LF90LS Operations and Service Manual PDF

LF90
Long Stroke
Operations and
Service Manual
MKT1542 Rev 3
LF90 Diamond Core Drill System
LUBE
PRESSURE
MANIFOLD
PQ
ROTATION
UNIT
CROWN BLOCK
ASSEMBLY
TRANSMISSION
SHIFT LEVERS
YOKED ROD
CENTRALIZER
(2)
MAST SUPPORT
LEG (2)
ALUMINIUM
ROD SLIDES (2)
STEEL
ROD SLIDE
MAST RAISING
CYLINDER (2)
ROD/CHUCK
GUARD
MECHANICAL/
HYDRAULIC
LEVELLING JACK (4)
(Actual equipment may not be exactly as shown)
Important Safety Information
Hazard Signal Words

Hazard signal words are used throughout this manual. They appear in the
narrow left-hand column of numerous pages and, with their additional text
description, are intended to alert the reader to the existance and relative
degree of a hazard.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury and death.
DANGER indicates an imminently hazardous situation which, if not
avoided, could result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially
hazardous situation which, if not avoided, may result in property damage.

Read and understand all safety instructions carefully
before operating this machine. Failing to follow these
instructions may result in serious personal injury or
death.
Keep clear of rotating equipment. Never wear any loose clothing which
could become tangled in the machine.
Never rotate the drill rods without the water swivel attached to the drill
string. (Ensure the hoisting cable is attached to water swivel bail.)
Never rotate the drill rods with a rod joint located behind or above the
chuck.
Keep guards installed and maintained in good working order.
Always keep the work area clean.
Avoid dangerous working environments.
Do not operate equipment while under the influence of drugs, alcohol,
or medication.
Keep visitors a safe distance away from the work area.
Wear personal protective equipment such as a hard hat, safety glasses,
ear protection and steel toed work boots.
Read and understand the operations manual and labels affixed to the
machine.
Use only Boart Longyear replacement parts. Failure to do so could
cause severe damage to the machine or result in operator injury, and
may void your warranty.
Use only qualified service technicians. Failure to do so could cause
severe damage to the machine or result in operator, and may void
your warranty.
Never climb on top of the machine.
Ensure that the drill and accessories fully comply with applicable local
safety and health regulations.
Do not exceed rated capacity of any piece of equipment.
DO NOT store the overshot in the mast as this could result in damage or
injury.
Never rotate the drill rods with a rod joint located behind or above the
chuck.
Do not adjust the hydraulic system before consulting a Boart Longyear
Technician.
Ensure that all commissioning checks and adjustments have been

thoroughly carried out before operating the machine.
Do not change or alter the drill, its components, optional equipment or
accessories without prior approval from Boar t Longyear Inc.
Unauthorized alteration may void the warranty, render the equipment
unsafe or result in decreased performance.
Before operating any controls, be certain you know what function they
control and the ramifications of that function.
Before operating any hoist, ensure the rope is free and clear to travel.
When hoisting/lowering rods, make sure the hoisting cable is in complete
tension before releasing the chuck.
For additional information on training or start up, contact your Boart
Longyear representative.
Do not use multiple part lines on the main hoist of the drill.
NOTE:See following page for safety decals that appear on the

machine.
BOART LONGYEAR
Table of Contents
Chapter 1 Recommended Practices for Maintenance
and Use of Masts
1-2
1-4
Introduction
Visual Inspection of the Mast
Chapter 2 Drill Introduction

2-2
General Information
2-3
Ordering and Returning Parts
2-4
Safety Warning
2-5
Standard Warranty
Chapter 3 Modular Drill Components

3-2
Power Unit Module
3-3
Hydraulic Module
3-4
Draw Works Sub Frame Module
3-5
Drill Base Module
3-6
Lower Mast Section Module
3-7
Upper Mast Section Module

Middle Mast Section Module
3-8
Rotation Unit Module
3-9
The Control Panel
Chapter 4 Drilling Operations

4-2
Pre-Start Check List
4-4
Anchoring the Drill
4-9
Start Up Procedures
4-11 Mast Installation and Raising

4-14 Collaring the Hole
4-16 Rod Handling
4-18 Force on Diamond Bit
4-20 Shutdown Procedure
4-21 Lowering the Mast
Chapter 5 PQ Rotation Unit Group

5-2
PQ Head Drive Group
5-3
PQ Head Disassembly Procedures
5-15 PQ Head Reassembly Procedures

5-51 Transmission and Head Box Lubrication
5-52 PQ Nitro Gas Chuck Planograph
5-53
PQ Nitro Gas Chuck Assembly Procedures
5-61
Installation of New Jaws
5-62
Nitro Gas Springs
Table of Contents
Table of Contents
BOART LONGYEAR
contd
contd
Chapter 6 Hydraulic Explanation

6-2
Drive Source
6-3
Primary Circuit
6-7
Rotation Circuit
6-8
Fast Feed Circuit
6-9
Mainline Hoist Cable Circuit
6-11
Wireline Hoist Circuit
6-12
Auxillary Circuit
6-23
Secondary Circuit
6-25
Case Drain Return Circuit
Chapter 7 Hydraulic Schematics

7-2
Hydraulic Schematic Diagram
Chapter 8 Wireline Hoist

8-2
Wireline Hoist Assembly Diagram
Chapter 9 General Maintenance and Troubleshooting

9-2
Head Slide Wear Bars
9-3
LF90 Lubrication Chart
NOTE:
Actual equipment may not be exactly as shown and should be verified with
your Boart Longyear representative.
Not withstanding any other statements that may appear in this publication,
Boart Longyear makes no guarantee that adoption of its suggested
guidelines will yield a specific performance; neither does it accept
responsibility for any lose, damage, or other consequences that may so
arise.
All volumes are in US gallons and litres.
Release date: May 2005
BOART LONGYEAR
CHAPTER 1
Recommended Practices for

Maintenance and Use of Masts
1-2
Introduction
Safeguards
Routine Checks
1-4
2005 Boart Longyear Inc.
Visual Inspection of the Mast
Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
BOART LONGYEAR
Recommended Practices for Maintenance and Use of Masts
1-2
Introduction
The following are recommended guidelines and practices to help prolong
the life of your newly obtained Boart Longyear mast.
Enclosed is a checklist for a visual inspection which should be done
every 1000 hrs of operation. (Inspections may have to be done more
often when operating in extreme environmental conditions.) Make
copies of the checklist for each inspection. The checklist should be
signed and filed for future reference.
Safeguards
The operator shall be familiar with the equipment and its proper care. If
adjustments or repairs are necessary, or if any damage is known, the operator
shall report the details promptly to an appointed person and shall notify the
next operator upon changing shifts.
In the erecting and lowering operations, the slowest practical line speed should
be used.
There is no way of judging the remaining strength of a rusty rope, therefore
rusty cable lines must be replaced. Areas adjacent to end connections should
be examined closely for any evidence of corrosion.
Design modifications or welding to the mast is not advised. These
modifications could result in weakening the mast and may cause failure.
BOART LONGYEAR
1-3
Routine Checks
Routine checks should include:
Inspection of welds in erecting mechanism, for cracks and other signs of

deformity.
Inspection of wire rope, including operating lines, raising lines, and guy
lines, for kinks, broken wires, or other damage. Make certain that guy
lines are not fouled.
Check unit for level and correct placement before erecting operation.
Check lubrication of crown sheaves.
During drilling operations, it is advisable to make scheduled inspections
of all bolted connections to ensure that they are tight. 48 hours after the
initial erection of the mast, check the bolts for correct torque.
Ensure that the Load Rating and Warning decals are installed on the
mast and are in good shape.
Steel becomes brittle when operating in low temperature conditions.

Extreme caution must be exercised when operating at or below 25C
(13F) as the mast may no longer hold the rated load. Frequent visual
inspection of mast members and welds is even more critical at these
temperatures.
Ensure support legs are located on a solid footing and tied back to a solid
anchoring point.
Never exceed the Rated Hook

Load, which is indicated on the
Load Rating decal.
When calculating hook load,
always include load handling
devices (travelling blocks, etc.)
BOART LONGYEAR
1-4
Visual Inspection of Masts

The following is a checklist for a visual inspection of the mast. Ensure that the inspection is performed
by an individual with knowledge of all mast operational procedures during erection or relocation of
mast. Each section has a pass or fail choice. If there is a problem, it should be noted and corrected
immediately. Make copies of this checklist and file this check list for future reference.
1
Crown Assembly:
Condition:
Sheaves
Grooves
Spacers or Seals
Grease Fitting
Crown Frame
Warped
Worn
Bad
Missing
Bent Flanges
Cracked Welds
Comments:
2
Vertical Members:
A. Front Leg, Drillers Side
Condition:
Bow
Pin Connection
Pin Hole
Safety Pins
Bent Webs
Rusty
Needs Painting
Needs Repair
Other:
Slight
Bad
Bad
Missing
Bad
Cracked Welds
B. Front Leg, Off Drillers Side

Condition:
Bow
Slight
Pin Connection
Bad
Pin Hole
Bad
Safety Pins
Missing
Bad
C. Rear Leg, Off Drillers Side

Condition:
Bow
Slight
Pin Connection
Bad
Pin Hole
Bad
Safety Pins
Missing
Bad
Cracked Welds
Cracked Welds
D. Rear Leg, Drillers Side (Not applicable for T style mast)

Condition:
Bow
Slight
Bad
Pin Connection
Bad
Pin Hole
Bad
Cracked Welds
Safety Pins
Missing
Comments:
3
Bracing
Condition:
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
Needs Repair
Other:
Slight Damage
Needs Repair
Badly Damaged
OK
Cracked Welds
Needs Repair
OK
Adjustable Support Legs and Feet

Condition:
Damaged
Worn Pins/Hole
Corroded
OK
OK
OK
OK
OK
OK
BOART LONGYEAR
Working Platform
Condition:
Racking Platform
Frame:
Pin Connections
Safety Pins
Fingers
Working Platform
Handrails
Damaged
Worn
Missing
Damaged
Damaged
Damaged
Guyline Anchorage
Condition:
Guyline
Damaged
Needs Adjusting
Cable Clamps
Loose
Turnbuckles
Damaged
Anchor and Deadman
Replace
Cracked Welds
1-5
OK
OK
OK
OK
OK
OK
Worn
Needs Repair
Cracked Welds
Needs Repair
Needs Replacing
Needs Repairing
Needs Replacing
OK
OK
OK
OK
Bolt Connections
All bolted connections are to be inspected, tightened, and missing parts replaced or
visibly marked as missing or damaged and in need of repair.
All connections found to be satisfactory as checked and loose bolts tightened
OK
All connections visually inspected and spot checked for tightness and no further
bolt tightening or repairs necessary.
OK
Substructures for Mast

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

Condition:
Oil Leaks
10 Summary of Inspection
Appearance:
Repairs Needed:
Number of Missing Parts:
Good
None
Hose/Tubing Damage
Fair
Minor
Poor
Major
11 List of work to be completed:
Signature :
Date:
Ref No.:
BOART LONGYEAR
1-6
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BOART LONGYEAR
CHAPTER 2
Drill Introduction
2005 Boart Longyear Inc. Boart Longyear
2-2
General Information
2-4
Drilling Safety
2-4
2-5
Standard Warranty
is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
BOART LONGYEAR
Drill Introduction
2-2
General Information
The purpose of this manual is to furnish the operator with detailed information
which will enable him to achieve the maximum operating performance from
his drill. It will also give information necessary to perform preventative
maintenance and make minor repairs and adjustments.
To obtain the utmost in performance and life of the equipment, it should be
given regular care and operated in accordance with the instructions.
Read this manual carefully before attempting to operate the drill and keep
this book handy at all times for reference when any question arises.
BOART LONGYEAR
Drill Introduction
2-3
Drilling Safety
Most accidents are caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to
potential hazards. This person should also have the necessary skills and
tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this Unit can be
dangerous and could result in personnel injury or death. Only trained
personnel should service this unit.
Do not operate or perform any maintenance or repairs until you have read
and understood the provided information. If you are unsure, contact a factory
trained representative!!! Do not take risks.
The successful operation of this unit depends on clean, high quality hydraulic
fluid. As with any hydraulic system, observe proper installation procedures
ensuring overall cleanliness. The accidental introduction of contamination
will inevitably cause system malfunctions or a complete system failure.
Boart ongyear cannot anticipate every circumstance that might involve a
potential hazard. The warnings in this manual are therefore not all inclusive.
If working on the Unit, you must satisfy yourself that it is safe for you and
others and that you thoroughly understand the actions you are about to
undertake. You should also ensure that the Unit will not be damaged or
made unsafe by the operation, lubrication, maintenance or repair you
choose.
BOART LONGYEAR
Drill Introduction
2-4

Ordering Parts
The following procedure will expedite the filling of your parts order, eliminate
delays and assure correct replacement parts:
1. List the model and serial number of the drill.
2. State exact quantity required.
3. Specify description and part number as shown in Parts Manual.
4. Specify method of shipment, ie: Parcel Post, Express, Freight; for
Overseas shipment, Air Freight, Air Parcel Post, or Ocean Freight.
All parts are priced F.O.B., our factory and a separate charge will be made
for transportation and export packing.
Returning Parts
NOTE:
DO NOT attempt to ship
parts until you receive an
RGA number and shipping
instructions otherwise we
have no way to track your
claim for returned goods.
Boart Longyear will not be
held responsible for any
par ts shipped without a
return good authorization
number.
If you wish to return parts whether for repairs, replacement, or warranty,

you should communicate the details of the return request in writing with
your local Boart Longyear representative.
In Canada the request can be sent:
via email to: orderdeskrga@boartlongyear.com
or faxed to: 705-474-2373
The request should reference the model and serial number of the product
as well as:
part number and quantity
reason for return
Once the return is approved you will be issued an RGA (Return Goods
Authorization) number to track your claim.
All parts for return are subject to incoming inspection and minimum restocking charge of 20% will apply.
Special, "made to order", or obsolete, parts will not be accepted this
includes small items such as nuts, bolts and o-rings.
All parts must be returned prepaid.
BOART LONGYEAR
Drill Introduction
2-5
Standard Warranty
Boart Longyear Inc. makes no warranty that the products sold hereunder
shall be merchantable or that such products shall be fit for any particular
purpose and there are no warranties expressed or implied made by Boart
Longyear Inc. except its following standard warranty.
Boart Longyear Inc. warrants each product, and accessory equipment sold
by it (except items not manufactured by Boart Longyear Inc. such as power
units, pumps, and other trade accessories sold with, attached to, or operated
with Boart Longyear drills or other products) to be free from defects in
material and workmanship under normal use and service for 90 days from
date of use, but not to exceed 6 months from the date of shipment from a
Boart Longyear Inc. factory, the obligation of this warranty being limited to
the replacement or repair at a Boart Longyear Inc. facility in Ontario, Canada,
or at a point designated by it, of such parts as shall appear to it upon
inspection at such point to have been defective in material or workmanship
at the time sold, providing that the part or parts claimed defective are
returned to inspection point, transportation charges prepaid.
This warranty applies only to new and unused products and accessory
equipment which after shipment from the Boart Longyear factory, have not
been altered, changed or repaired in any manner.
Exclusion of Liability for Consequential Damages
It is further agreed by the purchaser that in no event shall Boart Longyear
be liable for increased costs, loss of profits or goodwill or any special, indirect,
incidental, or consequential damages whatsoever.
BOART LONGYEAR
Drill Introduction
2-6
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BOART LONGYEAR
CHAPTER 3
Modular Drill Components

