accessories for your particular
project.
REMEMBER:
The accessories do the actual drilling, the drill only powers the
drill heads, which in turn only rotate and guide the drill string into
the ground.
Should you have any queries or doubts about a particular
application, you can refer to the the selection of Boartlongyear
accessory brochures which are readily available from your
BL representative, or look up our web site
(www.boartlongyear.com).
If you need further assistance contact your Boart technical
representative.
Once you have decided which system and method will work best
on your particular site, it is very important to ensure that all
components required are actually on site.

DB525_OM_20081002D

Operations

Flushing

4-27

One of the most important aspects in efficient drilling, especially


in ground engineering applications, is to flush the hole completely
during drilling.
This can be done with air, water, or a combination of the two,
depending on ground conditions on the jobsite.
Whatever flushing media you select, it is important to remember
the following:

Air requires an uphole velocity of at least
900 metres per minute.

Water requires an uphole velocity of at least 45 metres

per minute.
If you not sure how to calculate these factors contact your Boart
Longyear technical representative.
Make sure that you have a compressor or pump of adequate
capacity, and the right pressure in the hose.
For air flushing to be effective your compressor should be able
to maintain constant output of at least 10.2 bar during drilling.
Water pressure should be at a minimum of 10 bar.

Blow Down (option)


Reverse Circulation applications utilise the Blow Down facility for
control of the flushing and hole clearing process. Activation of
Blow down automatically applies flushing air flow down the rod to
clear blockage of the rod, bit or annulus.
The system is mounted under the rig chassis with the
compressed air inlet at the rear. This inlet pipe is split to feed
two electric actuator ball valves that are controled by switches
on the swing-out panel (Air valve open/close and Blow down on/
off). The Air valve is a manual detent valve contolling the normal
RC drilling, it is subject to automatic closing upon activation of
any Emergency stop. The Blow Down valve is a normally closed
manually operated hold to run valve that reverses the air flow
down the rod to the bit and up the annulus, (note the RC rods
have inner and outer strings). Activation of the Blow Down switch
also energises the Blow Down hydraulic cylinder that directs the
Blow Down supply down the rod.
See next page for the Blow Down circuit.

Reverse Circulation/ Blow Down (Option) Air Hose


Whip Check Connections
When the Rig is equipped for R C / Blow Down duties involving
high volume Compressed air, the hose system is protected by
the application of Whip Checks and anchors. These safety items
must always be utilised and must be monitored regularly for
wear and damage - replace any item that shows signs of wear or
damage.
DB525_OM_20081002D

Operations

Blow Down circuit (option)

DB525_OM_20081002D

4-28

Operations

4-29

Trailer (option)
All Jacks must
be applied before
activating any Trailer
controls

The Trailer option can be applied for Reverse Circulation


operations

Cyclone
door control

Cyclone door
cylinder

Cyclone
Cyclone
Slew control Lift control

Air and Hydraulic


connection points.
DB525_OM_20081002D

Operations

All Jacks must


be applied before
activating any Trailer
controls

4-30

The Trailer shown with Jacks applied and the Cyclone sampler
raised and slewed ready for operation.

When the Rig is equipped for R C


/ Blow Down duties involving high
volume Compressed air, the hose
system is protected by the application
of Whip Checks and anchors. These
safety items must always be utilised
and must be monitored regularly for
wear and damage - replace any item
that shows signs of wear or damage.

Typical Whip Checks and Anchors

DB525_OM_20081002D

SECTION 5

Table of Contents
5-3

Section 5 Care and Maintenance

5-3 Introduction
5-3

Operational Requirements

5-3

Safety Requirements

5-4

Tools and Equipment

5-6

Recommended Tool Kit

5-7

Bolt Torques and Safe Loads

5-7

Preventive Maintenance
5-7

Repairs to Hydraulic Components

5-8

Tilt and Slide Support

5-9

Mast and Crowd Cylinder

5-10 Crown Block and Jib extend/slew


5-11 Holder clamp and Breakout clamp

5-12 DD52 Rotary Drillhead


5-13 DD52 Rotary Drillhead disassembly and assembly
5-14 DD52 Rotary Drillhead motor Gearbox assembly
5-16 DD52 Rotary Drillhead Gearbox assembly
5-17 DD52 Reducer Reference Parts List

5-21 Alternative HY79 Rotary Drillhead


5-22 HY79 Rotary Drillhead disassembly and assembly
5-23 HY79 Drillhead Exploded View
5-24 HY79 Rotary head - Reference Parts List

5-26 HY79 Rotary Drillhead with Reverse Circulation Swivel


and Blowdown (option)
5-27 Cyclone Sampler and Trailer (option)
5-28 SPT Option (Standard Penetration Tester)
5-29 Levelling Jacks
5-30 Main Frame Assembly
5-31 Changing the Hydraulic Oil

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081022D

2012 BoartLongyear

Table of Contents

5-32 Lubrication, Maintenance, and Service Intervals


5-34 Recommended Oils and Lubricants
5-34 Selection of Hydraulic Oils
5-34 Selection & Application of Gearbox Oils and Grease
5-35 Gear Oil & Greasing Table

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081022C

2010 BoartLongyear

Section 5 Care and Maintenance


Care and Maintenance

5-3

Introduction
Cost consciousness and the call for greater efficiencies have led to an everincreasing 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.

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.

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.
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 equipments 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
contractors personnel.
Structural changes, additions, mountings, adjustment of pressure limiting
valves, etc., which modify the equipments 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.
DB525_OM_20081002D

Care and Maintenance

5-4

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

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

DB525_OM_20081002D

Care and Maintenance

5-5

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

Spirit Level or Angle Indicator for Drill Mast


Alignment

Grease Gun with Pressure gauge for


Crawler Track tensioning

Chain Wrench

DB525_OM_20081002D

Care and Maintenance

Recommended Tool Kit

DB525_OM_20081002D

5-6

Care and Maintenance

5-7

Bolt Torques and Safe Loads

Preventive Maintenance
! 9#40+0)

Repairs to Hydraulic Components

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.

DB525_OM_20081002D

Care and Maintenance

5-8

Preventive Maintenance
Tilt and Slide Support
! 9#40+0)

Heavy awkward items Any


work carried out on the
Feeder and Support
must be done in a work
shop with lifting slings and
craneage facilities of
above 5 tonne.

