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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 tech nical 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. [email protected]

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 LONGYEAR’S ONLY WARRANTY. BOART LONGYEAR MAKES NO OTHER WARRANTY, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. As a condition to Boart Longyear’s warranty obligations, Purchaser must: (i) contact Boart Longyear and request authorization to return any goods claimed to be defective promptly upon Purchaser’s discovery of the alleged defect, (ii) upon receipt of an approved authorization code from Boart Longyear, return any goods claimed to be defective under the foregoing warranty, at Purchaser’s expense, to the facility designated by Boart Longyear, and (iii) with respect to consumable products purchased through an authorized Boart Longyear distributor, the party making the warranty claim must also deliver to Boart Longyear reasonable evidence of the date of purchase. Boart Longyear shall perform its examination of the goods so returned by Purchaser and shall report the results of its examination to Purchaser within thirty (30) days following its receipt of such goods from Purchaser, or, if longer time is required to complete such examination, within such time as would be required through the exercise of reasonable diligence. As a further condition to Boart Longyear’s obligations hereunder for breach of warranty, Purchaser shall offer its reasonable cooperation and assist Boart Longyear in the course of Boart Longyear’s review of any warranty claim. If requested by Purchaser, Boart Longyear will promptly repair or replace, at Boart Longyear’s expense, goods that are confirmed to be non-

conforming as a result of Boart Longyear’s examination and according to Boart Longyear’s warranty as set forth herein. All removal and installation of goods shall be at Purchaser’s expense; provided, however, Boart Longyear will reimburse the Customer for an amount equal to the reasonable expenses incurred by the Customer and attributable to the removal and shipment of any defective goods. Boart Longyear reserves the right to reimburse Purchaser for an amount equal to the purchase price of any defective goods in lieu of providing repaired or replacement goods. Anything contained herein to the contrary notwithstanding, in no event shall Boart Longyear be liable for breach of warranty or otherwise in any manner whatsoever for:(i) normal wear and tear; (ii) corrosion, abrasion or erosion; (iii) any goods, components, parts, software or services which, following delivery or performance by Boart Longyear, has been subjected to accident, abuse, misapplication, modification, improper repair, alteration, improper installation or maintenance, neglect, or excessive operating conditions; (iv) defects resulting from Purchaser’s specifications or designs or those of its contractors or subcontractors other than Boart Longyear; (v) defects associated with consumable parts or materials, the lifetime of which is shorter than the warranty period set forth in this Section; (vi) defects associated with Purchaser’s specifications or designs or those of its contractors or subcontractors other than Boart Longyear; (vii) defects resulting from the manufacture, distribution, promotion or sale of Purchaser’s own products; or (viii) accessories of any kind used by the Purchaser which are not manufactured by or approved by Boart Longyear.(d) Sourced Goods. If the defective parts or components are not manufactured by Boart Longyear, the guarantee of the manufacturer of those defective parts or components is accepted by the Purchaser and is the only guarantee given to the Purchaser in respect of the defective parts or components. Boart Longyear agrees to assign to the Purchaser on request made by the Purchaser the benefit of any warranty or entitlement to the defective parts or components that the manufacturer has granted to Boart Longyear under any contract or by implication or operation of law to the extent that the benefit of any warranty or entitlement is assignable. Boart Longyear Global Headquarters 10808 South River Front Parkway Suite 600 South Jordan, Utah 84095 United States of America [email protected] 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.

2

The Manual set includes a spare parts catalogue depicting and describing the individual components of the rig.

3

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 rig’s 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 3/8”A.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 Ø12 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. [email protected]

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.

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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

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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.

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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.

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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.

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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

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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

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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 operatorís 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.

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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 rig’s 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 rigís 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

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Safety Considerations

Fire Extinguisher Instructions

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

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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 rig’s stability may be impaired by: - Excessive load - High Winds - Unsecured ground - Incorrect drill mast position - ‘Jerky’ acceleration and stopping during tramming, - Slewing movements, 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 rigís 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 contractorís 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 operatorís vision is impaired during tramming and working, someone must give signals for assistants or the tramming/working area must be cordoned off. Only reliable persons should be designated to give signals. They must receive instruction and be aware of this responsibility. Communication must be co-ordinated and exclusively used between the operator and the signaller. The signaller’s attention must not be diverted by any additional tasks.

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.

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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. [email protected]

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)

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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

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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

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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

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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.

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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).

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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

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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

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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).

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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

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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.

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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

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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

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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. [email protected]

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

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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 0,5…10s 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. [email protected]

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. [email protected]

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 rev’s 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 ìOî 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 Drillís 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. [email protected]

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. [email protected]

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 equipmentís operational safety. For the purpose of these care and maintenance instructions this means that: Care, service and maintenance measures can be carried out by the contractor’s personnel. Structural changes, additions, mountings, adjustment of pressure limiting valves, etc., which modify the equipmentís 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 ìrunning-inî 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 ësloppyíor 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 ësloppyíor 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 ! �)'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 3/8”FLANGED 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)

X

Check for Leaks Check Oil Temperature

 



Change Oil (first after 500 h)

X

Clean Filling and Ventillating Filter





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

X

 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 markedí*í

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. [email protected]

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 50°C 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. [email protected]

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. [email protected]

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. [email protected]

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. [email protected]

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. [email protected]

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. [email protected]

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. [email protected]

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. [email protected]

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. [email protected]

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