3-2
Power Unit Module
3-3
Hydraulic Module
3-4
3-5
Drill Base Module
3-6
3-7
3-8
3-9
The Control Panel

Power Unit Instrument Control Panel
Hydraulic Control Panel
Control Panel Plan-O-Graph
BOART LONGYEAR
3-2
Power Unit Module

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

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

BOART LONGYEAR
3-4

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

BOART LONGYEAR
3-5
Drill Base Module

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

BOART LONGYEAR
3-6

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

BOART LONGYEAR
3-7

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

BOART LONGYEAR
3-8

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

BOART LONGYEAR
3-9
The Control Panel
For clarity the control panel is broken down into two parts, the power unit
instrument control panel (part of the power unit module) and the hydraulic
control panel.
Power Unit Instrument Control Panel

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

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

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


BOART LONGYEAR
3-10
Lift up the switch to test the engine protection warning bulbs. The oil
pressure, coolant temperature, engine overspeed and emergency stop
warning bulbs should illuminate.
If one of the lights do not illuminate the bulb is burnt. Release the
switch after testing the bulbs. If the engine shuts down due to a oil
pressure, coolant temperature, engine overspeed or emergency stop
fault, the relevant bulb will illuminate to warn the operator of the problem.
Test the warning bulbs prior to each engine start up.
Engine Pre-heat Switch

In cold ambient temperatures, lift this switch up to preheat the intake
manifold prior to cranking the engine to start. Hold the switch up for
approximately 30 seconds prior to starting.
NOTE:
After activating the emergency

switch, it must be reset by lifting it
up to the top position before the
engine can be restarted.
Emergency Stop Switch

Two position, on/off push button switch.
Depress this switch to stop the engine in a emergency.
Engine Speed Switch (Throttle)

The engine speed switch controls the rpm of the diesel engine. Hold
toggle switch up to bring engine up to desired high idle rpm or down to
bring engine to low idle speed.
7
5
BOART LONGYEAR
3-11
Oil Pressure Fault Light

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

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

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

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

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

Allows the operator to monitor the engine coolant temperature.
14
Voltmeter
Allows the operator to monitor the battery condition and charging
system.
15
Hour Meter
Allows the operator to monitor the engine hours for service intervals.
16
Tachometer
Allows the operator to monitor the engine RPM .
BOART LONGYEAR
3-12
13
12
16
14
15
Hydraulic Control Panel

NOTE:
17
Rotation Directional Control Lever

This controls the forward or reverse rotation of the chuck.
Move the lever upward for forward rotation and downward for reverse
rotation. The lever incorporates a mechanical lockout to prevent the
operator from shifting from forward rotation directly into reverse. This
valve section is detented in the forward and reverse directions. The
control lever has a mechanical lockout device to prevent accidental
operation.
18
Fast Feed Directional Control Lever

This lever controls the up and down traverse of the drill head.
It is not used when fine feeding during drilling operations (i.e. it remains
in the neutral position). Upward movement of the lever raises the drill
head, downward movement of the lever will lower the drill head. This
valve section is spring centred.
19
Mainline Hoist Control Lever

Movement of this lever in the upward direction will spool the hoisting
cable onto the mainline hoist drum (raising the drill string), while moving
the lever downward, will unspool cable off the mainline hoist drum
(lowering the drill string). This valve section is spring centred.
To prevent damage to the chuck

never rotate the drill head with the
chuck in the open position.
NOTE:
When hoisting and lowering rods,
make sure the hoisting cable is in
complete tension before releasing
the chuck.
20
19
18
17
BOART LONGYEAR
NOTE:
3-13
20
Wireline Hoist Control Lever

Upward movement of this lever spools cable onto the wireline hoist
drum (raising the overshot), while moving the lever downward,
unspools cable off the wireline hoist drum (lowering the overshot).
The control lever has a mechanical lockout device to prevent accidental
operation.
21
Feed Pressure Gauge

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

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

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

This gauge indicates the hydraulic system pressure of the water pump
circuit. It serves as a torque gauge for the hydraulic driven water pump.
In order to prevent damage to the

hydraulic motor, completely stop
the rotating drum before changing
direction.
25
24
23
22
21
BOART LONGYEAR
25
3-14
Auxiliary Circuit Pressure Gauge

This gauge indicates the system pressure of the auxiliary circuit. The
auxiliary circuit has the following functions:
Chuck Open/Close
Rotation Speed Control
Rod Clamp Open /Close
Mast Raising/Lowering
Mudmixer Motor Rotation
Rod Making/Breaking
Fine Feed Control
The maximum pressure in the following two circuits is limited by

individual pressure control valves:
Boart Longyear PQ Chuck
1400 to 1450 psi
25 to 400 psi (0.2 to 2.8 MPa)
Both the feed and auxiliary control will be up to full system pressure,
which is set at 2000 psi (13.7 MPa). This gauge reads secondary pump
compensator setting which is set at 2000 psi (13.7 MPa). This is
explained in greater detail in the Hydraulic Explanation.
26
Chuck Open/Close Valve

This two position detented selector valve will open or close the chuck.
Moving the lever forward closes the chuck, rearward movement of the
lever opens the chuck. There is a mechanical lockout device on this
lever to prevent accidental operation.
27
Hydraulic Rod Clamp Valve

This two position detented selector valve will open or close the rod
clamp. Moving the lever forward closes the rod clamp, rearward
movement of the lever opens the rod clamp. There is a mechanical
lockout device on this lever to prevent accidental operation.
28
Mast Raising/Lowering Valve

This three position spring return selector valve controls the speed and
direction of travel of the dual mast raising cylinders when raising and
lowering the mast. Moving the lever forward raises the mast and
rearward movement of the lever lowers the mast. The mast raising
cylinders are located in the draw works module.
29
Hydraulic Mud Mixer Valve

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

This three position spring return selector valve activates the head float
down while making rods joints and up while breaking rod joints. Moving
the lever forward causes the head to float downwards and rearward
movement of the lever causes the head to float upwards.
Never rotate the drill head with

the chuck in the open position.
Never close the rod clamp while

the rods are rotating.
Do not operate this valve until

you are familiar with the mast
raising and lowering
procedures.
Never activate this lever while

in the drilling mode.
BOART LONGYEAR
31
3-15
Feed Control Selector Valve

The detented three position feed selector controls movement of the
drill head when in fine feed (drilling) mode. The center position blocks
the fine feed circuit and allows the direction of the drill head to be
controlled by the fast feed lever.
Moving the lever forward will convert the system to fine feed in the
downward direction (drilling mode). Rearward movement of this lever
will convert the system to fine feed in the upward direction (back
reaming, getting weight off the bit).
30
31
29
27
26
28
33
34
32
Do not release the mainline

winch brake unless in fine feed
drilling mode or rods are
securely held in the chuck or
rod clamp.
32
Chuck Adjustment Control

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

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

This two position, detented, 90 rotary valve controls the oil flow to
release or apply the mainline winch brake. Rotate the lever in the
clockwise direction to apply the brake to hold the rod weight with the
hoisting cable . Rotate the lever counterclockwise to release the brake
when in drilling mode.
BOART LONGYEAR
NOTE:
The valve that controls the float up
pressure of the head while making
rods is located on the opposite
side of this valve. It also requires
readjustment whenever there is a
change in the drilling angle or the
rod size being used.
3-16
35
Rod Clamp Adjustment Control

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

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

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

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

This valve controls the float up pressure of the head when breaking
rods. It requires readjustment whenever there is a change in the drilling
angle or the rod size being used. Adjustment is located on rear side of
auxiliary manifold.
40
Rod Making Float Control

This valve controls the float down pressure of the head when making
rods. It requires readjustment whenever there is a change in the drilling
angle or the rod size being used.
41
Rod Making/Breaking Pilot Operated Check Valves

One check valve is positioned on each side of the manifold. The
purpose of these check valves is to ensure that the head does not
move when the rod making float control valve is in the neutral position.
42
Rod Making Torque Limiter Valve

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

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

This valve controls the desired sensitivity of Feed Rate Control (item
42) as required when rod weight contributes to the force on bit.
BOART LONGYEAR
3-17
43
40
41
44
38
35
Never operate the levelling

jacks when the mast is erected.
36
45
Water Pump Control (not shown)

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

If the drill is equipped with the optional hydraulic levelling jack group,
this valve is located inside the control console. To access the valve
open the small door in front of the control console.
To operate the levelling jacks, first open the diverter ball valve located
above the levelling jack control valve bank to divert oil from the auxiliary
manifold to power the levelling jacks.
Lifting the control lever causes the levelling jack selected to extend,
lifting the drill. Pushing down on the control lever causes the levelling
jack selected to retract, lowering the drill.
Refer to the control decal for levelling jack selection and direction of
operation. Once the drill is levelled return the diverter ball valve to the
closed position to prevent accidental operation.
BOART LONGYEAR
3-18
Water
Temperature
Gauge
Oil Pressure
Fault Light
Coolant
Temperature
Fault Light
Overspeed
Fault Light
Voltmeter
Tachometer
Feed
Pressure
Gauge
Rod
Torque
Gauge
Emergency
Stop
Fault Light
Oil Pressure
Gauge
Auxiliary Circuit
Pressure
Gauge
Secondary
Pressure Gauge
Bit Weight Gauge
Hour Meter
Lamp Test
Light Switch
Wireline Hoist
Control Lever
Mainline Hoist
Control Lever
Engine
Start Switch
Fast Feed
Directional
Control Lever
Ignition Switch
Rotation
Directional
Control Lever
Protection
Bypass Switch
Emergency
Stop Switch
Feed Control
Selector Valve
Engine
Pre-heat Switch
Hydraulic
Mud Mixer
Valve
Rod Making
Torque Limiter Valve
Chuck
Open/Close
Valve

Hydraulic Rod
Clamp Valve
Engine Speed
Switch (Throttle)
Rod
Making/Breaking
Valve
Feed Pressure
Reducing Control
Rod Making
Float Control
Mast
Raising/Lowering
Valve
Rod Making/Breaking
Check Valve
Mud Mixer
Speed Control
Mainline Brake
Release Control
Mast Raising
Adjustment Control
Chuck
Adjustment
Control
Rod Clamp
Adjustment
Control
BOART LONGYEAR
CHAPTER 4
Drilling Operations
4-2
Pre-Start Check List
4-4
Anchoring the Drill
4-9
Start Up Procedures
4-11
Mast Installation and Raising
4-14
Collaring the Hole

Casing Guide Bushing
Casing Adapter Collar
4-16
Rod Handling
Inserting the Core Barrel
Rod Making Procedure
Rod Breaking Procedure
Opening the Head
Yoked Rod Centraliser
4-18
Force on Diamond Bit
4-19
Shutdown Procedure
4-20
Lowering the Mast
BOART LONGYEAR
Drilling Operations
4-2
Pre-Start Checklist
1 Check diesel engine oil level.
2 Check all fluid levels. Refer to Lubrication Chart for lubricant types and
quantities.
If any of the above require attention, be sure to thoroughly clean the

area surrounding the filler locations before adding liquids. Use only
clean, uncontaminated containers for filling, not ones that have been
used to hold foreign fluids.
For more detailed diesel engine servicing requirements, refer to the
diesel engine operations and maintenance manual.
For more detailed hydraulic servicing requirements, refer to the
Lubrication Chart for recommended service intervals.
BOART LONGYEAR
Drilling Operations
4-3
3 Visually check the drill for any loose or unserviceable components, leaks,
faulty equipment, etc., and repair these before operating the machine.
If the mast has not been raised,
ensure the drill is properly
supported by the four levelling
jacks in a level orientation.
Before raising the mast, ensure
there are no overhead power
lines, trees or structures which
could foul the tower during
raising, drilling or lowering.
Make certain there are no loose
objects on the mast which may
fall off during the raising of the
tower or when operating the
drill.
BOART LONGYEAR
Drilling Operations
4-4
Anchoring the Drill

Do not operate the LF90 without
the drill being levelled and
securely anchored.
The LF90 is a highly mobile, lightweight diamond core drill. Because of

these attributes, it is essential that the drill is securely anchored to the
formation being drilled. This can be achieved in a variety of ways which will
be discussed below.
Unconsolidated Overburden
The most expeditious means of securing the LF90 in unconsolidated
formations is to use twin anchor logs cemented and buried in the ground
with chain or wire rope attached to them, protruding to the surface. The
chain or wire rope can then be passed through the lifting eyes on the four
corners of the drill base and the entire machine cinches down onto
supporting timbers.
1 Dig two trenches 10 ft (3 m) long and 3 ft (1 m) wide in front of and behind
the drill. These trenches should be a minimum of 3 ft (1 m) deep.
Ensure that log or rod bundle

(3 rods) placement at the rear
of the drill will not interfere with
any proposed drill hole angles.
2 Into each trench place a log (minimum 10" (25 cm) diameter, preferably
hardwood in good condition) or alternately, 3 old 10 ft (3 m) HQ drill rods.
Securely fasten enough 3/8" (1 cm) diameter chain or 5/8" (16 mm) wire
rope to each end of the log or drill rod bundle so there will be 5 ft (1.5 m)
protruding from the surface after the trenches have been filled.
3 Place a covering of rocks and boulders over the logs or drill rod bundles
and lay the free end of the chain or cable over the top of the trench,
removing any slack.
Run chain or wire rope
through two lifting lugs
and attach as per #5.
No Drill Hole
Interference
Log or
Rod Bundle
DRAW
WORKS
Trenches
DRILL BASE
POSITION
Winch or
Turnbuckle
ENGINE
Log or
Rod Bundle
3/8 (1 cm) Dia. Chain or

5/8 (16 mm) Dia. Wire Rope
BOART LONGYEAR
Drilling Operations
4-5
4 Cement the log or rod bundles into position with enough grout mixture to
cover the layer of rocks and boulders. Backfill and compact the soil into
the trenches and restore the site to a level condition. Allow 12 hours for
the cement to cure.
5 Position some 10" X 10" (25 cm X 25 cm) timbers longitudinally under
where the drill base levelling jacks will be positioned.
6 Place the drill on the timbers and run additional 3/8" (1 cm) chains through
the two front and two rear lifting lugs on the drill base. Attach each chain
to one free end of the chain or wire rope protruding from the trenches
(which is attached to the cemented log or rod bundle) and tension the drill
down with a come-along style winch, turnbuckles, etc.
The chain or wire rope must be adequately pretensioned so that it is
immediately effective in transferring load. This tensioning can be verified
by applying a load to the midspan of the cable and measure the deflection
perpendicular to the cable. For a 17" (432 mm) rope, a deflection of 1/4"
(6 mm) under a 150 lb (68 kg) force will indicate that the required preload
of 1000 lbf (454 kg) is present.
Apply a 150 lb (68 kg) force and
adjust the tension until a deflection
of 1/4 (6 mm) is observed.
17 (432 mm) Rope
45
7 Ensure the drill is level in both directions and the mechanical levelling
jacks have been securely clamped into the drill base. If the drill is equipped
with hydraulic levelling jacks ensure that the mechanical lockout devices
are in place.
Winch or
Turnbuckle
3/8 (1 cm) Dia.