! %#76+10

Oil contamination can


cause malfunction in
hydraulic valves, ie dirt in
load controls will allow a
cylinder to sink under
load. Observe strict
cleanliness when servic
ing hydraulic components

Regular Service - Daily - Thoroughly clean out any drilling debris


in the Support Frame
Weekly - Clean and lubricate the Mast slides and Tilt pivots; also clean
and lubricate the Mast slide and Tilt cylinder clevises .
Inspection - Observe the Tilting operation, look for any loosness or
siezure in the Pivots, Support Frame Trappings and Slides. Examine the Cylinder Rods for pitting or damage and look for oil leaks,
observe the cylinders for excessive sinking which could mean Piston
seal internal bypass leakage (a small amount of sinking overnight is
normal).
Preventive Maintenance - If any pivots or clevises are siezed or loose
consider the safety aspect, ie. if severely sloppyor totally siezed,
strip out the joint and re-new the Pin, and fixings. Leaks in hydraulic
cylinders can lead to unsafe conditions (ie. sinking under load and oil
contamination), prevent this by re-sealing the affected cylinder.
Repairs - Other than negligence of the Preventive Maintenance, this area
should be free from damage, however if a part is subjected to damage
from external forces, then the assembly will need to be examined
thoroughly and any distorted part replaced or refurbished.

Support Frame
trappings(4 each
side)
Mast Slide Cylinder Pin
Grease point

Mast Tilt Pivot Grease points


(one each side)

DB525_OM_20081002D

Mast Slide Grease


points
(4 each side)
Tilt Cylinder
Clevis Grease
points (both sides)

Care and Maintenance

! 9#40+0)
Heavy awkward items Any
work carried out on the
Feeder and Support
must be done in a work
shop with lifting slings and
craneage facilities of
above 5 tonne.

! %#76+10

Oil contamination can


cause malfunction in
hydraulic valves, ie dirt in
load controls will allow a
cylinder to sink under
load. Observe strict clean
liness when servicing
hydraulic components
Feed Chain
lubricate

Mast and Crowd Cylinder

5-9

Regular Service
Daily - Thoroughly clean out any drilling debris in the Mast frame and
lubricate the Mast slides. Examine the Feed Chains and Pulleys for
wear and damage, re-tension the chain if necessary and re-lubricate
(see section 3).
Weekly - Clean and lubricate the Feed and Crowd cylinder clevises.
Measure feeder chain stretch and replace if more than 2%.
Inspection - During operation observe the Mast Frame for distortion, and
also the slideways and trappings for loosness or binding. Adjust or
re-new as required. Look for any loosness in the Mast Slide Pivot,
and Feed Chain Pulleys. Examine the Feed Cylinder Rod for pitting
or damage and look for oil leaks, observe the cylinder for excessive
sinking which could mean Piston seal internal bypass leakage (a
small amount of sinking overnight is normal).
Preventive Maintenance - If any pivots or clevises are siezed or loose
consider the safety aspect, ie. if severely sloppyor totally siezed,
strip out the joint and re-new the Pin, Bushes and fixings. Leaks in
hydraulic cylinders can lead to unsafe conditions (ie. sinking under
load and oil contamination), prevent this by re-sealing the affected
cylinder.
Repairs -Observance of the Preventive Maintenance in this area should
avoid normal operational damage, however parts may be subjected
to damage as a result of the drilling process, ie. abrasion from drillings, blows from drill rods and flushing medium corrosion etc. The
operator must monitor and initiate repair of any damage from these
causes as necessary.

Feed Pulleys
Lubricate
Feed Chain
lubricate

Mast Extension
Pivot lubricate
Mast Slides
Lubricate

Feed Cylinder
Clevises

Wire Rope Pulleys


lubricate

DB525_OM_20081002D

Care and Maintenance

! 9#40+0)
Heavy awkward items Any
work carried out on the
Feeder and Support
must be done in a work
shop with lifting slings and
craneage facilities of
above 5 tonne.

! %#76+10

Oil contamination can


cause malfunction in
hydraulic valves, ie dirt in
load controls will allow a
cylinder to sink under
load. Observe strict clean
liness when servicing
hydraulic components

Crown Block and Jib extend/slew

5-10

Regular Service
Daily - Thoroughly clean out any drilling debris in the frame and lubricate the Jib extend slides. Examine the Slides and Pulleys for wear
and damage, replace if necessary and re-lubricate.
Weekly - Clean and lubricate the Slew and Extend cylinder clevises.
Inspection - During operation observe the Crown Block Frame for
distortion, and also the Jib slideways for loosness or binding. Adjust
or re-new as required. Look for any loosness in the Tilt and Slew
Pivots, and Rope Pulleys. Examine the Cylinder Rods for pitting or
damage and look for oil leaks.
Preventive Maintenance - If any pivots or clevises are siezed or
loose consider the safety aspect, ie. if severely sloppy or totally siezed,
strip out the joint and re-new the Pin, Bushes and fixings. Leaks in
hydraulic cylinders can lead to unsafe conditions (ie. sinking under
load and oil contamination), prevent this by re-sealing the affected
cylinder.
Repairs -Observance of the Preventive Maintenance in this area should
avoid normal operational damage, however parts may be subjected to
damage as a result of the drilling process. The operator must monitor
and initiate repair of any damage from these causes as necessary.

Jib Extend cylinder


Pivots lubricate

Slew cylinder Pivots


lubricate
Wire Rope Pulleys
lubricate

Jib Slides
lubricate

DB525_OM_20081002D

Care and Maintenance

! 9#40+0)

Holder clamp and Breakout clamp

Heavy awkward items.


Finger traps, take care
when dealing with Keys.

! %#76+10
Oil contamination can
cause malfunction in
hydraulic cylinders.
Observe strict clealiness
when servicing hydraulic
components

5-11

Regular Service
Daily - Thoroughly clean out any drilling debris in the ClampJaws.
Examine the Jaws for wear and damage, replace if necessary.
Weekly - Clean and lubricate the Breakout cylinder clevises, Clamp
cylinder clevises and Breakout bracket.
Inspection - During operation observe the Jaws for wear. Look for any
loosness or siezure in the Breakout bracket pivot, look for slack
causing rocking. Examine the Cylinder Rods for pitting or damage and
look for oil leaks.
Preventive Maintenance - If any pivots or clevises are siezed or loose
consider the safety aspect, ie. if severely sloppy or totally siezed,
strip out the joint and re-new the Pin, Bushes and fixings. Leaks in
hydraulic cylinders can lead to unsafe conditions (ie. sinking under
load and oil contamination), prevent this by re-sealing the affected
cylinder.
Repairs -Observance of the Preventive Maintenance in this area should
avoid normal operational damage, however parts may be subjected to
damage as a result of the drilling process, ie. abrasion from drillings,
blows from drill rods and flushing medium corrosion etc. The operator
must monitor and initiate repair of any damage from these causes as
necessary.