Chain or 5/8
(16 mm) Dia.
Wire Rope
Leveling Jacks
Timbers
Backfill and Compact Trenches
Min. 3 ft
(1 m) Deep
Rocks and Boulders

Hardwood Logs or HQ Drill Rods
End View of Engine
BOART LONGYEAR
Drilling Operations
4-6
Alternate Anchoring Methods

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

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

Hard Surface
HQ Drill Rod
Hardwood Logs
Anchoring with Compacted Back Fill
9 Another pattern of anchoring when the site is difficult to dig is uses concrete
in a shallow trench. Use four (4) pieces of 2' (0,6 m) minimum length
scrap HQ drill rod, each with 3/8" (1 cm) diameter chain or 5/8"
(16 mm) wire rope attached . The chain or wire rope should be long enough
so that 5' (1,5 m) protrudes after the trench has been filled.
Place one piece of rod and chain or wire rope in each of the four (4) outer
corners of the trench, beyond the levelling jacks. Fill the trench with
concrete, covering the pieces of rod and chain or wire rope to surface
level, and keeping the protruding chain or wire rope ends free.
BOART LONGYEAR
Drilling Operations
4-7
The collar area for drilling vertical holes should be kept clear of concrete.
Allow 12 hours for the concrete to cure. Next, position two (2) 10" x 10"
(25 cm x 25 cm) timbers longitudinally under where the drill base levelling
jacks will be positioned. Place the drill on the timbers. Use additional 3/8"
(1 cm) diameter chain or 5/8" wire rope around each of the outer four (4)
corners of the drill base. Attach each chain or wire rope to the free end of
the chain or wire rope protruding from the concrete and tension the drill
down with a come-along style winch, turnbuckle, etc.
Chain or wire rope must be adequately pretensioned so that it is
immediately effective in transferring load. This tensioning can be verified
by applying a load to the midspan of the cable and measure the deflection
perpendicular to the cable. For a 17" (432 mm) rope, a deflection of 1/4"
(6 mm) under a 150 lb (68 kg) force will indicate that the required preload
of 1000 lbf (454 kg) is present.
Apply a 150 lb (68 kg) force and
adjust the tension until a deflection
of 1/4 (6 mm) is observed.
17 (432 mm) Rope
45
Top View
Anchor Chain
or Cable
Concrete Pad
Hole
Collar
Tie-Downs
(4) Cable
or Chain
Timbers
Drill Base
Mast End
Side View
Draw Works Unit
Drill Base
3/8 (1 cm) Dia.

Chain or 5/8
(16 mm) Dia.
Wire Rope
Tie-Downs
(4) Cable
or Chain
Timbers
Concrete Pad
Hard Surface
HQ Drill Rods
Anchoring on a Concrete Pad

BOART LONGYEAR
Drilling Operations
4-8
Ensure the drill is level in both directions and the mechanical levelling
jacks have been securely clamped into the drill base. If the drill is
equipped with hydraulic levelling jacks ensure that the mechanical
lock out devices are in place.
Ensure the location of any obstacles at the rear of the drill will not be in
the way of all proposed drill hole angles.
10 Alternatively, if the drill site is heavily forested, the LF90 can be anchored
to the base of sturdy, healthy trees in the immediate area. Once again,
the machine should be anchored so that the drill will not push itself off the
hole when high bit loads are encountered.
11 Burning Casing In
Experienced operators may find that burning a piece of casing into the
ground may be the fastest means of anchoring the drill.
12 Drill and Insert Rockbolts if on bedrock.
BOART LONGYEAR
Drilling Operations
4-9
Start Up Procedures
1 Proceed to start the drill as follows, only after the pre start check has
been completed.
2 Ensure the control panel levers and gear box selector are in the following
position:
Before operating controls, know
how each control functions.
Chuck Lever (10)
Forward
(Closed)
Mainline Brake Lever (18) Fully Clockwise
(Applied)
Rod Clamp Lever (11)
Forward
(Closed)
Mast Raising Lever (12)
Center Position
(Neutral)
Mud Mixer lever (13)
Forward
(Off)
Rod Making/Breaking Lever (14)

Center Position
(Neutral)
Feed Selector (15)
Center Position
(Neutral)
Head Rotation Lever (1)
Center Position
(Neutral)
Fast Feed Lever (2)
Center Position
(Neutral)
Mainline Hoist Lever (3)
Center Position
(Neutral)
Wireline Hoist Lever (4)
Center Position
(Neutral)
Rotation Speed (17)
Fully counterclockwise (Slow)
Feed Rate (26)
Fully clockwise
(Off)
Water Pump Control (28) Fully clockwise
(Off)
Drill Head Gear Selector
(Neutral)
Feed Pressure Reducing Control (27)

Fully clockwise
(Max)
Mainline Winch Brake Release Valve

Fully clockwise
(Applied)
3 Lift up the ignition switch to energise the circuit.

4 Push down the engine speed switch , then release to ensure the engine
speed is set to a low idle prior to starting.
5 Lift the lamp test switch to check the bulbs in the engine protection warning
lamps.
6 For a cold ambient engine start, lift the engine preheat switch for
60 seconds to preheat the engine intake manifold.
7 Lift the protection bypass switch to bypass the protection circuit. Hold up
this switch up for approx. 60 seconds after engine startup to allow the oil
pressure to rise to its normal operating level.
8 Lift the engine start switch to engage the engine starter, and release it
once the engine starts.
Do not continue to crank the engine if it doesnt start after 30 seconds.
Excessive cranking can damage the electrical starter solenoid or
motor.
Before operating controls, know all of the functions.
Investigate why the engine will not start (i.e. fuel or electrical
problems) before cranking excessively.
BOART LONGYEAR
Drilling Operations
4-10
9 Allow the diesel engine to warm up for two minutes before gradually
increasing the rpm.
If operating in extremely cold, ambient conditions, allow the engine at
least seven minutes to warm up before increasing the engine speed or
placing any load on the machine.

Water
Temperature
Gauge
Oil Pressure
Fault Light
Coolant
Temperature
Fault Light
Overspeed
Fault Light
Voltmeter
Tachometer
Feed
Pressure
Gauge
Rod
Torque
Gauge
Emergency
Stop
Fault Light
Oil Pressure
Gauge
Auxiliary Circuit
Pressure
Gauge
Secondary
Pressure Gauge
Bit Weight Gauge
Hour Meter
Lamp Test
Light Switch
Wireline Hoist
Control Lever
Mainline Hoist
Control Lever
Engine
Start Switch
Fast Feed
Directional
Control Lever
Ignition Switch
Rotation
Directional
Control Lever
Protection
Bypass Switch
Emergency
Stop Switch
Feed Control
Selector Valve
Engine
Pre-heat Switch
Hydraulic
Mud Mixer
Valve
Rod Making
Torque Limiter Valve
Chuck
Open/Close
Valve

Hydraulic Rod
Clamp Valve
Engine Speed
Switch (Throttle)
Rod
Making/Breaking
Valve
Feed Pressure
Reducing Control
Rod Making
Float Control
Mast
Raising/Lowering
Valve
Rod Making/Breaking
Check Valve
Mud Mixer
Speed Control
Mainline Brake
Release Control
Mast Raising
Adjustment Control
Chuck
Adjustment
Control
Rod Clamp
Adjustment
Control
BOART LONGYEAR
Drilling Operations
4-11
Mast Installation and Raising

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

Spacers and Bolts
Mainline Cable Retainer

Spacers and Bolts
5 Secure the overshot and hoisting plug, if connected (or mainline hoist
and wireline hoist cables) to the mast, to prevent them from falling during
the raising operation.
6 Start the drill as described in the previous section and position the head
over the mast pivot blocks.
7 Loosen the four bolts on the mast swivel mounting blocks (do not
completely unscrew, loosen only two turns).
BOART LONGYEAR
Ensure there are no overhead

power lines, trees or structures
which could foul the mast
during the raising, drilling or
lowering operations.
Drilling Operations
4-12
8 Before raising the mast, loosen the nuts which hold the mast support legs
in their travelling position. (Do not remove completely.) Also, loosen the
locknut and set screw on the mast support leg clamping jaws.
Accomplishing these steps prior to raising the mast will avoid any
unnecessary delays in securing the mast support legs, once the tower
has been raised.
9 Prior to raising the mast, make sure that all hoses, fittings, and cables are
free and will not get caught on anything during the raising operation.
10 Slowly begin to raise the mast by moving the mast raising control lever
forward, sending oil to the mast raising cylinders, and causing the mast to
raise.
Raising the mast should be accomplished in a gentle, smooth fashion.
Avoid jerky and erratic stop and start motions.
Once mast raising has commenced, under no circumstances should
any person (or part there of) get under or perform any work in that
area until the mast raising is complete (as detailed in this section)
and the tower is firmly secured by the mast support legs.
During the raising operation, double-check that no hoses, fittings,
or cables are hanging up or getting caught.
11 Continue to raise the mast until it is in the vertical position.
As the mast nears the vertical position, the resultant action changes
the mast raising cylinder geometry. As the mast breaks over center
it causes an acceleration in the mast travel speed. Because of this,
reduce the raising speed when nearing vertical to allow the mast to
come to a smooth, gentle stop.
BOART LONGYEAR
Drilling Operations
4-13
12 Stop the diesel engine.

13 Once the mast has broken over center and is in the vertical position,
release the outside mast support leg (i.e. furthest away from the control
panel) from its retaining bracket on the lower mast section and position it
in its respective bracket on the rear of the drill base.
14 Secure the clamping jaw firmly.
15 Once the mast is firmly supported in a vertical position by the outside
mast support leg, remove the inside mast support leg from its retaining
bracket and position in its respective bracket on the drill base (do not
tighten the clamping jaw set screw).
16 Next loosen the outside mast support leg clamping jaw set screw.
17 Restart the diesel engine and place the mast to the desired drilling angle
by slowly moving the mast raising control valve forward to lower the mast.
18 Once the desired angle has been reached return the mast raising control
valve to the neutral position, firmly secure the outside mast support leg
clamping screw and locknut before doing the same to the inside mast
support leg clamping jaw.
19 Tighten the four mast pivot block bolts.
BOART LONGYEAR
Drilling Operations
4-14
Collaring the Hole

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

The bores of these bushings are very close to the O.D. of the particular
casing string that is being used to collar the hole (ie. BW, NW, etc.). The
casing guide bushing is designed to stabilize the casing string and maintain
hole alignment. The casing guide bushing should be used throughout the
entire casing run.
The casing should be firmly seated into bedrock before reducing to the coring
system that will be used. As both the casing guide bushing and casing adapter
collar are designed to be used together, operators should follow the
procedures outlined in this section to ensure the drill is set up correctly.
BOART LONGYEAR
Drilling Operations
4-15
Casing
Guide
Bushing
Casing
Adapter
Collar
Casing Adapter Collar

To avoid a possible pinch point,
when installing the casing
adapter collar into the casing
positioner base, the casing
adapter collar should be
threaded onto the casing from
the underside of the casing
positioner base.
The casing adapter collar has the same shoulder to shoulder length as the
casing guide bushing. When drilling the casing, the operator should advance
the casing joint he intends to disconnect at, until it is flush with the bottom of
the casing guide bushing. Once the casing is firmly seated in bedrock (after
the casing has been disconnected), the casing guide bushing is replaced
with the casing adapter collar.
The previous step of drilling the casing joint to the bottom of the casing guide
bushing will now allow the casing adapter collar to connect to the casing
string and bolt to the lower mast casing positioner base.
BOART LONGYEAR
Drilling Operations
4-16
Rod Handling
Inserting the Core Barrel
1 Run the drill head to the base of the mast and open the chuck and rod
clamp.
2 Attach the water swivel or hoisting plug to the core barrel.
3 Attach the main hoist cable to the water swivel or hoisting plug bail.
4 Lift the main hoist lever which will raise the core barrel (guide the water
swivel or hoisting plug into the rod slide when doing this) above the drill
head.
5 Depress the main hoist lever to lower the core barrel assembly into the
casing.
6 Securely clamp the core barrel in the chuck or rod clamp.
7 Remove the water swivel or hoisting plug from the core barrel and attach
to drill rod.
8 Using the mainline hoist control lever, raise the rod above the drill head
and attach the rod to the core barrel .
Rod Making Procedure

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

1 Position the rod joint to be broken above the rod clamp using the mainline
hoist control lever.
2 Close the rod clamp on the rod.
3 Slacken the mainline hoist cable slightly
4 Close the chuck on the rod
5 Engage rod making/breaking valve rearwards to allow the head to float
up while the threads are being broke.
6 Slowly press the rotation directional lever downwards to rotate the rod
counterclockwise breaking the rod joint.
BOART LONGYEAR
Drilling Operations
4-17
Opening the Head

Use extreme caution when
opening the head on angle
holes due to potential
interference problems around
the mast and leveling jack.
Never allow the head to travel up

or down the mast while in the
open position.
If it is necessary to open the head to handle large casing, ensure that the
rod is rmoved from the chuck.
Yoked Rod Centralizer

Both the middle and upper mast sections have yoked rod centralizers which
are activated by the cable from the operators platform. If the middle mast
section is being used for a 20 ft pull, only the yoked centralizer closest to the
lower mast is used to help thread joint alignment when adding or removing
rods from the hole.
When opening the head on

angle holes support the weight
of the head using a suitable pry
bar due to the increase weight
as the head pivots open.
BOART LONGYEAR
Drilling Operations
4-18
Force on Diamond Bit

The force exerted on the diamond bit while drilling is approximately equal
to the weight of the rods plus the down force exerted by the hydraulic feed
cylinder.
Measuring the weight on the bit requires two different pressure readings.
1 Suspend the rods a short distance above the bottom of the hole with the
rods rotating.
2 With the fine feed control valve closed, engage the fine feed directional
valve to the feed down position.
3 Note the pressure reading on the bit weight gauge, The gauge will read
the maximum pressure that can be exerted on the bit.
4 Slowly open the fine feed control valve. As the bit contacts the rock at
bottom of the hole the reading on the bit weight will reduce. The difference
between the suspended rod pressure and the reduced pressure reading
with the bit in contact with the rock at the bottom of the hole while drilling
is called the OFF PRESSURE.
NOTE:
The lower the bit weight pressure
on the gauge the higher the actual
pressure on the bit.
5 The OFF PRESSURE, when multiplied by the effective area of the hydraulic
cylinder of 7.06 in2 (45 cm2), will give the downward force in pounds exerted
on the diamond bit.
EXAMPLE:
Hydraulic Pressure w/rods suspended
1500 PSI
(10.343 MPa)
Hydraulic Pressure w/bit contacting bottom of hole
1000 PSI
(6.895 MPa)
Off Pressure is the difference
500 PSI
(3.448 MPa)
Total force on bit =
12.56 in2 x 500 PSI
(81 cm2 x 3.448 MPa)
6,280 lbf.
(27,934 N)
BOART LONGYEAR
Drilling Operations
4-19
Shutdown Procedure
1 If the drill string is rotating, close the fine feed valve and allow any drill
string compression or stretch to drill out. You will notice the bit weight
gauge needle begin to rise as the weight comes off the bit.
2 Return the fine feed selector to neutral (center position) and close the
feed rate control valve.
3 Lower the diesel engine rpm to about half, then wind the rotation speed
control counterclockwise to reduce the drill string rpm. Next, feather the
rotation control level back to neutral making sure the mechanical lockout
is in position to prevent the lever from going into reverse.
4 Use the fast feed lever to raise the drill head to break the core and pull the
bit at least 12 in (30 cm) off bottom.
5 Retention the winch cable and apply the mainline winch brake.
6 Allow the fluid pump to flush the hole for about 5 minutes before turning
the water pump control completely clockwise to stop the fluid pump.
7 Reduce the diesel rpm and allow the unit to idle for 5 minutes. This is very
important. It allows the turbocharger sufficient time to slow down prior to
stopping the engine.
8 Press down the ignition switch toggle switch to stop the diesel engine.
If an emergency shutdown
is required, depress the
EMERGENCY STOP
immediately, regardless
of the drilling operation.
BOART LONGYEAR
Drilling Operations
4-20
Lowering the Mast

1 Position the head over the mast pivot blocks.
2 Stop the diesel engine.
Under no circumstances should

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

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

5-2
PQ Head Drive Group
5-3
5-15
PQ Head Reassembly Procedures

Internediate Gear Assembly
Intermediate Shaft and Gear Assembly
Input Pinion and Shaft Assembly
Output Shaft Assembly (Spindle)
Output Carrier and Pump Mounting
Transmission Assembly
5-51
Transmission and Head Box Lubrication

Head Bearing Caps
5-52
PQ Nitro Gas Chuck Planograph
5-53
BOART LONGYEAR
5-2
PQ Head Drive Group

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

level when the spindle is not
rotating, the oil level should be 1
(25 mm) below the top elbow of the
sight tube when the head is in a
vertical position.
To check the maximum or full level

when the spindle is rotating in 4th
gear at 1250 rpm, the oil level
should be 1 (25 mm) above the
bottom elbow of the sight tube when
the head is in a vertical position.
Actual equipment may not be exactly as shown
BOART LONGYEAR
5-3

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

the lower carrier seal.
Using the existing 1/2"
UNC jack screw holes,
remove the lower carrier
seal.
NOTE:
This is a right hand thread.
Spindle Bushing
Adapter Nut
14 Remove the spindle bushing adapter nut.
BOART LONGYEAR
5-5
16 Using a punch, drive out the two oil seals.

17 Remove the six 3/8" UNC bolts and internal tooth lock washers from the
outer locking ring.
18 Thread off the outer locking ring.
19 Remove the two 1/2" UNC bolts from the intermediate lock plate.
BOART LONGYEAR
5-6
20 Remove the intermediate lock plate. This plate will have to be prised off
due to a silicone seal.
21 Remove the 3/4" NPT plug from the bottom of the main housing. This is
a magnetic plug and must be cleaned.
Magnetic
Drain Plug
22 Using a 3/8" Allen wrench, remove the six 1/2" UNC capscrews from the
input carrier.
BOART LONGYEAR
5-7
23 Insert two bolts into the 1/2" UNC jack screw holes, and remove the input
carrier.
24 After removing the input carrier, remove the shim pack from inside the
input shaft bore.
NOTE:
25 Check to make sure all shims are located.
26 Remove inner lock ring from the spindle.
NOTE:
It may be necessary to install a
3/8" UNC x 3/4" bolt in one of
the existing bolt holes on the inner
lock ring to assist with removal.
The spindle thread is a right hand
thread.
BOART LONGYEAR
5-8
27 Remove the bottom cone bearing from spindle.
NOTE:
If problems persist in the removal
of this cone bearing, you may
want to leave it on. It will drop
off the spindle by itself during
removal of the main housing
cover.
28 If the bearing is removed at this time, remove the large snap ring from the
spindle. This is the snap ring that holds the output gear in place.
Large Snap Ring
NOTE:
Blocks must not interfere with the
removal of the spindle.
29 Using the appropriate lifting devices, lift the PQ head and rotate it so the
spindle is vertical to the work bench. Lower the PQ head down on blocks
so that it is approximately 8" (200 mm) above the work bench.
30 Remove the six 1/2" UNC bolts and lock washers from the pump mounting
cover.
BOART LONGYEAR
5-9
Pump Mounting Cover
NOTE:
31 Remove the pump mounting cover.
Break the silicone seal first.
32 Remove the 1/2" UNC bolts and lock washers from the output carrier.
NOTE:
33 Remove the output carrier.
Break the silicone seal first.
BOART LONGYEAR
5-10
34 Place the output carrier face down on the work bench. Using a punch,
drive the two oil seals out of the output carrier bore.
35 If the large snap ring is removed from the spindle, the spindle can now be
removed.
3/4" UNC
Lifting Eyes
36 To remove the spindle, insert two 3/4" UNC lifting eyes into the 3/4" UNC
tapped holes in the chuck adapter flange. Connect a chain or sling and
use an overhead hoist to lift the spindle up and out of the PQ head.
NOTE:
Caution is advised so as not to
damage the threads on the
spindle.
It is recommended that a punch
made of a soft material be used,
preferably brass.
37 With the threaded end of the spindle resting on the work bench, drive the
output wear sleeve down and off the chuck adapter flange portion of the
spindle.
38 Now drive off the top cone bearing with the same punch.
BOART LONGYEAR
NOTE:
During the removal of the wear
sleeves, be careful to avoid
damaging the spindle O.D.
5-11
39 Turn the spindle over so that the chuck adapter flange is resting on the
work bench. Remove the two wear sleeves.
40 Remove the eighteen 1/2" UNC x 1-3/4" capsrews.
41 Locate and remove the four 1/2" UNC x 3/4" setscrews. These locations
are the four jack screw locations.
Jack Screw Holes
42 Install four 1/2" UNC bolts with approx. 2" of thread length.
43 Begin removal of the housing cap by tightening the jack screw bolts in a
cross hatch pattern.
44 When the housing cover has broke lose from the main housing by approx.
1/2" (13 mm), install a proper lifting arrangement so as to lift the housing
cover off the main housing as level as possible.
45 If the lower spindle cone bearing was left on the spindle, it will now drop
off and onto the work bench. The spindle, output gear and the intermediate
idle shaft and gear assembly will also be removed with the main housing
cover.
BOART LONGYEAR
5-12
46 Lay the main housing cover down flat on the work bench with the output
gear exposed.
47 Remove the larger spindle snap ring, spacer and output gear.
48 Raise the cover up and off of the main spindle.
BOART LONGYEAR
5-13
49 The intermediate idle shaft and gear assembly can be removed with a
soft punch or set up in a press and pressed out of the intermediate shaft.
50 Turn the cover upside down and blocked up approx. 2" (50 mm) above
the work bench.
51 Drive out the two remaining bearing races.
52 Slide the intermediate spacer off the intermediate idler shaft.
53 Slide the intermediate gear assembly off the intermediate idler shaft.
54 Remove the two intermediate idler shaft cone bearings.
55 Remove the cone bearing spacer.
56 Drive the bearing race down and off of the intermediate gear with a punch.
57 Remove the bearing race spacer.
58 Drive the second bearing race off of the intermediate gear with a punch.
59 Lift out the input pinion and shaft from the main housing. Place it input
side down on the work bench.
BOART LONGYEAR
5-14
60 Remove the snap ring.
61 Drive out the 1/4" (6.4 mm) x 3-1/4 (82.6 mm) dowel pin.
62 Remove the pump adapter tang.
63 Remove the pump adapter.

64 Remove the two input pinion and shaft cone bearings using appropriate
bearing pullers.
BOART LONGYEAR
5-15
PQ Head Reassembly Procedures

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

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

Make sure race is pressed tight against bottom of counter bore.
BOART LONGYEAR
NOTE:
Note direction of race installation to
accommodate shaft bearing.
NOTE
5-16
3 Apply a thin film of oil on outside diameter of bearing race before

installation. Install bottom bearing input shaft race using appropriate driver.
Install race approx. 1/4" (6.4 mm) into the bore.
4 Clean and reinstall the magnetic pipe plug using an appropriate pipe
thread sealant.
5 Turn main housing over, face-up. Check dowel pins for signs of wear or
burrs.
6 Place housing cover face-up. Apply a film of oil on bore diameter before
installation. Install top spindle bearing race using an appropriate driver.
Ensure that bearing race is seated firmly at bottom of counter bore.
BOART LONGYEAR
5-17
Apply a film of oil on bore diameter before installation. Install top input
shaft bearing race into bore approximately 1/4" (6.4 mm) deep.
Install the two 3/8" NPT pipe plugs using an appropriate pipe thread
sealant.
Intermediate Gear Assembly

7 Install snap ring into snap ring groove in gear.
BOART LONGYEAR
5-18
8 Install bearing race spacer into gear.
NOTE:
This spacer must be installed
in the proper direction.
The measurement out to end of
the gear must be approximately
1-5/16" (3.33 cm) both sides.
NOTE:
Press bearing races in, one on each side of snap ring.
Note the orientation of races.
When the races are pressed in, they must be tight on spacer.
BOART LONGYEAR
5-19
9 Place intermediate gear shaft on work bench, with the large diameter
down.
Slide the intermediate shaft tapered roller bearing down the shaft until it
bottoms out. Note the orientation of the bearing.
Install the intermediate gear on the shaft.
BOART LONGYEAR
5-20
Install the bearing spacer.
Slide the intermediate shaft tapered roller bearing down the shaft and
into the intermediate gear.
Install the intermediate spacer.
BOART LONGYEAR
5-21
Intermediate Shaft and Gear Assembly

10 With the PQ Head main housing resting flat on the work bench, place the
intermediate shaft and gear assembly into the bore. Using a soft-face
hammer, gently tap the intermediate shaft and gear assembly in the
housing bore. Ensure that the intermediate shaft and gear assembly is
square in the bore.
NOTE:
Take note of the orientation of
the two 1/2" UNC threaded holes,
they must be at right angles to the
main housing.
Using a proper lifting sling, roll the main housing on its side, so as to
have access to the bottom bore.
BOART LONGYEAR
5-22
11 Use the intermediate lock plate and two 1/2" UNC bolts of the appropriate
length to draw the intermediate shaft into place in the main housing.
Tighten each bolt alternately, being careful not to bottom out the bolts in
the thread holes.
12 When intermediate shaft is drawn into position, remove the intermediate

lock plate. There must a gap of approximately .060" (1.5 mm) from the
end of the intermediate shaft and the bottom of the counter bore.
13 Apply RTV high temp silicone to the outer edge of the intermediate lock
plate.
BOART LONGYEAR
5-23
Install lock plate with the 1/4" NPT thread hole on your left hand side.
Apply Locktite 242 to the threads of the two 1/2" UNC x 1-1/2" bolts.
Install the bolts part way, then apply RTV high temp sealant to the bolt
heads, to seal the bolt holes in the intermediate lock plate. Torque these
bolts to 50 lbf ft (67.79 Nm).
NOTE:
Main housing must be blocked up in
a way that is very rigid due to the
weight and amount of force that
must be applied to complete the
assembly.
14 Roll the main housing face up on the work bench. Raise and block up the
main housing approximately 8" (200 mm) off the work bench. Make sure
not to block the main spindle bore or the input shaft bore. These bores
must be left open to accommodate the installation of the main spindle
and the input gear shaft assembly.
BOART LONGYEAR
5-24
Install a dial indicator inside the main housing. Position the dial point on
the face of the intermediate gear. Using a short pinch bar, check for
bearing end play of the intermediate gear assembly. It must be between
0.002" to 0.004" (0.05 mm to 0.10 mm).
In the absence of a dial indicator the following method can be used as a

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

15 Using an appropriate driver and press, press the tapered roller bearing
onto the input pinion and shaft.
NOTE:
The correct orientation of the
tapered roller bearing.
Make sure the bearing bottoms
out on the shaft.
The cover side of the input
pinion and shaft is the end of the
shaft that is shortest to the gear
face. The main housing side of
the input pinion and shaft is the
end of the shaft that is furthest
from the gear face
BOART LONGYEAR
5-25
Install the second bearing in the same manner.
16 Install the pump adapter into the bore of the input pinion and shaft. Line
up the matching holes.
Install the pump adaptor drive tang. Push the 1/4" (6.4 mm) diameter
dowel all the way through the input pinion and shaft, pump adaptor and
pump adapter drive tang.
Install the snap ring in the snap ring groove.
BOART LONGYEAR
Pinch-point condition in this

part of the assembly.
5-26
17 Coat the input pinion and shaft bearing race, (in the main housing) with
a thin film of oil. Install the input pinion and shaft into the main housing,
meshing the pinion with the intermediate gear.
NOTE:
Make sure that the pump adapter
tang is in the vertical position.
18 Install the output gear inside the main housing while meshing with the
intermediate gear.
Pinch-point condition in this
part of the assembly.
BOART LONGYEAR
5-27
Coat the face and the internal spline of the gear with a thin film of oil.
Place the output spacer on top of the spindle gear, centering it on the
bore diameter.
19 Install four 1/2" x 5" UNC bolts (remove the heads), one in each corner
of the main housing. These will act as lineup pins for the installation of
the housing cover.
BOART LONGYEAR
5-28
20 Spread a coating of RTV high temp sealant in the groove in the top of
the intermediate shaft. Run a bead of RTV high temp sealant on the
face of the main housing, inside the bolt pattern.
21 Using an appropriate sling or chain method, sling the housing cover in

such a manner that it can be lifted vertically, while being balanced and
level.
22 Lower the housing cover onto the four line up pins, letting the cover down
slowly so as to rest square and level on the top of the intermediate shaft.
BOART LONGYEAR
5-29
23 Using a suitable washer or bar and appropriate 1/2" UNC bolt, draw the
cap down evenly to the face of the main housing.
The cap must be drawn down
evenly or it will gall the
intermediate shaft. 1/2" UNC
bolts of the appropriate length
can be inserted into the
housing cover bolt holes in
order to assist with this
operation. Care must be taken
as not to bottom out the bolts in
the thread holes which would
damage the threaded holes of
the main housing. Once the
housing cover has seated firmly
to the main housing, remove all
bolts, line up pins and the
washer or bar from the
intermediate shaft.
24 Coat the beginning of the thread on all 18 1/2" UNC x 1-3/4" capsrews
with RTV high heat sealant. Install the capscrews and torque to 50 ft lbs
in a cross-hatch pattern.
BOART LONGYEAR
NOTE:
Run a bead of RTV high heat
sealant between the top edge of
the intermediate idle shaft and the
mating bore chamfer of the main
housing cover.
5-30
25 Install the five 1/2" UNC x 3/4" set screws. One in each of the four jack
screw locations and one in the center of the intermediate shaft. This will
protect the threads of the holes for removal of the housing cover.
Jack Screw Holes
BOART LONGYEAR
5-31
Output Shaft Assembly (Spindle)