Clamp Jaws
Breakout
Clamp Jaws
Breakout Clamp
Cylinder Clevises

Breakout
Cylinder
Clevises

Breakout
Bracket

DB525_OM_20081002D

Holder Clamp
Cylinder Clevises

Care and Maintenance

! 9#40+0)
Heavy awkward items Any
work carried out on the
Feeder and Support
must be done in a work
shop with lifting slings and
craneage facilities of
above 5 tonne.

! %#76+10
Oil contamination can
cause malfunction in
hydraulic cylinders.
Observe strict clealiness
when servicing hydraulic
components

DD52 Rotary Drillhead

Regular Service Daily - Thoroughly clean off any drilling debris, check the Gearbox
oil level with the mast vertical, top-up if necessary. Check the Flushing Swivel connecting thread; if loose, clean and fix in position with
Loctite thread lock.
Weekly - Check the Slide Trapping and Alignment Guide rollers on the
Feeder Frame, adjust if necessary (see section 3). Check the Drillhead
Connection Flange fasteners and torque-up if required. Clean and
lubricate the Side Slides and cylinder clevises.
Inspection - During operation observe the motion of the Drillhead down
the mast, this should be smooth without wobble, also observe the Mast
Frame and Slideways for distortion, and trappings for looseness or
binding. Adjust or re-new as required. Look for oil leaks from the front
of the Gearbox and also from the drive motor. The Flushing medium
should not leak in the area of the Flushing Swivel. Examine the Side
Slide Cylinder Rod for pitting or damage and look for oil leaks.
Preventive Maintenance - Any misalignment in the feeding of the
Drillhead needs to be corrected by adjusting the Guide Rollers (see
section 3) or replacing the Slide Trappings. Excess grease in the area
of the outlet shaft of the Gearbox could mean that the shaft seal is
worn. Any oil leak in the area of the flange of the drive motor could
mean motor shaft seal damage, possibly by high return line pressure,
check it out. Leakage from the Flushing Swivel could mean a loose
connection or worn seals, check it out. Leaks in hydraulic cylinders
can lead to unsafe conditions (ie. sinking under load and oil contamination), prevent this by re-sealing the affected cylinder.

Hydraulic Motor

Water Swivel
Side Shift cylinder
clevises
Drillhead Carrying
pin

Drillhead
Mast
Trapping

5-12

Mast
Alignment Rollers
DB525_OM_20081002D

Drillhead Side Shift


Trapping

Care and Maintenance

5-13

Rotary Drillhead and Flushing Swivel (continued)


Repairs -Observance of the Preventive Maintenance in this area should avoid
normal operational damage. Misalignment of the Drillhead can occur
as a result of damage caused to the Feeder parts during the drilling
process. The Gearbox seal can be damaged by debris from drilling
or abraded by corrosion from flushing medium.The Drillhead output
! &#0)'4
Connection Flange fasteners, and the Flushing Swivel fasteners, may
Loose fasteners in this
loosen during multiple rotation reversal operations. The operator must
area can lead to
monitor and initiate the repair of any damage from these causes as
danger of falling objects.
soon as necessary.

DD52 Rotary Drillhead disassembly and assembly


Major Service Some operating malfunctions may require some dismantling of the Drill! 9#40+0)
head (seizure, noisy operation or excessive leakage etc). The following
pointers give suggestions for disassembly and re-assembly.
Heavy awkward items.
Thoroughly clean all debris and excess oil from the drillhead. Remove the
Any work carried out on
Drillhead assembly from the mast, have sufficient craneage to keep the
the Drillhead must be
drillhead from moving, and observe strict cleanliness when disconnecting
carried out in a workshop
hydraulic hoses. Remove the Assembly to a workshop bench.
with lifting slings and
craneage facilities of
above 5 tonne.

DB525_OM_20081002D

Care and Maintenance

5-14

DD52 Rotary Drillhead motor Gearbox assembly

Reference Parts List ( Item numbers are shown in the parts lists in section 13)
Position Quantity Description
1
1
GEARBOX ASSEMBLY
2
1
MOTOR MOUNTING BRACKET
3
1
COUPLING
4 1 SPLINED SHAFT
5
1
O-RING
6 1 GASKET
7
1
HYDRAULIC MOTOR
8
2
FLOATING SHAFT
9
1
FLUSHING SWIVEL BRACKET
10
1
MOUNTING FLANGE
11
1
GREASE NIPPLE
12
1
O RING
13
1
2 3/8FLANGED ADAPTOR
14
9
M12 X 45 HEX. SCREW
15
2
FLANGED ADAPTOR
18
8
WASHER SCHNORR M18
19
8
M8 SKT CAPSCREW
20
4
WASHER SCHNORR M20
21
4
M20 X 50 HEX.HD.BOLT
22
18
WASHER SCHNORR M12
23
1
M12 X 25 HEX.HD.BOLT
24
9
M12 HEX.NUT
25
8
7/16 X 1 3/4 HEX.HD.BOLT
DB525_OM_20081002D

Care and Maintenance

5-15

Rotary Drillhead and Flushing Swivel (continued)

! %#76+10 Disassembly Drill head -


Oil contamination can

cause enviromental damage
observe local legislation and
dispose of carefully









Dismount the motor assembly (7) by removing fasteners (20 & 21)
Remove the motor mounting adaptor (2) by removing fasteners ( 18 & 19)
Remove coupling (3) and splined shaft (4)
Position the assembly with the axle output (8) facing upwards
Remove fasteners (14 & 24) to release Flange (10), unscrew the flange
adaptor (13)
Turn the assembly over
It is now possible to extract the floating shaft (8)
Hints on refurbishmentAlways renew seals.
Examine all items for wear and re-place as necessary.
Examine all bores and surfaces for damage, remove any sharp edges and
scuffing, check for distortion and refurbish or replace as necessary.
Re-Assembly- Re-assemble the Drillhead in the reverse order as above.
Note- take great care when fitting shafts and spigots through seals. Ensure
that any shims and gaskets are re-fitted between the body.
Disassembly- Gear box
A full strip down of the gear box is probably unnecessary. If there is noise
coming from the gear box and shafts are loose, or there is excessive leakage around the output, the operator must pinpoint the fault and assess the
situation using the section drawings to identify the area in need of attention.
Removal of the cover (60) allows full view of the internal gearing for assessment of any problem areas. This approach minimises the amount of down
time and disruption and normally yields a quick economical solution.

DB525_OM_20081002D

Care and Maintenance

DD52 Rotary Drillhead Gearbox assembly

DB525_OM_20081002D

5-16

Care and Maintenance

5-17

DD52 Reducer Reference Parts List


( Item numbers are shown in the parts lists in section 13)
Position Quantity Description
1
1
REDUCER BODY
2
4
BRONZE BUSH
3
4
SEEGER JV35 RING
4
1
LUBRICATION PUMP REGULATION BEARING
5
1
O-RING
6 1 INTERMEDIATE SHAFT
7
1
O-RING
8 2 BEARING
9
1
INTERMEDIARY CROWN GEAR
10
2
KEY
11
1
O-RING
12
1
SHAFT WASHER
13
1
M10X25 SCK SCREW
14
1
REDUCER STOP PLATE
15
1
SPRING PIN
16
1
BEARING
17
1
LUBRICATION PUMP COVER
18
1
PINION
19
2
STEEL BALL MM.7
20 2 SPRING
21
2
CAP GAS 1/8 SHORT
22
1
SPLINED SHAFT
23
1
BEARING FLANGE
24
1
DUST COVER
25 1 BEARING
26 1 CIRCLIP
27 1 SHAFT
28
1
O-RING
29
1
FORK
30
1
STEEL BALL MM.8
31 1 SPRING
32
2
O-RING
33
1
REDUCER STOP PLATE
34 2 BEARING
35
1
FLOATING SPINDLE FLANGE
36
1
COUNTERFLANGE FOR SPINDLE
37 1 SPINDLE
38 1 WASHER
39
2
KEY
40
1
PLATE WHEEL
41
1
THRUST RING (TWO HALVES)
42
1
UPPER SPACER
43 2 SEAL
44
2
INNER RING
45
1
RETAINING RNG
46
2
O-RING
47
1
DUST SHIELD BRACKET
48
24
WASHER SCHNORR M12
49
12
M12X25 SCREW
50
1
BODY REDUCER SPACER
51
1
CYLINDER HEAD CAP
52
1
CONTROL PIN
DB525_OM_20081002D

Care and Maintenance

53
1
54 1
55
1
56
1
57
1
58
1
59
1
60
1
61
1
62
2
63
1
64
1
65
1
66
37
67
8
68
1
69
1
70
8
71
29
72
4
73
8
74
2
75
6
76
8
77
1

SPACER PIN
SEAL
TIE ROD
SPHERICAL KNOB
KEY
RETAINING RING
REDUCER COVER GASKET
REDUCER COVER
OIL-LEVEL CONTROL
GREASE NIPPLE
CLUTCH FOR LUBRICATION PUMP
DUST PROTECTOR BRACKET
LUBRICATOR
WASHER SCHNORR M6
M6X16 SCREW
GASKETS SET
LEAK CAP
M12x55 HEX SCREW
M6x20 HEX SCREW
M12X35 HEX SCREW
WASHER SCHNORR M8
M8x80 HEX SCREW
M8x40HEX SCREW
M12 HEX NUT
GEARBOX FORK CROWN GEAR

DB525_OM_20081002D

5-18

Care and Maintenance

Reduction gearbox (continued)

DB525_OM_20081002D

5-19

Care and Maintenance

Reducer (continued)

DB525_OM_20081002D

5-20

Care and Maintenance

5-21

Alternative HY79 Rotary Drillhead


! 9#40+0)

Heavy awkward items.


Any work carried out on
the Drillhead must be
done in a workshop with
lifting slings and craneage
facilities of above 5 tonne.

! %#76+10

Oil contamination can


cause malfunction in
hydraulic motors.
Observe strict clealiness
when servicing hydraulic
components

Regular Service Daily - Thoroughly clean off any drilling debris, check the Gearbox
oil level with the mast vertical, top-up if necessary. Check the Flushing Swivel connecting thread; if loose, clean and fix in position with
Loctite thread lock.
Weekly -Check the Drillhead Connection Flange fasteners and torqueup if required. Clean and lubricate side slide cylinder clevises and the
Centralising Rollers.
Inspection - During operation observe the motion of the Drillhead down
the mast, this should be smooth with out wobble, also observe the
Mast Frame and Slideways for distortion, and trappings for loosness
or binding. Adjust or re-new as required. Look for oil leaks from the
front of the Gearbox and also from the drive motor. The Flushing
medium should not leak in the area of the Flushing Swivel. Examine
the Cylinder Rods for pitting or damage and look for oil leaks.
Preventive Maintenance - Any misalignment in the feeding of the
Drillhead needs to be corrected by replacing or adjusting theTrappings on the Guides. Excess grease in the area of the outlet shaft of
the Gearbox could mean that the shaft seal is worn. Any oil leak in
the area of the flanges of the drive motor could mean motor shaft seal
damage, possibly by high return line pressure, check it out. Leakage
from the Flushing Swivel could mean a loose connection or worn
seals, check it out. Leaks in hydraulic cylinders can lead to unsafe
conditions (ie. sinking under load and oil contamination), prevent this
by re-sealing the affected cylinder.

Rod
Connection

Centralising Rollers

Rotary Drillhead
Gearbox Oil Level

Side slide Cylinders

Trapping
Sliders
DB525_OM_20081002D

Care and Maintenance

5-22

Rotary Drillhead and Flushing Swivel (continued)


Repairs -Observance of the Preventive Maintenance in this area should avoid
normal operational damage. Misalignment of the Drillhead can occur
as a result of damage caused to the Feeder parts during the drilling
process. The Gearbox seal can be damaged by debris from drilling
or abraded by corrosion from flushing medium.The Drillhead output
Connection Flange fasteners, and the Flushing Swivel fasteners, may
loosen during multiple rotation reversal operations. The operator must
monitor and initiate the repair of any damage from these causes as
soon as necessary.

HY79 Rotary Drillhead disassembly and assembly


Major Service Some operating mal-functions may require a complete dismantling of the
! 9#40+0)
Drillhead (seizure, noisy operation or excessive leakage etc). The following
Heavy awkward items.
pionters give suggestions for disassembly and re-assembly.
Any work carried out on
Thoroughly clean all debris and excess oil from the drillhead. Remove the
the Drillhead must be
Drillhead assembly from the mast,have sufficient craneage to keep the
done in a workshop with
drillhead from moving, and observe strict cleanliness when disconnecting
lifting slings and craneage
hydraulic hoses. Remove the Assembly to a workshop bench.
facilities of above 5 tonne.