26 Place the spindle in a press. Apply a film of oil on the spindle bearing
shoulder. Assemble the top tapered bearing cone onto the spindle with
the large bearing O.D. towards the chuck flange on the spindle.
Place the output spacer over the spindle and on top of the bearing.
BOART LONGYEAR
5-32
Now place the output gear onto the spindle, as the gear will only be
used to press the top bearing cone into position against the chuck adaptor
flange and then removed.
Position a suitable piece of hollow tubing over the threaded section of the
spindle onto the output gear.
Press the top bearing into position against the chuck adaptor flange.
BOART LONGYEAR
NOTE:
Use a suitable material under the
threaded end of the spindle so as
to protect the threads.
5-33
27 Place the spindle with the threaded section resting on the work bench
and the bearing up.
Coat the top end of the spindle with a thin film of oil.
Install the output wear sleeve on top of the spindle.
BOART LONGYEAR
5-34
Tap the output wear sleeve down the spindle chuck adaptor flange so
that it is approx. 0.030" (0.8 mm) below the face of the adaptor flange.
Take care as not to damage

spindle threads while installing
the wear sleeve.
28 Turn the spindle so that the chuck adaptor flange is resting on the work
bench and the thread end is up. Coat the machined diameter between
the two threaded portions of the spindle with a light film of oil.
Place the first wear sleeve, lip down over the first threaded portion of the
spindle.
Using an appropriate driver, drive the wear sleeve down until it rests on
the shoulder of the beginning of the second threaded portion of the spindle.
BOART LONGYEAR
5-35
Place the second wear sleeve, lip up over the first threaded portion of the
spindle.
Using an appropriate driver, drive the wear sleeve down till it is tight against
the first wear sleeve.
Take care as not to damage
spindle threads while installing
the wear sleeve.
BOART LONGYEAR
5-36
Using a utility knife, re-score the existing score lines of the two wear
sleeves.
Care must be take to avoid
personal injury and external
damage to the wear sleeves in
this part of the assembly
procedure. The re-scoring of
the wear sleeves ensures a
good clean break of the wear
sleeve lip. Any sharp jagged
edges will cut the seals of the
lower seal carrier upon
installation.
Using an appropriate tool, cut through the lip of each wear sleeve.
BOART LONGYEAR
The lip being removed from the

wear sleeves is extremely
sharp, so caution is advised.
5-37
Roll the lip off each wear sleeve by inserting a pair of needle nose pliers
into the lip and rolling the severed lip off the wear sleeve and around the
needle nose pliers.
29 Turn the completed spindle up so that the threaded end of the spindle is
resting on the work bench. Using the 3/4" UNC tapped holes in the spindle
chuck adaptor flange, install the appropriate lifting aid. Sling the spindle
up and guide it through the main housing being careful not to damage the
threaded portions of the spindle. A slight twist of the spindle may be
required to line up the spline of the spindle with the internal spline of the
output gear. Be sure that the tapered roller bearing on the spindle is
completely seated in the bearing race of the housing cover.
BOART LONGYEAR
5-38
Output Carrier and Pump Mounting

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

installed square and not blocking
the grease fitting port.
Drive the oil seal down to a measurement of 1" (25.4 mm).
BOART LONGYEAR
5-39
Install the 1/8" NPT grease fitting. It must be installed in the proper hole
location so that grease enters between the oil seals and not into the main
housing cavity.
Install the 1/8" NPT plug.
Pack the oil seals with a multipurpose EP2 grease.
BOART LONGYEAR
5-40
Apply a bead of RTV high heat sealant to the flange area of the output
carrier, just inside the bolt circle.
31 Apply a film of grease to the chuck adapter flange on output spindle.
32 Install the output carrier with the 1/4" NPT port to the front of the main
housing.
BOART LONGYEAR
5-41
Install the eight 1/2" UNC x 1-1/2" bolts and lockwashers.

Torque to 50 lbf ft (67.79 Nm), using a cross hatch tightening pattern.
33 Place the pump mounting cover upside down on the work bench. Apply a
bead of RTV high heat sealant inside the bolt circle. Install the pump
mounting cover.
NOTE:
The 1/4" NPT port must be on your
right hand side as viewed from the
front of the main housing.
1/4" NPT Port
BOART LONGYEAR
5-42
Install the six 1/2" UNC x 1-1/2" bolts and lockwashers.

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

addition of any debris inside
the main housing.
BOART LONGYEAR
NOTE:
Observe correct orientation of the
cone bearing.
5-43
35 Coat the bottom spindle bearing race and spindle threads with a film of
oil. Install the bottom spindle cone bearing.
NOTE:
Use two 3/8" UNC x 5" bolts,
installed at 180 apart on the inner
lock ring bolt circle, tt thread the
lock ring onto the spindle, pressing
the cone bearing on the spindle,
square and inline.
With the aid of the inner lock ring, the cone bearing can be installed on
the spindle.
BOART LONGYEAR
5-44
36 Tighten the inner lock ring until the cone bearing is seated in the bearing
race on the main housing.
Should be exercised so as not
to damage the threaded section
of the output shaft.
37 Clean and coat the original shim pack for the input pinion and shaft with a
film of oil. Install the shim pack in the input pinion and shaft bore of the
main housing.
38 Lay the input carrier flat on the work bench, lip up, and apply a bead of
RTV high heat sealant around the outside edge lip.
BOART LONGYEAR
5-45
Install the input carrier in the input pinion and shaft bore of the main
housing. The correct position of the input carrier is with the large counter
bore on top with the input carrier protruding over the front of the main
housing.
Apply Locktite 242 to the threads of the six 1/2" x 1-3/4" capscrews.
Install and torque to 50 lbf ft (67.79 Nm).
39 Back off the inner lock ring one turn. Remove the two 3/8" UNC x 5"
bolts used for installation of the bearing. Install a 3/8" UNC x
3/4" bolt and flat washer. Torque the inner lock ring to preload the output
shaft for a rolling torque of approximately 70 lbf in (7.91 Nm).
After setting the proper torque

and before removing of the
3/8" UNC x 3/4" (1.91 cm) bolt,
scribe a line on the main
housing and inner lock ring.
BOART LONGYEAR
NOTE:
The output shaft should be rotated
and the inner lock ring tightened
alternately several times to ensure
that the bearings are indeed
seated in the housing and the
torque value is maintained.
Double check your scribe lines to
verify that the position of the inner
lock ring has not changed.
5-46
Fit the in/lb torque wrench with a 9/16" socket and by utilizing the 3/8"
UNC x 3/4" bolt and washer installed previously, thread the inner lock
ring up against the bearing to the required torque.
Remove the 3/8" UNC x 3/4" bolt, being careful not to disturb the position
of the inner lock ring.
40 Thread on the outer lock ring. Leave a distance of approximately 0.060"
(1.5 mm) between the inner and outer lock rings. Position the outer lock
ring so that it can be bolted to the inner lock ring.
Apply Locktite 242 and a 3/8" internal tooth lockwasher to each of the
six 3/8" UNC x 1-3/4" bolts. Install the bolts and washers and torque in a
cross hatch pattern to 120 lbf in (7.9 Nm).
BOART LONGYEAR
5-47
41 Place the lower seal carrier face up on the work bench. Place the first oil
seal, lip down, into the lower seal carrier. Drive the first oil seal down until
it bottoms out on the bottom of the counter bore in the lower seal carrier.
NOTE:
Place the second oil seal, lip up, into the lower seal carrier.
Check the gap between the two

seals to ensure that the grease
access port is clear.
Drive the second oil seal down until it is flush with the top of the counter
bore in the lower seal carrier.
BOART LONGYEAR
5-48
Install the 1/8" NPT grease fitting, #8 ORB plug and the 1/4" NPT plug in
the lower seal carrier. Pack the oil seals with a multipurpose EP2 grease.
With the lower seal carrier sitting face up on the work bench, apply a
bead of RTV high temp sealant just inside the bolt circle and the lip of the
lower seal carrier.
Install the lower seal carrier with the notch in the proper location so as to
allow access to the main housing 3/4" NPT return port.
Use eight 1/2" UNC x 1-1/2" bolts and lock washers to fasten the lower
seal carrier to the main housing. Torque to 50 lbf ft (67.79 Nm) in a
crosshatch tightening pattern.
BOART LONGYEAR
5-49
42 Put a bead of RTV high temp sealant around the flange of the service
cover. Put a bead of RTV high temp sealant around the thread of the four
5/16" UNC x 3/4" bolts. Install the service cover and hand tighten the
bolts.
43 Coat the remaining spindle thread with a film of multipurpose (EP2) grease
and then install the spindle nut. Four 3/8" UNC x 3/4" capscrews are
used in the spindle nut to secure the desired spindle bushing.
BOART LONGYEAR
5-50
Transmission Assembly
44 Position the transmission, machined surface down and output shaft facing
horizontal on the work bench.
45 Slide the splined adapter on to the spline of the output shaft with the
machined O.D of the splined adaptor against the transmission output shaft
bearing.
Machined O.D.
of Splined Adapter
Install the shim pack and retaining washer with the two 7/16" UNF x
1-1/2" bolts to the end of the transmission output shaft. Torque these
two bolts to 40 lbf ft (54.23 Nm).
Using feeler gauges check the distance between the end of the splined
adapter and the retaining washer. There must be .005" to .010" (0.13 to
0.25 mm) end play. Lockwire these two bolts together.
46 Apply a Lithium based grease to the splined adapter and the internal
spline of the input pinion and shaft. Apply a bead of RTV high heat sealant
to the mounting face of the transmission, just inside the bolt hole mounting
pattern.
47 Using a suitable sling and lifting device mount transmission to the input
carrier.
Do not force the transmission
into place. Line up the
transmission and main housing,
and gently rock the
transmission until it slides
freely into place.
Apply Locktite 242 to the threads of the six 1/2" UNC x 1-3/4" bolts.
Install with lock washers and torque to 50 lbf ft (67.79 Nm).
BOART LONGYEAR
5-51
Transmission and Head Box Lubrication

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

The grease fittings on upper and lower bearing caps should have three (3)
shots of multipurpose grease from a hand operated grease gun every 8
hours while rotating slowly.
Grease Nipple
Lower Bearing Cap
PQ Head
Spindle Nut
Grease Nipple
Upper Bearing Cap
PQ Chuck
BOART LONGYEAR
5-52
PQ Nitro Gas Chuck Planograph

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

Internal Retaining Ring
External Retaining Ring
Wear Sleeve, Upper
N/A
Cap Screw, 3/8-16 UNC X 1-1/4 Lg
Cap Screw, 3/8-16 UNC X 3/4 Lg
Cap Screw, 1/2-20 UNF X 2 Lg
Cap Screw, 1/2-13 UNC X 1-1/2 Lg
Seal Kit
Support Plate
Grease
28
6
22
31
26
20
25
10
27
29
33
5
15, 16
11
33
19
9
17, 18
4
30
12
13
23
11
33
8
BOART LONGYEAR
5-53

Refer to Planograph on previous page.
1 Install the three dowels (item # 23) into the piston (item #3).
NOTE:
The orientation of the seals should
be as shown in the planograph.
NOTE:
The orientation of the seal should
2 Install the two urethane cup seals (item #13) on the piston (item #3) outside
diameter grooves. Be sure to coat the seals with hydraulic oil before
installation.
3 Lubricate the inner urethane cup seal (item #12) with hydraulic oil and
install it inside groove of the piston bore (item #3).
BOART LONGYEAR
NOTE:
The location and proper orientation
of seal should be as shown in the
planograph.
NOTE:
The installation order should be as
shown in the planograph.
5-54
4 Lubricate the urethane cup seal (item #14) and install in outer chuck
cylinder (item #4).
5 Lubricate the O-ring (item #17) and the backup ring (item #18). Install in
the O.D. of the inner cylinder (item #2).
6 Install the external retaining ring (item #30) on the PQ chuck spindle
(item #1).
BOART LONGYEAR
5-55
7 Install the lower spindle wear ring (item #19) on the PQ chuck spindle
(item #1).
NOTE:
The orientation and location should
8 Lubricate and install the O-ring (item #15) and the back-up ring (item
#16) on the PQ chuck spindle O.D.
9 Install the upper spindle wear sleeve (item #31) on the PQ chuck spindle.
NOTE:
The piston dowel must align

with outer cylinder for proper
assembly.
10 Align dowel with the first hole to the right hand side of the O-ring bussport
of the outer cylinder (item #4).
11 Install the piston (item #3) into the outer cylinder (item #4). Gently tap
piston down into place until piston is flush to the bottom of the outer cylinder.
BOART LONGYEAR
NOTE:
Be sure to align the two oil ports as
shown.
NOTE:
There are twelve bolts required,
but only install ten bolts, leaving
two bolts out to allow for the
attachment of a lifting device for
ease and safety of further
assembly.
5-56
12 Install the inner cylinder (item #2) into the outer cylinder assembly
(item #11) from step 5. Tap into place using a soft face mallet. Use two
3/8" UNC bolts of the proper length to align the parts.
13 Install the 3/8" UNC x 1-1/4" long socket head cap screws (item #33)
using an anti-seize, and torque to 35 ft-lbs.
14 Bolt the PQ chuck spindle (item #1) to the shipping plate, using 3/4" UNC
bolts.
OR
Bolt the PQ chuck spindle (item #1) to the head spindle using 3/4" UNC
bolts supplied with the drive head module and torque to 280 ft-lbs.
15 Install the internal retaining ring (item 29) in the PQ chuck spindle bore
(item #1).
BOART LONGYEAR
5-57
16 Grease the PQ chuck spindle O.D. with grease (item #39).
NOTE:
Boart Longyear strongly advises
the use of Chevron Ultra-Duty
Premium Grease (Item #39),
EP #NLG12, as the only
recommended grease for
the PQ Nitro Chuck!
17 Bolt adapter plate (item #8) to piston (item #3).
18 Install cylinder assembly over spindle.
19 Install bearing (item #9) starting with lower thrust bearing race (larger
O.D.).
BOART LONGYEAR
5-58
20 Install bearing roller race. Pack bearing with grease (item #39) supplied.
21 Install upper thrust bearing race.