DB525_OM_20081002D

Care and Maintenance

HY79 Drillhead Exploded View

DB525_OM_20081002D

5-23

Care and Maintenance

HY79 Rotary head - Reference Parts List


Description
Drawing Ref.
Rotary head body HY79RC
1
Rear cover,HY79RC
2
Spindle HY79RC
3
Large gear wheel
4
Hydraulic Fitting
5
Mounting cube,HY79RC
6
Gear-change Arm
7
Gear-change Lever
8
Gear Change Wheel
9
Rotary Head Flange
10
Hydraulic Motor Bracket
11
Distance Plate
12
Gear Wheel - OMT
13
Shaft - OMT
14
Sleeve Bearing
15
Washer 16
Change Ring
17
Lift Ring
18
Distance Ring
19
Indirect Insert
20
Gear Wheel - Volvo Motor 21
Indirect Shaft
22
Distance Sleeve
23
Mounting Bracket Stud
24
Suspension Washer
25
Hydraulic Fitting
26
Nord-lock Washer M10
27
Screw M10 X 35
28
Pin
29
Screw M12X60
30
Nord-lock Washer M6
31
Screw M6X16
32
Screw M8X16
33
Spring Washer M12
34
Nord-lock Washer M8
35
Screw M12x100
36
Screw M6X20
37
Nord-lock Washer M12
38
Screw M12X30
39
Bearing 40
Bearing 41
Bearing 42
Bearing 43
Seal Ring
44
Seal Ring
45
Bearing 46
Bearing 47
Hydraulic Motor (DA)
48
DB525_OM_20081002D

Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
8
8
2
8
32
32
2
1
18
1
8
1
1
1
1
1
1
1
1
1
1
1

5-24

Care and Maintenance

HY79 Rotary Drillhead - Reference Parts List (cntnued)


Description
Drawing Ref.
Quantity
Hydraulic Motor (PA)
49
1
Hydraulic Fitting
50
2
O Ring
51
1
Retaining Ring
52
2
Retaining Ring
53
2
Retaining Ring
54
18
Screw M8X25
55
1
Retaining Ring
56
1
ORING
57
1
O Ring
58
1
Retaining Ring
59
1
O Ring
60
1
Breather 61
1
Seal Ring
62
1
Seal Ring
63
1
Screw M6 X 10
64
1
Locking Pin
65
1
Sight Glass
66
1
Spring Pin
67
1
Bushing
68
2
Ball Bearing
69
3
Manifold-V12 Motor
70
1
O Ring
71
2
Hydraulic Fitting
72
1
Bushing 73
1
Hydraulic Fitting
74
1
Nut - Self Locking - M20 75
4
Washer Schnorr - M20
76
4
Manifold-TMT315 Motor
77
1
SEAL BSP 3/4
78
2
Hydraulic Fitting
79
1
By-Pass Screw Valve
80
2
O Ring
81
2
Hydraulic Fitting magnetic 82
1
Washer Schnorr M10
83
8
Hydraulic Fitting
84
1
Mounting cube2, Hy79
85
1
Screw - M10 X 70
86
8
Hydraulic Fitting
87
1
Hose Kit - Hy79rc
89
1
Oil Gearway PS45 75w-90 90
1
Hydraulic Fitting
91
1
Screw - M12 X 45
92
2

DB525_OM_20081002D

5-25

Care and Maintenance

! 9#40+0)
Heavy awkward items.
Any work carried out on
the Swivel must be
done in a workshop with
lifting slings and craneage
facilities of above 5 tonne.

5-26

HY79 Rotary Drillhead with Reverse Circulation Swivel


and Blowdown (option)

Regular Service Daily - Thoroughly clean off any drilling debris. Check the Flushing
Swivel connecting threads; if loose, clean and fix in position with
Loctite thread lock.
Weekly -Check the all fasteners and torque-up if required. Clean and
lubricate the 6 blowdown cylinder grease nipples. Clean and lubricate
the 7 Dual Swivel grease nipples. Check the condition of the wear
components inside the deflector Box, if worn - replace.
Inspection - During operation observe the Swivel and Blowdown.
Look for oil or air leaks from the Blowdown unit and also from the
Swivel. The Flushing medium should not leak in the area of the
Flushing Swivel.
Preventive Maintenance - Any leaks or siezure must be remedied
immediately by replacing or adjusting the part. Any oil leak in the
area of the Blowdown cylinder could mean seal damage, check it out.
Leakage from the Flushing Swivel could mean a loose connection
or worn seals, check it out. Leaks in hydraulic cylinders can lead to
unsafe conditions (ie. oil contamination), prevent this by re-sealing
the affected cylinder.

Deflector Box - wear


parts inside

Blowdown Hydraulic cylinder


Blowdown air inlet
Blowdown Greasers
Both sides

Dual Swivel - Greasers

HY79 Driilhead

DB525_OM_20081002D

Care and Maintenance

5-27

Cyclone Sampler and Trailer (option)


! 9#40+0)
Heavy awkward items.
Any work carried out on
the Cyclone must be
done in a workshop with
lifting slings and craneage
facilities of above 5 tonne.

! %#76+10

Oil contamination can


cause malfunction in
hydraulic valves, ie dirt in
load controls will allow a
cylinder to sink under
load. Observe strict
cleanliness when servic
ing hydraulic components

Regular Service Daily - Thoroughly clean off any drilling debris, check the Trailer tyres,
brakes and lights.
Weekly -Check all the cylinders for damage or leaks. Examine the
Cyclone sampler door and the Cyclone wear plate, fix if needed.
Inspection - During operation observe the motion of the Cyclone Tilt and
Slew look for loose pins and pivots. Adjust or re-new as required.
Examine the Cylinder Rods for pitting or damage and look for air or
oil leaks.
Preventive Maintenance - Any misalignment in the Cyclone Tilt and Slew
needs to be corrected by replacing or adjusting the pivot pins. Leaks
in hydraulic cylinders can lead to unsafe conditions (ie. sinking under
load and oil contamination), prevent this by re-sealing the affected
cylinder.

Cyclone Sampler door


Cyclone Wear plate (inside)

Tilt Frame Pivots - Lubricate


Tilt cylinder Pivots Lubricate

Tilt cylinder Pivots - Lubricate


Slew cylinder Pivots - Lubricate

DB525_OM_20081002D

Care and Maintenance

SPT Option (Standard Penetration Tester)


! 9#40+0)

Heavy awkward items.


Any work carried out on
the Drillhead must be
carried out in a workshop
with lifting slings and
craneage facilities of
above 5 tonne.

! %#76+10

Oil contamination can


cause malfunction in
hydraulic valves, ie dirt in
load controls will allow a
cylinder to sink under
load. Observe strict
cleanliness when servic
ing hydraulic components

5-28

Regular Service - Daily - Thoroughly clean out any drilling debris


in the drive assembly. If the guard is removed, ensure that the rig
is fully isolated
Weekly - Clean and lubricate the Drive assembly, soak in solvent if
necessary to free up the chain and weight .
Inspection - Observe the SPT in operation, look for any looseness or
seizure in the falling weight and the drive chain. Examine the guide
for pitting or damage.
Preventive Maintenance - If the drive mechanism is seized or loose
consider the safety aspect, ie. if severely sloppy or totally seized,
strip down and re-new or replace.
Repairs - Other than negligence of the Preventive Maintenance, this area
should be free from damage, however if a part is subjected to damage
from external forces, or excessive drilling debris, then the assembly
will need to be examined thoroughly and any distorted part replaced
or refurbished.

SPT positioning shaft


lubricate bearings and shaft

DB525_OM_20081002D

Care and Maintenance

Levelling Jacks

! 9#40+0)

Heavy awkward items.


Any work carried out on
the Rod Racks must be
done in a workshop with
lifting slings and
craneage facilities of
above 5 tonne.

! %#76+10

Oil contamination can


cause malfunction in
hydraulic valves, ie dirt in
load controls will allow a
cylinder to sink under
load. Observe strict clean
liness when servicing
hydraulic components

5-29

Regular Service - Weekly - clean and lubricate the Jacks


Inspection - Observe the cylinders in operation, look for any loosness or
siezure in the Pivoting foot. Examine the Cylinder Rods for pitting or
damage and look for oil leaks, observe the cylinders for excessive
sinking which could mean Piston seal internal bypass leakage (a small
amount of sinking overnight is normal).
Preventive Maintenance - If any swivelling foot is siezed or loose
consider the safety aspect, ie. if severely sloppy or totally siezed, strip
out the joint and re-new the bearing, and fixings. Leaks in hydraulic
cylinders can lead to unsafe conditions (ie. sinking under load and oil
contamination), prevent this by re-sealing the affected cylinder.
Repairs - Other than negligence of the Preventive Maintenance, this area
should be free from damage, however if a part should be subjected to
damage from external forces, then the assembly will need to be examined thoroughly and any distorted part replaced or refurbished.

Levelling Jack Cylinder


(one at each corner)

Load Control valves


Levelling Jack pivoting foot
(one each jack)

DB525_OM_20081002D

Care and Maintenance

Main Frame Assembly

! 9#40+0)

Heavy awkward items.


Any work carried out on
the Main Frame must be
done in a workshop with
lifting slings andcraneage
facilities of above 5
tonne.

! %#76+10

Oil contamination can


cause malfunction in
hydraulic motors.
Observe strict clealines
when servicing hydraulic
components

5-30

Regular Service Daily - Thoroughly clean off any debris from the Main Frame and
Tracks ( see section 10 for full instructions on Track servicing,
especially Track tensioning pages 64 to 66, and Trackdrive
gearbox servicing pages 57 to 58). Prior to start-up walk round
the Rig and check for any damage or anything out of place. Look
for any new oil spills as an early indication of problems.
Weekly - Check over the Main Frame for
damage. Clean and lubricate the cylinder clevises.
Inspection - Observe the Rig when tramming mode, look for loose
parts, sloppy cylinders and rattling joints. Examine Cylinder rods
for pitting or damage and look for oil leaks, observe the cylinders
for excessive sinking which could mean Piston seal internal bypass
leakage (a small amount of sinking overnight is normal).
Preventive Maintenance - If any pivots or clevises are siezed or loose
consider the safety aspect, ie. if severely sloppy or totally siezed,
strip out the joint and re-new the Pin, Bushes and fixings. Leaks in
hydraulic cylinders can lead to unsafe conditions (ie. sinking under
load and oil contamination), prevent this by re-sealing the affected
cylinder. See separate sections for Engine, Hydraulic Pump,
Water/Mud Pump, and Winches.
Repairs -Observance of the Preventive Maintenance in this area should
avoid normal operational damage, however parts may be subjected
to damage as a result of Tramming around the drilling site or
through the drilling process. The operator must monitor and initiate
repair of any damage from these causes as soon as necessary.

DB525_OM_20081002D

Care and Maintenance

! %#76+10

Oil contamination can


cause can cause serious
environmental damage.
Eliminate spills and dis
pose of waste oil
in accordance
with local regulations.

5-31

Changing the Hydraulic Oil

Drain oil only when at operating temperature.


Be sure to clean all connections thoroughly prior to opening the system.
Drain and inspect oil from pumps and motors separately if metal particles are
detected in the drained oil.
Metal particles indicate above average attrition. This leads to losses in capacity
and subsequent major damage. Replace pump and/or motor immediately.

Cleaning the Oil Tank


Required at every oil change.
Use only lint-free cleaning rags.
Thoroughly check cleanliness.
Filling the Oil Tank
Be sure to fill only through filter.
New oil is always contaminated!

016+%'

Condensation
High humidity and extreme fluctuations in oil temperature often create
condensation.

Water present in the oil leads to saponification and frothing, and subsequent cavitation and damage of pumps.

Check the condition of the oil visually at the filling level indicator.

016+%'

Park drill rig on incline and let oil in tank settle.


Drain the oil/water mixture and dispose of according to environmental stipulations.