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

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

BOART LONGYEAR
5-59
26 Install gas springs (item #10).
27 Install spring retainer (item #6).

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

30 Install jaws (supplied separately).
31 Install jaw retainer (item #7).

BOART LONGYEAR
5-60
32 Install 1/2"-20 UNC x 1-1/2" long socket head cap screws (item #36)
and torque to 80 ft-lbs.
33 Install upper bushing (supplied separately).
34 Install guide bushing retainer (item #21)
35 Install 1/2"-20 UNC x 3/4" long socket head cap screws (item #34) and
36 Chuck assembly shown on shipping plate.
37 For chuck disassembly, follow the instructions in reverse order.
BOART LONGYEAR
5-61
Installation of New Jaws

NOTE:
The lower spindle bushing and
lower chuck bushing are NOT used
for HWT/PQ sizes. To insert PQ
core barrel assembly, the upper
chuck bushing will have to be
removed and replaced after
insertion, otherwise cuttings will
infiltrate the area around the
mitogen gas springs.
Do not open chuck while rotating
otherwise bearing life will be greatly
reduced.
1.
2.
3.
4.
Remove the top bushing.

Remove jaws.
Remove the bottom bushing.
Clean jaw slots with diesel fuel or a solvent and lubricate with EP2
grease.
5. Reassemble using appropriate jaws and bushings.
6. Remove lower spindle bushing and replace with appropriate bushing.
Lubrication
1. Lubricate the chuck as per the lubrication schedule in chapter 9.

Maintenance
1. Inspect and clean jaws regularly. Replace in sets of seven only,

when worn.
2. For replacement parts, refer to the chuck assembly drawing in your
Parts Manual.
BOART LONGYEAR
5-62
Nitrogen Gas Springs

We do not recommend field recharge of the gas springs, please
contact your Boart Longyear
service representative for more
information.
Nitrogen gas springs are designed to have a long service life. Inspect
the gas springs periodically while changing jaws (3 month intervals).
1. Remove the spring retainer to access the gas springs for inspection
and replacement.
2. Measure the free length of the exposed piston rod above the barrel.
If the gas spring is still charged with nitrogen, the rod will be extended 1 (25mm). Replace any spring that does not meet this
requirement.
BOART LONGYEAR
CHAPTER 6
Hydraulic Explanation
6-2
Drive Source
6-3
Primary Circuit
Main Valve Bank
6-7
Rotation Circuit
Rotation Motor
6-8
Fast Feed Circuit
6-9
6-11
6-12
Auxillary Circuit
Auxillary Manifold Valve Adjustments
6-23
Secondary Circuit
6-25
BOART LONGYEAR
6-2
Drive Source
Triple stacked hydraulic pumps are driven by a toothed composite (synthetic)
adapter plate (flywheel coupling) which is bolted to the flywheel of the diesel
engine.
The main pump has a toothed driven sprocket mounted on its input shaft
which fits into the composite flywheel adapter plate, with the pump flange
being bolted to a bell housing adapter plate.
The secondary pump is piggy-backed to the main pump and connected by a
through shaft.
The auxiliary pump is piggybacked to the secondary pump and is driven by
a through shaft.
Three separate hydraulic circuits transmit the output power of the diesel
engine to the various drill functions.
A description of each circuit follows.
BOART LONGYEAR
6-3
Primary Circuit
Rotation, Fast Feed, Mainline Hoist, Wireline Hoist
If the ball valves are ever closed
to perform any work on the
hydraulic system, ensure they
are fully opened and resealed in
that position, with the hydraulic
reservoir filled to the correct
level before operating the drill.
Use only the correct grade of
clean, hydraulic oil from
uncontaminated containers.
To refill the reservoir, use the
rotary hand pump on the side of
the hydraulic module.
The primary pump is a variable displacement, axial piston, pressure

compensated design with a low pressure standby. This is directly driven
through a toothed gear on its input shaft which is powered by a composite
adapter plate (flywheel coupling) bolted to the flywheel of the diesel engine.
This pump features a 2" (5 cm) inlet hose which is connected to a ball valve
on the hydraulic reservoir. The ball valve allows the operator to isolate the
hydraulic reservoir fluid, should he wish to work on a particular section of the
circuit. All three ball valves are secured with a cable tie, in the open position,
when the LF90 leaves the factory.
The internal inlet of the hydraulic reservoir for the primary pump features a
100 mesh strainer which is fitted with a 3 psi (0.02 MPa) vacuum bypass
valve. This allows a full flow of oil to the primary pump if the strainer becomes
clogged or when starting in extremely cold climatic conditions.
The strainer is removable and can be washed and reused if it becomes
clogged.
Primary Pump
Strainer
The outlet of the primary pump goes directly to a high pressure filter (10 micron
absolute rating) which is fitted with a clogging indicator (this should only be
monitored at operating temperature, as cold oil may give a false reading).
High Pressure
Filter Clog Indicator
BOART LONGYEAR
6-4
Oil from the high pressure filter is then directed to the inlet section of the
main valve bank which is fitted with a rapid response relief valve, factory set
at 4640 psi (32 MPa).
Main Valve
Primary Relief
NOTE:
If the low pressure standby
feature requires adjustment, the
pressure can be read from the rod
torque gauge.
Setting the low pressure standby
must be accomplished with all
main valve bank levers in neutral
and the diesel engine at idle.
Correct setting is 220 psi
(1.5 MPa).
When the drill is initially started, all levers on the main valve bank should be
in the neutral position. As this is a closed centre valve, pressure will
immediately begin to build up. However, a signal is transmitted from the
main valve bank to the low pressure standby feature on the primary pump.
This causes the primary pump to destroke itself to maintain 220 psi
(1.4 MPa) in this circuit. The low pressure standby feature is the upper
(i.e. farthest from the pump) adjustment screw. This is factory set at 220 psi
(1.5 MPa).
Alternate way of setting the Primary Pump standby pressure

to 220 psi (1.5 MPa)
1 Connect a Quadra gauge to the test port on left hand side of main valve.
2 Remove and plug the load sense hose to the compensator (the hose
closest to the console).
Leave the compensator adapter open to atmosphere.
3 All Primary valve control levers in neutral position.
4 Start engine, leave at idle.
5 Adjust standby pressure (the furthest adjustment from the pump body) to
220 psi by turning the thumb screw and using a 1/2" wrench to unlock the
jam nut.
6 Lock the jam nut.
7 Shut off the diesel engine.
8 Reconnect load sense hose to compensator.
Maximum pressure of the primary pump is limited by the pressure
compensator which is factory set at 4500 psi (31.0 MPa). This is the thumb
screw adjustment closest to the pump body.
BOART LONGYEAR
NOTE:
If the engine starts to labour when
increasing pressure, it may be
necessary to increase the main
relief setting a little above
compensator, as detailed in the
following section.
6-5
If the pressure compensator requires adjustment, stop the engine, disconnect

the rotation motor hoses at the bulkhead and plug or cap both the hoses and
the bulkhead fittings, then start the engine and engage the rotation direction
control lever. This will dead head the main pump.
The pressure can be read from the rod torque gauge. The correct setting is
4500 psi (31.0 MPa) maximum. To increase, loosen the lock nut and turn the
adjustment screw clockwise. To decrease, turn the adjustment screw
counterclockwise.
Main Valve Bank

The main valve bank controls the functions of rotation, fast feed, mainline
hoist and wireline hoist.
These functions are protected from pressure spikes by a quick response
relief valve located in the inlet section of the main valve bank. This is factory
set at 4640 psi (32 MPa) which is 140 psi (0.97 MPa) above the pressure
compensator setting of the primary pump.
To set the Main Valve Bank Relief Valve to 4640 psi (32 MPa)
1 Turn the main valve bank relief adjustment fully clockwise using an Allen
wrench.
2 Disconnect the rotation motor hoses at the bulkhead and plug and cap
both the hoses and the bulkhead fittings.
3 Start the engine. Set engine throttle to 1,300 RPM.
4 Move rotation control lever forward (up).
5 Temporarily adjust the Primary pump compensator thumb screw (closest
adjustment to the pump body) to 4,750 psi. Use a 1/2" wrench to loosen
the jam nut.
Low Pressure
Standby Adjustment
Compensator
Adjustment
BOART LONGYEAR
6-6
6 Adjust the Primary valve main relief to 4,640 psi (32 MPa) while monitoring
the rod torque pressure gauge.
7 Readjust the primary pump compensation back to 4500 psi (31.0 MPa).
Head
Rotation
Fast
Feed
Mainline Wireline
Hoist Hoist
Lockout
Primary Circuit Return Oil

After passing through the heat exchanger, the exhaust oil from the main
valve bank is then directed to the main return filter.
The main return filter is a 10 micron assembly located in the top of the
aluminium hydraulic reservoir. A clogging indicator and full flow bypass valve
are included in this assembly. It removes any contamination prior to oil entering
the hydraulic reservoir.
Primary Circuit
Main Return Filter
BOART LONGYEAR
6-7
Rotation Circuit
When rotation is initiated, full primary pump output (43 gpm - 163 L/min) is
directed to the rotation motor via the rotation spool on the main valve bank.
This is a detented, three position spool with lockout. The lockout is to prevent
accidentally shifting from forward rotation directly into reverse which could
cause the rod string to back off down the hole.
Rotation Motor
The rotation motor is a variable displacement, bent axis design with hydraulic
control of the swash plate (i.e. the displacement of the motor can be adjusted
from minimum to maximum by adjusting the rpm control on the control panel).
Turning the rpm control fully clockwise will place the motor on minimum
displacement (i.e. maximum rpm, conversely, counterclockwise movement
of the rpm control will allow the motor to shift from minimum displacement
towards maximum displacement, thus decreasing the spindle rpm and
increasing the available torque).
Maximum pressure within the rotation circuit is limited by the pressure
compensator setting of the primary pump (i.e. 4500 psi, 31.0 MPa). The
pressure within the rotation circuit is displayed on the rod torque gauge on
the control console which monitors the pressure within the main valve bank.
Rod Torque
Gauge
BOART LONGYEAR
6-8
Fast Feed Circuit

The fast feed section of the main valve bank controls the rapid traverse of
the drill head. This mode is normally used for rechucking at the completion
of the core run, or for locating the drill head in a desired position on its feed
stroke.
The valve spool is a spring centered, 3 position design with a closed centre.
Full primary pump output (43 gpm - 163 L/min) can be directed to the feed
cylinder through this spool.
Work port relief valves limit the pressure within the fast feed circuit to:
for LF90 3000 psi (20.7 MPa).
for LF90LS 2500 psi (17.2 MPA).

These valves are located on both A and B ports of the fast feed valve
section and are nonadjustable.
The function of the work port relief valves is to protect the feed cylinder from
over pressurization.
The A and B ports of the fast feed valve section are plumbed directly to a
manifold at the rod end (base) of the feed cylinder. The feed cylinder is a
double acting design which features internal porting to direct oil either above
or below the cylinder piston, depending upon whether extension or retraction
is desired.
Also plumbed into the fast feed circuit is the fine feed circuit. The fine feed
circuit is a function of the secondary pump and is controlled by a 3 position,
closed centre, detented selector valve. When in neutral, the fine feed valve
will not allow oil from the main valve bank fast feed circuit to enter the fine
feed circuit due to its closed centre.
Pressure within the fast feed circuit is monitored on the rod torque gauge on
the control console.
BOART LONGYEAR
6-9

This is a spring centered, 3 position, closed centre valve spool, which can
receive full primary pump output (43 gpm - 163 L/min).
Full system pressure of 4500 psi (31.0 MPa) is available within the mainline
hoist circuit.
The mainline hoist circuit incorporates a counterbalance valve on the exhaust
oil side of the hoist motor (when in the lowering mode). This valve is normally
closed and will not allow the hoist to lower until a positive pressure is applied
to the motor A port (i.e. to lower the load). When the hoist lever is returned
to neutral, the counterbalance valve will once again close and isolate the
hoist motor to prevent loads running away.
Mainline Hoist Motor

Counter-Balance Valve
The mainline hoist planetary reduction assembly also incorporates a spring

applied, hydraulically released brake. This locks the hoist assembly when
the lever is in neutral. A positive pressure on either the A or B port of the
hydraulic motor is required to release the brake to allow the hoist to raise or
lower.
As a third measure of preventing hoist overrun, the planetary gear assembly
incorporates a sprag type bearing. This ensures that the mainline hoist
hydraulic motor must be powered ahead of hoist drum rotation (i.e. if the
hoist drum rotation begins to overrun the hydraulic motor, the sprag bearing
will lock).
When in drilling mode, the mainline hoisting cable is connected to the water
swivel bail. A slight tension is kept on the cable to prevent rod whip above
the drill head. During drilling operations, with the drill head feeding down, a
means of allowing the hoisting cable to unspool under tension has been
incorporated into the mainline hoisting circuit.
BOART LONGYEAR
When hoisting or lowering rods,

make sure the main hoisting
cable is in tension before
opening the chuck. Failure to
do so could result in the hoist
slipping and the rods dropping
uncontrollably. Damage could
result to the hoist and chuck.
Personal injury could result.
Once the mainline winch brake
release valve is rotated in the
clockwise position, hoisting
can be undertaken with the
spring applied brake and pilot
operated check valves
controlled from the mainline
hoist lever on the main valve
bank and not the mainline
winch brake release circuit.
6-10
When the mainline winch brake release valve is rotated in the

counterclockwise direction while in the fine feed drilling mode, a signal is
sent to a shuttle valve mounted in the hoist motor manifold block. This signal
moves the shuttle valve and allows a flow of oil to release the spring applied
brake on the hoist. Oil is also directed to open the two pilot operated check
valves in the hoist manifold block.
When this signal is applied, the hoist is free to unspool, as the hydraulic
motor can now bypass oil from the A and B port, due to the pilot operated
check valves being open in conjunction with the spring applied brake being
released.
Tension is retained on the hoisting cable due to internal friction of the 16:1
(nominally for Geroler type motor) mechanical planetary reduction in the hoist
drum and recirculation of hydraulic oil between the A and B ports of the
large displacement mainline hoist hydraulic motor.
NOTE:
Because of this circuit and the
in-built in logic that pays out hoist
cable as the drill head feeds
down, it is very important that the
mainline winch brake release
valve is rotated in the clockwise
position
to apply the brake whenever
switching from fine feed drilling
mode to rod hoisting or lowering
mode.
BOART LONGYEAR
6-11