DB525_OM_20081002D

Care
and
Maintenance
Care
and
Maintenance

BOART LONGYEAR

5-32
5-23

Lubrication,Maintenance,
Maintenance,and
andService
Service
Intervals
Lubrication,
Intervals
Item

Service Intervals in Operating Hours


8

16

40

100

200

500

10 0 0

2000

1. Diesel Engine
Check Oil Level in Engine
Clean Fuel Filter in Fuel Pumps
Change Engine Oil Volume = Litres
Clean Cooling Fins
Please refer to Manufacturer's Manual for details

Check Warning Device operation


Replace Lubrication Cartridge
Check V-belt tension
Check Valve clearance (first after 20 h)
Replace Diesel Fuel Cartridge
2. Hydraulic Oil Tank
Check Oil Level (X=1 after 8 h)

Check for Leaks


Check Oil Temperature




Change Oil (first after 500 h)

Clean Filling and Ventillating Filter

3. Oil Filters
Check Filters (X=1 after 8 h)


X

Replace Filter Cartridge (X=1 after 40 h)

4. Air Filter
Replace Filter Cartridge

5. Hydraulics, valves, fittings, hoses


Check for Leaks

Check Fittings for Tightness

6. Hydraulic Oil Cooler


Clean Cooler Block and Fins

7. Hydraulic Pumps and Motors


Check for Leaks and Abnormal Noises

8. Tramming Motors
X

Change Oil (X=1 after 100 h)


Check Setting Screws
Check Oil Fill Level




9. Battery
Check Aci d Level

10. Pump Gear Box


X

Change Oil (X=1 after 100 h)


Check Setting Screws
Check Oil Fill Level




Prepared by TSG - Printed in Poland - DB520_OM_20060119

DB525_OM_20081002D

Careand
andMaintenance
Maintenance
Care

BOART LONGYEAR

Item

5-33
5-24

Service Intervals in Operating Hours


8

16

40

100

200

500

10 0 0

2000

11. Undercarriage
Check Track Tension

Grease Oscillating Angle

Grease Idlers and Rollers

12. Drill Mast


Grease and Check all Nipples

Check Feed Chain Tension

Check Bearings and Bushings

13. Roller Slide


Check and Grease Rollers

Check and Grease Guide Rails

14. Boom and Mast Carrier


Check and Grease all Nipples

Check and Grease Guide Strips

Check Bearing Bolts

15. Hose Guide Chain


Check Rollers

16. Hydraulic Cylinders


Check and Grease Eyes and Bolts

016+%'

Loss of Warranty will apply if maintenance intervals are not complied with.

Capacities - Rig Type DB525


Loss
of Warranty will apply if maintenance intervals are not complied with.
Component Part Number Designation
Quantity
Engine

9016145 -

Statoil 10W40

13 litres

Hydraulic oil

4200778 -

Hydraway HVX68

380 litres

Diesel oil

50 litres

Crawler gear box

56311028 -

Statoil 80W90

2x1,5=3litres

Rotary head DD52

K41034 -

Gearway PS45 75W90

7 litres

Rotary head HY 79

K41034 -

Gearway PS45 75W90

5 litres

Winch Pull Master PL2

56311028 -

Statoil 80W90 - (SAE90)

0,5 litre

Winch Pull Master PL5

56311028 -

Statoil 80W90 - (SAE90)

1,1 litres

Winch Dinamic Oil: S45V, SH220

4200778 -

HydraWay HVX68 - (HLP ISO VG46)

2 litres

Winch Brevini Winch DW090

56311028 -

Statoil 80W90

2 litres

Winch BG6 Braden

9016147 -

Statoil Longway EP150

1,1litres

Water pump

FMC

W11

9016145 -

Statoil 10W40 - (SAE30)

3,7 litres

Water pump

FMC

L09

9016145 -

Statoil 10W40 - (5W40)

2,1 litres

Water pump

Delta Pump 100

9016145 -

Statoil 10W40

4 litres

Water pump

Delta Pump 200

9016145 -

Statoil 10W40

7 litres

Prepared by TSG - Printed in Poland - DB520_OM_20060119

DB525_OM_20081002D

Care and Maintenance

5-34

Recommended Oils and Lubricants


Selection of Hydraulic Oils

Please refer to the following list when selecting hydraulic fluids from leading
manufacturers. Other non-listed hydraulic fluids may also be used, providing
they meet the quality standard of the oils indicated below.
Boart Longyear strongly recommends using hydraulic oils of class
(ISO 4406)-17/15/13.

Recommended biolocally-degradable hydraulic oil:


STATOIL

HYDRAWAY BIO SE 32-68 *

Hydraulic Oil VG 32

AGIP
OSO 32
ARAL
VITAM HF 32, VITAM GF 32, VITAM DE 32
BP
ENERGOL HLP 32, ENERGOL HLP-D32, BARTRAN HV 32
CHEVRON EP OIL 32, EP OIL 32HV
ESSO NUTO H32, UNIVIOS N32
MOBIL
DTE 13, DTE 24
SHELL
TELLUS OIL 32, HYDROL DO32
TEXACO
RANDO OIL HD A-32

Hydraulic Oil VG 46

AGIP
OSO 46, ANICA 46
ARAL
VITAM HF 46, VITAM GF 46, VITAM DE 46
BP
ENERGOL HLP 46, ENERGOL HLP-D46, BARTRAN HV 46
CHEVRON EP OIL 46, EP OIL 46HV
ESSO NUTO H46, UNIVIOS N56
MOBIL
DTE 15, DTE 25
SHELL
TELLUS OIL 46, HYDROL DO 46
STATOIL HYDRAULIC SUPER 46*
STATOIL HYDRAWAY HVX-46
TEXACO
RANDO OIL HD A-46

Hydraulic Oil VG 68

AGIP
OSO 68
ARAL
VITAM GF 68, VITAM DE 68
BP
ENERGOL HLP 68, ENERGOL HLP-D68, BARTRAN HV 68
CHEVRON EP OIL 68, EP OIL 68HV
ESSO NUTO H68, UNIVIOS N56
MOBIL
DTE 16, DTE 26
SHELL
TELLUS OIL 68, HYDROL DO 68
STATOIL HYDRAULIC SUPER 68
TEXACO
RANDO OIL HD A-68
Rigs are Factory filled with Lubricants marked*

Selection & Application of Gearbox Oils and Grease

Please refer to the following list when selecting Gear oil or Grease. Other
non-listed lubricants may be used, providing they meet the quality standards
indicated below.
Boart Longyear strongly recommends using Gearbox Oils of class
SAE 80W-90 conforming to DIN 51517 Part 3 CLP,and Muti-purpose Lithium
based Grease for general lubrication and protection.
GEARBOX
GREASE
BP
ENERGEAR HT80W-90
ENERGREASE LS3
CHEVRON DELO ESI 80W-90
DELO EP NLG1
ESSO
GX 80W-90
RONEX EXTRA DUTY
MOBIL
GX 80W-90
XHP 220
SHELL
MALLEUS
ALVANTA
STATOIL
GEAR EP5 80W-90*
MOLYWAY LI 752
DB525_OM_20081002D

Care and Maintenance

Gear Oil & Greasing Table

5-35

Note - This table gives a typical list of the general lubrication requirements
for the Deltabase series of Drill rig, please refer to the relevant section of this
Operator Manual for specific instructions on ancilliary Drill rig
components such as Winches, Hoists and Water/Mud Pumps.

DB525_OM_20081002D

SECTION 6

Table of Contents
6-2

Boart Longyear

Section 6 Fault finding tables


6-2

No Pressure

6-2

Flow Low or Pressure Fluctuating

6-2

Valves not operating properly

6-2

Hydraulic oil temperature too high

6-3

Noises from Pumps - no oil supply

6-3

Leakage from Drillhead

6-3

Engine Stalling

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Care and Maintenance

6-2

Fault Finding Tables


Fault
/ Symptom Probable Cause Action
No Pressure

Insufficient Pump capacity


Too high pump temperature

Pump rpm too low or
insufficient engine capacity
Leakage from pressure
to return lines


Air entering suction line


Pump damaged
Viscosity of fluid too low
Pump gear box or engine damage

Seal suction line


Replace/repair
Change hydraulic oil
Repair/replace

Wrong pressure setting



Apply correct pressure
Valve not closing
Clean valve
Blocked by dirt or particles
Assess damage. Repair.
Damaged cylinder bore,
Replace damaged components
piston rod or piston seals.

Flow Low or Pressure Fluctuating


Valves sticking
Contaminated hydraulic oil
Drain hydraulic oil

Clean tank and components,

then fill with new oil
Air enclosure in system System not properly ventilated Bleed system
causing jerky movements
Valves knocking
Valve seat(s) damaged
Repair or replace

Valves not operating properly


Valve spool wedging
Contamination
Remove piston and clean the valve

Hydraulic oil temperature too high
Cool oil to 50C
No pilot pressure Check pilot pressure

(or insufficient pilot pressure)

Hydraulic oil temperature too high


Insufficient cooling
Cooler motor damaged

Cooler fins dirty and closed
Hydraulic fluid circulating
Fluid level in tank too low
too fast
Fluid is dumped to tank
Malfunction of valve caused by
via valves under pressure
dirt or damaged components
Pressure setting too low

DB525_OM_20081002D

Repair/replace
Clean cooler fins
Replenish hydraulic oil
to required level
Clean and repair or replace
damaged components
Adjust to right pressure setting

Care and Maintenance

6-3

Fault
/ Symptom Probable Cause Action
Noises from Pumps - no oil supply
Pump rotation in
wrong direction
Hydraulic fluid frothing



Engine defective
Mechanical vibrations


Cavitation of pump



Pump defective

Suction and pressure line


exchanged
Fluid level too low
Wrong hydraulic fluid
Air entering suction line
or suction line porous
Damaged or worn-out
Couplings damaged or misaligned
Vibrations caused by swinging
hydraulic hoses or lines
Restriction in suction line
i.e. partially closed stop-cock
Hydraulic fluid too cold
Damaged tubes or hoses

Damaged or worn out

Change connections
Replenish to level
Replace with correct hydraulic oil
Check and tighten connections
Repair or replace
Repair/replace
Repair or align as required
Tighten connection or replace
Open stop-cock fully
Pre-heat oil to required temperature
Replace tubes/hoses
Repair/replace

Leakage from Drillhead


Leakage from spindle
Leakage from space
hydraulic motor
Leakage from water
flushing head
Blocked up flushing head

Seal rings Worn


Case Drain too small
Shaft seal worn
Damaged packing
Damaged bearings

Replace upper and lower rings


Check if in limits 0.7 to 1.5 L/min.
Replace hydraulic motor
Replace packing
Replace bearings

Engine Stalling
Engine stalls shortly after start-up Operating too soon after start-up

After engine has started raise


RPM to 1200 until the red
ignition light extinguishes

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.

DB525_OM_20081002D

Table of Contents

Boart Longyear

7-2

Section 7 Authorised Service & Repair Agents

7-2

Boart Longyear Distributers

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 7 Authorised Service & Repair Agents


Authorised Service and Repair Agents

Boart Longyear Distributers

DB525_OM_20081002D

7-2

Authorised Service and Repair Agents

DB525_OM_20081002D

7-3

Authorised Service and Repair Agents

DB525_OM_20081002D

7-4

SECTION 8

Table of Contents
8-2

Section 8 Main Hoist


8-2

Boart Longyear

Main Hoist

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 8 Main Hoist


Main Hoist

8-2

Main Hoist

DB525_OM_20081002D

SECTION 9

Table of Contents
9-2

Section 9 Wireline Winch


9-2

Boart Longyear

Wireline winch

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 9 Wireline Winch


Wireline Winch

Wireline winch

DB525_OM_20081002D

9-2

SECTION 10

Table of Contents
10-2 Section 10 Crawler tracks
10-2 Crawler Tracks

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 10 Crawler tracks


Crawler tracks

Crawler Tracks

DB525_OM_20081002D

10-2

SECTION 11

Table of Contents
11-2 Section 11 Accessories
11-2 Accessories

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 11 Accessories
Accessories

11-2

Accessories

DB525_OM_20081002D

SECTION 12

Table of Contents
12-2 Section 12 Water Pump
12-2 Water Pump

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 12 Water Pump


Water/Mud Pump

12-2

Water Pump

DB525_OM_20081002D

SECTION 13

Table of Contents
13-2 Section 13 Parts Lists
13-2 Parts Lists

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002C

2010 BoartLongyear

Section 13 Parts Lists


Parts lists

13-2

Parts Lists

DB525_OM_20081002D

SECTION 14

Table of Contents
14-2 Section 14 Spares kit
14-2 Spares kit

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 14 Spares kit


Spares kit

14-2

Spares kit

DB525_OM_20081002D

SECTION 15

Table of Contents
15-2 Section 15 Trailer Option
15-2 Introduction

Boart Longyear

is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
infoEU@boartlongyear.com

www.boartlongyear.com

DB525 20081002D

2012 BoartLongyear

Section 15 Trailer Option


Trailer Option

15-2

Introduction
! 9#40+0)

Heavy awkward machinery, two men


needed to move the rig.
Observe all previousely
given safety cautions.
Read the relevant
instructions before attempting to operate the
rig.

As an Option the DB525 drill rig may be mounted on a 4 wheeled


Trailer, as shown below. The Trailer mounted rig is manually attached to a towing vehicle, take care that the ground of the operating
area is level and firm. Do not try to operate or move the rig on soft
un-even ground, the rig may become stuck or overturn. All other
aspects of the Trailer rig are as described on the previous sections
of this manual. As before; always apply the Stabilizing Jacks before
commencing drilling set-up

DB525_OM_20081002D