The wireline hoist spool is the final function circuit of the main valve bank. It
controls the hoisting or lowering of the wireline cable.
The valve spool for this section is a closed centre, 3 position, spring centered
design with mechanical lockout. The maximum pressure within this circuit is
limited to 2500 psi (17.2 MPa) by work port relief valves on the A and B
ports of the valve spool.
The wireline hoist is protected from overrun by a counterbalance valve which
is located on the motor exhaust oil port when in lowering mode.
This valve is in the closed position when the wireline hoist lever is in the
neutral position, which isolates the wireline hoist motor. A positive pressure
is required from the lowering side of the spool to open the counterbalance
valve and allow a load to be lowered.
If the load begins to overrun the hoist (i.e. when lowering an inner tube
assembly into a dry hole on the overshot), the counterbalance valve will
close, preventing the load from running away.
Wireline Hoist Lockout
Head Rotation Lockout
BOART LONGYEAR
6-12
Auxiliary Circuit
If the ball valves are ever closed
to perform any work on the
hydraulic system, ensure they
are fully opened and resealed in
that position, with the hydraulic
reservoir filled to the correct
level before operating the drill.
Use the correct grade
of clean, hydraulic oil from
uncontaminated containers.
The auxiliary circuit functions, comprising of the feed rate control valve, fine
feed mode selector (up, down or neutral), auxiliary circuit (mud mixer onoff), mast raising, rod clamp, rotation speed control, mainline winch brake
release control valve and chuck control (open, close) are supplied with oil
from the auxiliary pump. This is piggybacked to the secondary pump being
driven by a through shaft, and is an open loop circuit.
The auxiliary pump suction inlet features a 100 mesh strainer located inside
the aluminium hydraulic reservoir (3 psi - 0.02 MPa vacuum bypass valve)
and an external ball valve to isolate the reservoir, should the system require
maintenance. Maximum secondary pump output is 11 gpm (41.6 L/min).
To refill the reservoir use the

rotary hand pump on the side of
the hydraulic module.
Auxiliary Pump Strainer
The auxiliary pump is an axial piston pressure compensated design. The

compensator/vertical adjustment screw, located on the rear of the auxillary
pump, limits the pressure within this circuit to:
for LF90 2500 psi (17.2 MPa).
for LF90LS 2000 psi (13.7 MPa).
Pressure Compensator
Adjustment Screw
To set the auxiliary pump compensator, position the auxiliary circuit levers in
the following positions:
Fine Feed Control Lever Neutral (central position)

Auxiliary Control (Mud Mixer) Lever Off
Mast Raise Neutral (central position)
Rod Clamp Neutral (central position)
Chuck Control Lever Closed
Head Float Control Lever Neutral (central position)
BOART LONGYEAR
6-13
Monitor the feed pressure gauge when setting the auxiliary pump
compensator to its correct pressure of:
for LF90 2500 psi (17.2 MPa).

Oil enters the auxiliary circuit manifold from the auxiliary pump on the right
hand side when viewed from the operators platform. All valves on the
secondary circuit manifold are of closed centre design.
Chuck
Selector
Lockout
Rod Clamp
Selector
Lockout
Rod
Making/Breaking
Head Float
Mud Mixer
Feed
Selector
Selector
Selector
Mast
Raising/Lowering
Selector
Valve
Rotation
Speed
Control
Fine Feed
Adjustment
Chuck
Pressure
Adjustment
Feed
Pressure
Adjustment
Head Float
Adjustment
Main Winch
Brake Release
Rod Clamp
Pressure
Adjustment
Mud Mixer
Flow Control
Mud Mixer
Sequence Valve
Mast Raising
Pressure Adjustment
BOART LONGYEAR
6-14
Feed Selector Valve

This is the first valve on the right (when viewed from the operators position)
on the auxiliary circuit manifold. It is a four-way, three position, detented
valve and controls the fine feed mode in either the up or down direction.
Fine Feed Flow Control Valve

Situated below the fine feed selector valve and accessible from the front of
the hydraulic module is the fine feed flow control valve.
This rotary valve controls the penetration rate (weight on bit) when the fine
feed selector valve is in the down mode. Conversely, if the fine feed selector
valve is in the up mode, the fine feed flow control valve will control the rate
at which the drill head retracts (i.e. back reaming). Turning the rotary control
counterclockwise increases the rate of penetration (weight on bit). The
relationship between the fine feed flow control valve and the weight on bit
gauge on the control panel is evident as this valve is adjusted.
This valve has an adjustable orifice which meters oil from the T port of the
fine feed selector valve (piston end when in the down mode) and is known
as the bleed off pressure. If the valve is cracked slightly (i.e. counterclockwise),
the volume of oil escaping from the low pressure side is minimal, which
translates to a slow rate of penetration and bit weights.
The bit weight gauge is plumbed in between the T port of the fine feed
selector valve and the feed flow control valve. In the above scenario, we are
only allowing a small volume of oil to escape from the feed cylinder. This will
create only a slight pressure differential between the rod (pressure in) and
the piston (pressure out) end of the cylinder. This slight pressure differential
will register as a small reduction in the value displayed on the bit weight
gauge.
As the fine feed flow control valve is opened further (counterclockwise
rotation), more oil is allowed to escape from the (piston side) end of the
cylinder. This increased flow translates to a greater pressure differential which
will register as a larger drop in the value displayed by the bit weight gauge.
Feed Pressure Reducing Control Valve

Situated below the Fine Feed Flow Control valve and accessible from the
front of the Hydraulic Module is the Feed Pressure Reducing Control Valve.
This valve controls the desired sensitivity of the Feed Rate Control as required
when rod weight contributes to the force on bit.
At the start of the hole the Pressure Reducing Valve should be at maximum
setting or at maximum feed circuit pressure:
for LF90 3000 psi (20.7 MPa).
NOTE:
After the hole is completed,
always reset the Pressure
Reducing Valve to full open.
As the rod weight contributes to the force on the bit, the Pressure Reducing
Valve setting can be decreased to maintain a relatively constant hold back
pressure.
When the desired penetration sensitivity is lost it may be necessary to adjust
the Pressure Reducing Valve in order to regain the desired sensitivity.
Generally adjustment may be beneficial starting at approx. 3600 to 4100 lbf
(16,014 to 18,238N) of drill rod weight, but is dependent on many factors.
BOART LONGYEAR
6-15
Rod Making/Breaking Pressure Reducing Valve (Head Float)
Never use this rod making/

breaking float function as a
drilling float while in fine feed
mode. Damage to the drill bit or
stuck rods will result.
NOTE:
Pressure adjustments are required
for different drilling angles and rod
sizes. See rod making/breaking
pressures adjustments in
Chapter 6.
This feature enables the drill head to float while making and breaking rod
joints hydraulically, eliminating manual assistance during the process of
tightening or loosening the rod joint.
For breaking joints, the pressure reducing/relieving valves control the head
weight as the joint unscrews. This allows the head to float up as it is pushed
by the threads as the joint unscrews.
For making joints, the pressure reducing/relieving valves control the head
weight as the joint is screwed together. This allows the head to float downward
as it is pulled by the threads as the joint is screwed together.
While making or breaking rod joints always ensure that the engine rpm is set
at 1800 rpm, the transmission is in first gear and the rotation speed control is
in the maximum displacement setting.
Always start the rod threads by hand before using this function to make rod
joints.
Rod Making/Breaking PRV Adjustment
In order to properly set the PRV, the hydraulic oil temperature must be at
least 100F (37.8C)
Drill mast must be set at the drilling angle
Be careful not to over torque

the rod joint when making rods.
Refer to the procedure on
adjusting the torque limiter
valve earlier in this section.
NOTE:
This is the only flow control
metering device used in the LF90
hydraulic system. Because of the
low flows involved, efficiency of
the system is not impacted to any
degree by the use of such a valve.
Select the rod making/breaking valve in the proper direction while making or
breaking. Gradually lift or push down on the rotation control lever to make or
break the rod joint with the drill head while holding the rods in the hydraulic
clamp.
Auxiliary (Mud Mixer) Selector Valve

This is a detented, four-way, two position valve which either opens or closes
the mud mixer circuit.
A flow control valve is located below this selector valve and it controls the
mud mixer speed. Clockwise adjustment of the flow control valve will reduce
speed while counterclockwise adjustment will increase speed
A sequence valve is sandwiched below this flow control valve to ensure the
fine feed circuit receives priority from the auxiliary pump.
To set this sequence valve, join the two mud mixer hoses together and place
the lever in the Off position. Adjust the flow control valve to maximum open
by rotating the knob counterclockwise. When the auxiliary lever is put in the
On position, the indicated pressure on the feed pressure gauge should
drop 100 psi (0.7 MPa). That is:
for LF90 after adjusting the fine feed circuit to 2500 psi (17.2 MPa) the
reading should drop to 2400 psi (16.5 MPa) when the mud mixer circuit
is switched On.
for LF90LS after adjusting the fine feed circuit to 2000 psi (13.7 MPa)
the reading should drop to 1900 psi (13 MPa) when the mud mixer circuit
is switched On.
To maintain priority in the fine feed circuit, the sequence valve meters flow to
maintain pressure in the feed circuit before it will allow flow to the mud mixer
circuit.
BOART LONGYEAR
6-16
NOTE:
Mud Mixer Maintenance
The Piping Group includes all

fittings, hose, valves, hardware
and decals.
The mud mixer has two bearings which should be lubricated according to
the lubrication chart.
Mast Raising/Lowering Selector Valve

This is a spring centered motor spool, four way, three position valve which
either raises or lowers the mast assembly hydraulically when activated.
The lever for this valve is situated under the control panel surface to prevent
accidental actuation of selector valve. The front panel on the control console
must be opened to access the lever for raising or lowering the mast.
Rod Clamp Selector Valve

This two-position, detented selector valve will open or close the foot clamp.
Moving the lever forward closes the clamp, pulling the lever back towards
the operator opens the chuck. It comes with a mechanical lever lockout
device to prevent accidental actuation of selector valve. Lift to shift lever to
open/close the foot clamp.

This valve is dedicated to the rpm control of the rotation motor.
A pilot pressure from the rotary control strokes the lens of the hydraulic motor
swash plate. Change the hydraulic motor displacement.
This control has an orifice which keeps the secondary pump compensated
and reduces flow to the rotation motor control. This valve is adjustable from
25 400 psi (0.2 2.8 MPa) while the hydraulic rotation motor control is set
from 50 200 psi (0.3 1.4 MPa).
At pressures above 400 psi (2.8 MPa), this valve will vent to tank. As the flow
involved is only 0.5 gpm (2 L/min), heat generation is minimal.
BOART LONGYEAR
6-17
Main Winch Brake Release

If the valve is left in the
counterclockwise position
(i.e. released) while the chuck
is opened or while hoisting or
lowering rods, the rods will
drop because the mainline
winch brake is released.
NOTE:
Before making any adjustment to
this (PRD/PRV) valve, check
mechanical condition of chuck i.e.
clean and grease sliding surfaces
between chuck jaws and
surrounding parts.
This valve applies pressure to the hydraulic brake effectively releasing the
main brake winch.
Chuck Mode Selector Valve

This section on the auxiliary circuit manifold controls the opening and closing
of the hydraulic chuck. A four-way, two position, detented valve, controls the
oil flow direction for this function. It comes with a mechanical lever lockout
device to prevent accidental actuation of selector valve. Lift to shift lever to
open/close the chuck.
Sandwiched below this valve is a combination pressure reducing valve (PRD)/
pressure relief valve (PRV).
If adjustment is necessary, proceed as follows:
1 Install a pressure gauge (0 2000 psi, 0 13.8 MPa) on the diagnostic
coupler located on the back side (opposite cartridge adjusting screw) of
(PRD/PRV) valve
2 With the selector shifted to open the hydraulic chuck, turn the cartridge
adjusting screw clockwise to increase pressure setting JUST to the point
where the hydraulic chuck will fully open (not beyond this point)
For a PQ Chuck, the adjustment ranges from 1250 to 1400 psi (8.6 to
9.7 MPa)
3 Tighten the locknut
4 Remove gauge from back side of (PRD/PRV) valve
5 Once set, this should not be altered during normal operation.
BOART LONGYEAR
6-18
Auxiliary Manifold Valve Adjustments
NOTE:
A Quadra gauge is
recommended to simplify the
following adjustment procedures.
Without one, different ranges of
gauges will be required under
different circumstances to
accurately read pressures.
The Quadra gauge automatically
switches to the appropriate gauge
based on the amount of pressure
it is reading.
Head Float
Rear Adjustment
Diagnostic
Ports
Check rotation min/max signal

1 Connect a quadra gauge to the test port at the back of the min/max
displacement control valve
2 Start engine, leave at idle
3 Turn knob fully clockwise to minimum displacement
4 Quadra gauge should read approx. 400 psi (2.8 MPa)
5 Turn knob fully counterclockwise max displacement
6 Quadra gauge should read 50 psi (0.3 MPa) or lower
7 Remove the Quadra gauge.
Check the mainline winch brake release valve
1 Connect a Quadra gauge to the test port at the back of the brake release
control valve
3 Move the brake release control valve handle right to the Release position
4 Quadra gauge should read 2,500 psi (17.2 MPa) (auxiliary circuit pressure)
5 Move the brake release control valve handle left to the Apply position
6 Monitor the quadra gauge, the pressure should read approx. 0 psi
7 Remove the Quadra gauge.
Set rod clamp pressure to 750 psi (5.2 MPa)
1 Make sure the rod clamp quick couplers are disconnected
2 Connect a Quadra gauge to the test port at the back of the rod clamp
pressure reducing valve.
4 Pull rod clamp control lever to Open position.
BOART LONGYEAR
6-19
5 Adjust the rod clamp pressure reducing valve to 750 psi (5.2 MPa) using
a 5/32" Allen key and 9/16" wrench to unlock the jam nut
6 Lock jam nut
7 Push rod clamp control lever back to Close position, and remove the
Quadra gauge.
Set mast raising pressure reducing valve to 1800 psi (12.4 MPa)
1 Connect a Quadra gauge to the test port at the back of the mast raising
pressure reducing valve
2 Leave the mast raising control lever in the neutral position
4 Adjust mast raising pressure reducing valve to 1800 psi (12.4 MPa) using
a 5/32" Allen key and 9/16" wrench to unlock the jam nut
5 Lock jam nut, and remove the Quadra gauge.
Adjust Mud Mixer Sequence Valve
for LF90 to 2400 psi
for LF90LS to 1900 psi
1 Connect the mud mixer hoses together
2 Connect a Quadra gauge to the test port on front of sequence valve which
is located under the mud mixer directional control valve
3 Open flow control (counterclockwise) under the test port
5 Pull the mud mixer control lever to the On position
6 Monitor the Quadra gauge.
The pressure should drop 100 psi (0.7 MPa):
for LF90 from 2500 to 2400 psi (from 17.2 to 16.5 MPa)
for LF90LS from 2000 to 1900 psi (from 13.7 to 13 MPa).
7 Adjust sequence valve adjusting screw on the back of the valve using a
1/2" wrench and 9/16" wrench to unlock the jam nut
8 Lock jam nut, and remove the Quadra gauge.
BOART LONGYEAR
6-20
Check the mud mixer circuit flow direction

1 Disconnect quick couplers
2 Connect a Quadra gauge to the female quick coupler of the mud mixer
hoses. (B port on DO3 manifold)
3 Close mud mixer flow control (clockwise).
5 Pull mud mixer control lever to the On position. Quadra gauge should
be approx. 0 psi (0 MPa)
6 Open mud mixer flow control (counterclockwise). Quadra gauge should
now read 2500 psi (17.2 MPa)
7 Return the mud mixer control lever to the Off position
8 Close mud mixer flow control, and remove the Quadra gauge.
Rod Making/Breaking Pressure Reducing Valve function test
1 Connect the feed cylinder A & B hoses together with a #8 ball valve
(with attached 3000 psi/20.7 MPa gauges) if not already done
2 Close the ball valve
3 Start the engine, leave at idle
4 Push the Head Float control lever forward to the Down (rod making)
position. Monitor the gauges while adjusting the PRV adjustment screw
on front side of valve body
5 Adjust the pressure down to 0 and back up:
for LF90 to 2500 psi (17.2 MPa).
for LF90LS to 2000 psi (13.7 MPa).
6 Pull the Head Float control lever back to the Up (rod breaking) position.
Monitor the gauges while adjusting the PRV adjustment screw on the
rear side of valve body
7 Adjust the pressure down to 0 and back up:
for LF90 to 2500 psi (17.2 MPa).
for LF90LS to 2000 psi (13.7 MPa).
Rod Making/Breaking PRV Adjustment
In order to properly set the PRV, the hydraulic oil temperature must be at
least 100F (37.8C)
Drill mast must be set at the drilling angle.
BOART LONGYEAR
NOTE:
Always use first gear low range
when making up rod joints. Use
proper thread lubrication to
prevent possible thread damage.
6-21
Rod Making Torque Limiter Valve

This valve is situated at the rear of the control stand and limits the rotation
torque available for pretorquing rod joints. The adjustment screw is turned
clockwise to increase the make up torque.
Valve adjustment:
1 Turn the adjustment screw counterclockwise.
2 Start the engine and set the throttle to 1800 rpm
3 Place the transmission in first gear
4 Turn the rotation speed control fully counterclockwise
5 Close both the chuck and footclamp on a rod in a mast with the head
positioned at the bottom of the feed stroke
6 Place the rod making/breaking valve forward into the rod making position
7 Slowly lift the rotation direction lever upwards to the forward spindle rotation
direction
NOTE:
Turn clockwise to increase
pressure.
8 Monitor the pressure on the torque gauge while adjusting the torque limit
valve screw
9 Adjust to the proper pressure for the rod size being used
Pressure Settings for Rod:
BQ 460 psi
HQ 1150 psi
NQ 690 psi
HWT 1600 psi
10 Return all levers to the neutral position and shut down the engine.
Rod Making Adjustment
1 Place a 10 ft rod in the chuck
2 Push the head float control lever forward to the down float position
3 Adjust the PRV on the front side of the valve body until the head just
starts to float downwards.
Rod Breaking Adjustment
1 Place one or two 10 ft rods in the chuck depending on the mast length
being used
2 Pull the head float control lever backwards to the upward float position
3 Adjust the PRV on the rear side of the valve body until the head just starts
to float upwards
Test the rod making/breaking function and fine tune the adjustment as
required.
BOART LONGYEAR
6-22
Adjust fine feed pressure reducing valve

2 Move the fine feed control lever forward to the Feed Down position
3 Using a 5/32" Allen key and 9/16" wrench, adjust the pressure reducing
valve counterclockwise then clockwise to ensure that the feed pressure
can be reduced
4 Leave the pressure reducing valve set at full pressure, i.e. the
secondary pump compensator setting:
for LF90 2500 psi (17.2 MPa).
for LF90LS 2000 psi (13.7 MPa)
5 Remove the #8 ball valve (with attached 3000 psi/20.7 MPa gauges)
6 Connect the A and B hoses to the feed cylinder manifold.
BOART LONGYEAR
6-23
Secondary Circuit
This circuit powers the hydraulic driven fluid pump. The pump for this circuit
is an axial piston design.
This pump is piggybacked to the primary pump and connected by a through
shaft. The suction inlet for the auxiliary pump features a 100 mesh strainer
located inside the aluminium hydraulic reservoir (with 3 psi - 0.02 MPa vacuum
bypass valve) and an external ball valve to isolate the reservoir, should the
system require maintenance.
Secondary
Pump Strainer
This pump has a relief valve cartridge set at 3000 psi (20.7 MPa) to prevent
the fluid pump motor from being over pressurized.
To set the Secondary pump standby pressure to 340 psi (2.3 MPa)
1 Connect a Quadra gauge to test coupler on top of secondary pump flow
control.
2 Remove the load sense hose at the left hand side of the secondary pump
flow control.
3 Cap the #6 adapter at the left hand side of the secondary pump flow
control.
4 Leave the hose to the compensator open to atmosphere.
5 Close the secondary pump flow control (clockwise).
7 Read the standby pressure on the Quadra gauge.
8 Adjust standby pressure (closest adjustment to pump body) to 340 psi
(2.3 MPa) by turning the thumbscrew and using the box end of a 11/16"
wrench to unlock the jam nut.
9 Lock the jam nut.
10 Reconnect load sense hose to the flow control.
To set the Secondary pump compensator to 3000 psi (20.7 MPa)
1 Disconnect the secondary pump circuit quick couplers.
BOART LONGYEAR
6-24
3 Open secondary pump flow control (counterclockwise).

4 Monitor the pressure on a Quadra gauge.
5 Adjust the compensator (farthest adjustment from the pump body) to 3000
psi (20.7 MPa) using a 7/16" wrench and using a 1/2" wrench to unlock
the jam nut.
6 Lock the jam nut.
7 Reconnect the secondary pump circuit quick couplers.
Pressure Compensator Adjustment
Standby Pressure
Adjustment Pressure
BOART LONGYEAR
6-25

All hydraulic pumps and motors with external case drains have these plumbed
into the case drain filter. This is a 10 micron assembly located in the top of
the aluminium hydraulic reservoir.
A clogging indicator and full flow bypass valve are included in this assembly.
This will remove any contamination prior to oil entering the hydraulic reservoir.
Case Drain
Return Filter
BOART LONGYEAR
6-26
BOART LONGYEAR
CHAPTER 7
Hydraulic Schematics
7-2
BOART LONGYEAR
Hydraulic Schematics
7-2
BOART LONGYEAR
CHAPTER 8
Wireline Hoist
8-2
BOART LONGYEAR
Wireline Hoist
8-2
Hydraulic Motor
Wireline Guard
Wireline Drum
Side Plate (RHS)
Side Plate (LHS)

Retaining /
Disassemble Tool
Bearing Guard
Bearing Shaft
Support Bearing
NOTE: Refer to the Parts Manual for complete component breakdown
BOART LONGYEAR
CHAPTER 9
General Maintenance and Troubleshooting

9-2

Field Maintenance Check and Adjustment
9-3
BOART LONGYEAR
9-2

Field Maintenance Check and Adjustment
As the head slide wear bars wear down, the head movement will increase to
a point where replacement shims (p/n 100172) 0.015" and 0.018" (0,38 mm
and 0,45 mm) should be used to correct head movement.
Depending on the wear pattern or location, the shims can be used as is (full
length) or cut into shorter sections in order to fill gaps that may occur between
wear bars and lower mast slide surfaces.
This will maintain head positioning and extend the service life of the wear
bars.
Shims and
Nylatron Wear Bars
Shims and
Nylatron Wear Bars
1
2
3
4
5
6
7
8
9
10
Power Unit
PQ Head Reservoir
PQ Head
PQ Chuck*
Hydraulic Reservoir
Flange Bearing
Mainline Hoist
Sheave Block Assy*
Lower Mast/Draw Works Pivot
Wireline Sheave Wheel*
Options
11
Water Pump*
12
Mud Mixer*
13
Rod Clamp*
Lubricant Code
Season
Filter Reference Chart

Item Filter Description
Main Pump Pressure
Main Return Filter
Case Drain Filter
Drill Head Lube Filter
Quantity
(U.S.)
See Manufacturers Operation and Service Manual

Rotation Unit Group
1
NUTO H46
Bearing Cap
2
MPG
Chuck Bowl/Body
10
MPG
Hydraulic Module
1
Hyd Oil
Wireline Hoist
1
MPG
Draw Works Group
1
Gear Oil
Top of Mast
0
MPG
Near Control Panel
2
MPG
Top of Mast
2
MPG
Change
Grease Gun
Grease Gun
Change
Grease Gun
Change
Hand Packed
Brush/Hand
Grease Gun
10.5 Quarts 10 Litres

2-3 Shots
2-3 Shots
60 Gals
227 Litres
2-3 Shots
2 Quarts
1.9 Litres
Coat Shaft
2-3 Shots
250
8
8
as reqd
N/A
250
6 months
Upon Assembly
Every Setup
See Pump Manufacturers Specifications

Separate
2
MPG
Base of Drill
2
MPG
Grease Gun
Grease Gun
2-3 Shots
2-3 Shots
60
60
Summer
Quantity
(Metric)
Service
Level Check
Interval (hrs) Interval (hrs)
8
8
N/A
N/A
8
N/A
168
N/A
N/A
N/A
N/A
Hot Climate
-26
-22
20
25
See Engine Manufacturers Specifications
32
46
Nuto H32
Nuto H46
Tellus T32
Tellus T46
AW MV 32
ISO VG 46
DTE13M
DTE15M
0
31
68
Nuto H68
Tellus T68
ISO VG 68
DTE16M
* Not Shown
**Note: Upon cold start up allow engine to run at low idle until the
hydraulic tank is warm to touch before operating at high idle
otherwise damage to the Hydraulic system and/or Power unit
may occur .
Note: Colder Start Up - preheat engine and hydraulic oil in a safe
manner (No Open Flames)
***Note: Do not mix brands of oil, flush completely before changing.
Hydraulic system is filled with Imperial Oil Nuto H46 from
the factory.
Liquid volumes are original factory fill quantities only, they are not
80W90
GX-80W90
Spirax 80W-90
Delo 80W-90
Mobilube HD 80W90
refill quantities. Refer to Operations and Service Manual for proper

procedure to check oil levels.
All volumes are in US measure or litres.
Unirex EP 2
Darina XL EP 2
Ulti-Plex EP2
Mobilux EP2
Mobilith AW 2
Filtration
Element Part No.
10 Micron
Bypass Valve
10 Micron
Bypass Valve
10 Micron
Bypass Valve
25 Micron
Bypass Valve
Qty
3543987
100236
100236
3542297
Service Remarks
Change element when visual indicator displays
to do so or @ Hydraulic oil change
Change element @ 250 hour intervals or whenever
Drive Head hydraulic oil is changed
Lubrication Chart
Next Generation LF90-PQ
Drill Assembly
9-3
Lube
Method
Winter
Lubricant
Type
Start Up Temp Low (Celsius)**

Operating Temp High (Celsius)
Engine Oil
- SAE Grade
Hydraulic Oil - ISO Grade***
- Imperial Oil
- Shell
- Chevron
- Mobil
Not Affected by Temp
Gear Oil
- SAE Grade
- Imperial Oil
- Shell
- Chevron
- Mobil
MPG - Multipurpose Grease
- Imperial Oil
- Shell
- Chevron
- Mobil
Number of
Lube Points
BOART LONGYEAR
Location
Item Description
BOART LONGYEAR
BOART LONGYEAR
9-4
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LF90

LF90 Diamond Core Drill System

(Actual equipment may not be exactly as shown)

Important Safety Information

Hazard Signal Words

Important Safety Information

Ensure that all commissioning checks and adjustments have been

NOTE:See following page for safety decals that appear on the

Important Safety Information

Chapter 2 Drill Introduction

Ordering and Returning Parts

Chapter 3 Modular Drill Components

Power Unit Module

Draw Works Sub Frame Module

Drill Base Module

Lower Mast Section Module

Upper Mast Section Module

Rotation Unit Module

The Control Panel

Chapter 4 Drilling Operations

Pre-Start Check List

Anchoring the Drill

4-11 Mast Installation and Raising

Chapter 5 PQ Rotation Unit Group

PQ Head Drive Group

PQ Head Disassembly Procedures

5-15 PQ Head Reassembly Procedures

PQ Nitro Gas Chuck Assembly Procedures

Installation of New Jaws

Nitro Gas Springs

Chapter 6 Hydraulic Explanation

Fast Feed Circuit

Mainline Hoist Cable Circuit

Wireline Hoist Circuit

Case Drain Return Circuit

Chapter 7 Hydraulic Schematics

Hydraulic Schematic Diagram

Chapter 8 Wireline Hoist

Wireline Hoist Assembly Diagram

Chapter 9 General Maintenance and Troubleshooting

Head Slide Wear Bars

LF90 Lubrication Chart

Recommended Practices for

2005 Boart Longyear Inc.

Visual Inspection of the Mast

Recommended Practices for Maintenance and Use of Masts

2005 Boart Longyear Inc.

Recommended Practices for Maintenance and Use of Masts

Inspection of welds in erecting mechanism, for cracks and other signs of

Steel becomes brittle when operating in low temperature conditions.

Never exceed the Rated Hook

2005 Boart Longyear Inc.

Recommended Practices for Maintenance and Use of Masts

Visual Inspection of Masts

B. Front Leg, Off Drillers Side

C. Rear Leg, Off Drillers Side

D. Rear Leg, Drillers Side (Not applicable for T style mast)

Adjustable Support Legs and Feet

2005 Boart Longyear Inc.

Recommended Practices for Maintenance and Use of Masts

Substructures for Mast

Mast Raising and Angling Cylinders: