perforadora diamantina db525_om_20081002d

8/19/2019 perforadora diamantina DB525_OM_20081002D

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DeltaBase 525/525RC

Operating manual &Spare parts List

ORIGINAL DOCUMENT

DB525RC Option with Trailer

DB525RC Option Percussion Drifter


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Tth

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The Drill Rig number andadditional details can befound on the nameplate ofthe machine.(Location shown on theright)

Boart Longyear Sp. z o.o.ul Popieluszki 30

55-080 Katy WroclowskiePoland

Tel.: +48 71 3630 264Fax: +48 71 3630 201

This Operating Manual is valid for the following DELTA-BASE 525/DB525RC:

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

When making inquiries or ordering spare parts, be sureto specify the following information:

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

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

Quantity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Descriptions and pictures are of general nature only andmay be modied in the course of tech nical development.

Service engineers and qualied tters are always avail-able to assist and advise, where required.

Please contact YOUR Service Section for details.

The opt ional Trai lernumber and additional

details can be found on thenameplate of the Trailer.(Location shown on theright)


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Important NoteDO NOT START or OPERATE THE DRILL until you have READ this manualand UNDERSTAND the contents.Non-authorised personnel MUST NOT under any circumstances attempt

to operate or repair the machine.Safety Precautions listed in the manual are intended to alert the operatorand helpers to physical dangers inherant in various phases of operating andmaintaining mobile drilling equipment of this kind. Safety First must always be the primary consideration of all personnel whenoperating or maintaining the drill rig under normal, and espesially in unusualconditions.Since these Safety Precautions cannot cover every possible situation, eve-ryone is expected to exercise good judgement and common sense whileworking with, on or near the drill rig.Hazard signal Words and WarningsHazard signal words are used throughout this manual. They appear in the

narrow lefthand column of several pages and, with their additional text de-scription, are intended to alert the reader to the existance and relative degreeof hazard.The signs DANGER, WARNING, CAUTION and NOTICE are defnedas follows :-indicates an imminently hazardous situation which, if not avoided, will

result in serious injury.

indicates a potentially hazardous situation which, if not avoided, couldresult in serious injury.

indicates a potentially hazardous situation which, if not avoided, may resultin minor or moderate injury.

is used to make people aware of situations, and gives hints for operationand maintenance, which are important, but not hazard related. It generallyindicates an Operational Aid.

The machine number andadditional details can befound on the nameplate ofthe machine.As shown on the right.

The opt ional Trai lernumber and additional

details can be found on thenameplate of the Trailer.As shown below.


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Table of Contents

Table of Contents

1-3 Standard Warranty Terms and Conditions for Boart

Longyear Equipment

Section 1 Introduction

1-4 Warnings

1-4 DELTABASE 525 Operating Manual

1-4 General Description

1-5 DELTABASE 525 Drill Equipment


1-7 Trailer option

1-8 Features

1-9 Technical Data

1-9 DIMENSIONS AND WEIGHTS *

1-9 CRAWLER CHASSIS STEEL TRACKS

1-10 PRIME MOVER

1-10 ROTARY HEAD DD52

1-10 Alternative ROTARY HEAD HY 79

1-10 Reverse Circulation ushing attachments (optional)

1-10 HYDRAULIC SYSTEM

1-10 DRILL MAST AND FEED SYSTEM WITH FEED CYLINDER

1-11 WINCH

1-11 ROD CLAMPS

1-11 OPTIONS

1-11 MUD/WATER PUMP

1-11 WATER PUMP System (Option)

1-11 REVERSE CIRCUATION System (Option)

1-11 TRAILER System (Option)

1-11 MAST EXTENSION

1-11 WIRELINE HOIST

1-11 ACCESSORIES

1-11 Crawler with rubber tracks

1-11 Crawler with rubber tracks and steel tips

1-11 Rod and break-out clamps - 220 mm


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Table of Contents

1-11 Centraliser for 220 mm rod clamps

1-11 Drill pipe storage

1-11 Hand held tachometer

1-12 DRILLING SYSTEMS

1-12 STANDARD DRILLING SYSTEMS

1-12 OPTIONAL DRILLING PACKAGE

1-12 RECOMMENDED SPARES KITS

1-13 Transport Instructions

1-14 Ofoading.

1-14 Transport Dimensions.

1-15 Top Lifting Points Location

1-15 Front Lifting Points Location

Section 2 Safety Considerations

2-3 Location of Warning Signage

2-4 Typical Drillheads - Location of

Warning Signage

2-5 Trailer (Option) Location of

Warning Signage

2-6 Personal Protective Equipment

2-7 Emergency STOPS

2-7 Guard Emergency Stop Switch

2-7 Control Panel Emergency Stop Switch

2-8 In the event of an Emergency Stop:

2-8 Mast/Drillhead Safety Guard

2-8 Safety Precautions

2-8 General

2-9 Specic Safety Instructions for Drill-ing

2-11 Safety Requirements

2-11 SAFETY VALVES

2-11 HYDRAULICS

2-11 REPLACEMENT OF WORN PARTS


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Table of Contents

2-11 SAFETY DEVICES

2-11 STATIC COMPONENTS

2-11 DIRECTIVE OF APPLICATION

2-11 OPERATION

2-12 OPERATING INSTRUCTIONS

2-12 DANGER ZONE - 2.5 metres All round the Rig.

2-12 Danger Zone with Trailer (option)

2-12 SAFETY DISTANCE

2-12 TRANSPORT OF PERSONS

2-13 Fire Extinguisher Instructions

2-14 TRAMMING AND OPERATING CRAWLER DRILL RIGS

2-14 SAFE TRAMMING SET-UP (with Trailer option)

2-14 NOISE LEVELS

2-14 STABILITY

2-14 SECURING AGAINST FALL

2-15 SIGNALLING

2-15 UTILITY LINES

2-15 WORKING NEAR OVERHEAD LINES

2-15 OPERATIONAL INTERVALS

2-16 Extreme Environmental/Job Site Conditions

2-16 Extremely dusty Working Conditions.

2-16 Warm to Hot Ambient Air Temperature.

2-16 Extremely Cold Ambient Temperature.

2-16 Working At High Altitude (above sea level).

2-16 Working in Salty Atmosphere.

Section 3 Drill rig components

3-2 Drill Rig Complete

3-4 Optional Radio Control

3-6 Drilling Mast

3-10 General rules for Feed chains:

3-13 Drillhead Sideslide - DD52

3-14 Alternative Rotary Drill Head - HY79


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Table of Contents

3-15 Drillhead Sideslide - HY79

3-16 Reverse Circulation Swivel (option)

3-17 Clamping and Breaking Device

3-18 Automatic SPT (option)

3-19 Oil Liner DTH Lube system (option)

3-22 High Pressure Water Pump (option)

3-23 Vice (Option)

3-24 Vandal Covers (option)

3-25 Main Hoist

3-26 Wireline Winch

3-27 Crawler Tracks

3-28 Trailer (option)

3-29 Water/Mud Pump

3-30 Air Compressor and reservoir (Option)

3-30 Reverse Circulation (Option) Air Hose Whip Check Connections

3-31 Hydraulic circuit

4-2 Section 4 Operations

4-3 Introduction

4-3 Equipment Description and Identification

4-4 Component Location4-6 Diesel tank and Hydraulic tank location

4-7 Flushing Control valves

4-8 Flushing Control valves (circuit with RC option)

4-9 Auxiliary Controls

4-10 Main control panel description

4-10 Engine controls

4-11 Alignment controls

4-12 Swivel panel controls


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Table of Contents

4-13 Fixed panel controls

4-14 Tramming Control Panel Description

4-15 Crown Block control description

4-16 Pre-start checks

4-16 Prior to Start-up

4-17 Initial Start-up

4-18 Tramming (Tracking)

4-18 Transport Support

4-18 Tramming control hoses

4-18 Mast in Tramming Position

4-18 Radio Control (Option)

4-19 Drilling Methods

4-19 Hints for Optimum Application

4-20 Drilling Operations

4-20 Calculating Bit Weight

4-21 Down Hole Drilling4-22 Up Hole Drilling

4-23 Horizontal Drilling

4-24 Bit Weight Table

4-26 Flushing

4-26 Blow Down (option)

4-26 Reverse Circulation / Blow Down (Option) Air Hose

Whip Check Connections

4-27 Blow Down circuit (option)


Section 5 Care and Maintenance

5-3 Introduction

5-3 Operational Requirements


5-4 Tools and Equipment


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Table of Contents

5-6 Recommended Tool Kit

5-7 Bolt Torques and Safe Loads

5-7 Preventive Maintenance

5-7 Repairs to Hydraulic Components

5-8 Tilt and Slide Support

5-9 Mast and Crowd Cylinder

5-10 Crown Block and Jib extend/slew

5-11 Holder clamp and Breakout clamp

5-12 DD52 Rotary Drillhead

5-13 DD52 Rotary Drillhead disassembly and assembly

5-14 DD52 Rotary Drillhead motor Gearbox assembly

5-16 DD52 Rotary Drillhead Gearbox assembly

5-17 DD52 Reducer Reference Parts List

5-21 Alternative HY79 Rotary Drillhead

5-22 HY79 Rotary Drillhead disassembly and assembly

5-23 HY79 Drillhead Exploded View

5-24 HY79 Rotary head - Reference Parts List

5-26 HY79 Rotary Drillhead with Reverse Circulation Swivel

and Blowdown (option)

5-27 Cyclone Sampler and Trailer (option)

5-28 SPT Option (Standard Penetration Tester)

5-29 Levelling Jacks

5-30 Main Frame Assembly

5-31 Changing the Hydraulic Oil

5-32 Lubrication, Maintenance, and Service Intervals

5-34 Recommended Oils and Lubricants

5-34 Selection of Hydraulic Oils

5-34 Selection & Application of Gearbox Oils and Grease

5-35 Gear Oil & Greasing Table


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Table of Contents

Section 6 Fault finding tables

6-2 No Pressure

6-2 Flow Low or Pressure Fluctuating

6-2 Valves not operating properly

6-2 Hydraulic oil temperature too high

6-3 Noises from Pumps - no oil supply

6-3 Leakage from Drillhead

6-3 Engine Stalling

Section 7 Authorised Service & Repair Agents

7-2 Boart Longyear Distributers

Section 8 Main Hoist

8-2 Main Hoist

Section 9 Wireline Winch

9-2 Wireline winch

Section 10 Crawler tracks

10-2 Crawler Tracks

Section 11 Accessories

11-2 Accessories

Section 12 Water Pump

12-2 Water Pump

Section 13 Parts Lists

13-2 Parts Lists

Section 14 Spares kit

14-2 Spares kit

Section 15 Trailer Option

15-2 Introduction


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[email protected] www.boartlongyear.com DB525_20081002D © 2012 Boart Longyear

Boart Longyear is constantly striving to improve i ts products and must therefore, reserve the right to change designs, materials, specif ications and price without notice.

SECTION 1

Table of Contents

1-3 Section 1 Introduction

1-3 Standard Warranty - Boart Longyear Equipment

1-4 Warnings

1-4 DELTABASE 525 Operating Manual


1-5 DELTABASE 525 Drill Equipment


1-7 Trailer option

1-8 Percussion Drifter option

1-9 Features

1-10 Technical Data

1-10 Dimensions And Weights

1-10 Crawler Chassis Steel Tracks

1-11 Prime Mover

1-11 Rotary Head Dd52

1-11 Alternative Rotary Head Hy 79

1-11 Percussive Drifter (Option)

1-11 Hydraulic System

1-11 Drill Mast And Feed System With Feed Cylinder

1-12 Winch

1-12 Winch (Option)

1-12 Rod Clamps

1-12 Rod Clamps - (Option For Percussive Application).

1-12 Mud/Water Pump

1-12 Water Pump System (Option)

1-12 Reverse Circulation System (Option)

1-12 Trailer System (Option)

1-12 Mast Extension

1-12 Wireline Hoist

1-13 Accessories

1-13 Rod and break-out clamps - 220 mm


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DB525_OM_20081002D

1-2Introduction

1-13 Centraliser For 220 Mm Rod Clamps

1-13 Drill Pipe Storage

1-13 Hand Held Tachometer

1-13 Petol Tongue - Breakout Key

1-13 Tool Box

1-13 Drilling Systems

1-13 Standard Drilling Systems

1-13 Optional Drilling Package

1-13 Recommended Spares Kits

1-14 Transport Instructions

1-15 Ofoading.

1-15 Transport Dimensions.

1-16 Top Lifting Points Location

1-16 Front Lifting Points Location


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DB525_OM_20081002D

1-3Introduction

Standard Warranty Terms and Conditions for Boart Longyear Equipment

Section 1 Introduction

LIMITED WARRANTY

a. Consumables. Boart Longyear warrants for a period of

one (1) year after the date of shipment of the consumable

products manufactured by it, or the performance

of related services, under the Contract, that such

consumable products are free from defects in materials

and workmanship and such services are performed in a

professional and workmanlike manner; provided, however,

with respect to consumable products purchased through an

authorized Boart Longyear distributor, the warranty period

shall commence on the date of purchase by the end-user.

b. Capital Equipment. Boart Longyear warrants that the

capital equipment manufactured by it is free from defects in

materials and workmanship for a period equal to the lesser

of (i) one (1) year after the date of shipment, or (ii) the

initial 1,000 operating hours. Boart Longyear warrants fora period of six (6) months after the performance of related

services that such services are performed in a professional

and workmanlike manner.

c. General Terms. Boart Longyear further warrants that,

to the extent applicable, as of the date of shipment or

performance, all goods manufactured by it and services

performed shall conform to the written specications

agreed between the parties. THIS IS BOART

LONGYEAR’S ONLY WARRANTY. BOART LONGYEAR

MAKES NO OTHER WARRANTY, INCLUDING WITHOUT

LIMITATION, ANY WARRANTY OF MERCHANTABILITY

OR FITNESS FOR A PARTICULAR PURPOSE. As

a condition to Boart Longyear’s warranty obligations,

Purchaser must: (i) contact Boart Longyear and request

authorization to return any goods claimed to be defective

promptly upon Purchaser’s discovery of the alleged defect,

(ii) upon receipt of an approved authorization code from

Boart Longyear, return any goods claimed to be defective

under the foregoing warranty, at Purchaser’s expense,

to the facility designated by Boart Longyear, and (iii) with

respect to consumable products purchased through an

authorized Boart Longyear distributor, the party making

the warranty claim must also deliver to Boart Longyearreasonable evidence of the date of purchase. Boart

Longyear shall perform its examination of the goods so

returned by Purchaser and shall report the results of its

examination to Purchaser within thirty (30) days following

its receipt of such goods from Purchaser, or, if longer

time is required to complete such examination, within

such time as would be required through the exercise of

reasonable diligence. As a further condition to Boart

Longyear’s obligations hereunder for breach of warranty,

Purchaser shall offer its reasonable cooperation and

assist Boart Longyear in the course of Boart Longyear’sreview of any warranty claim. If requested by Purchaser,

Boart Longyear will promptly repair or replace, at Boart

Longyear’s expense, goods that are conrmed to be non-

conforming as a result of Boart Longyear’s examination

and according to Boart Longyear’s warranty as set forth

herein. All removal and installation of goods shall be at

Purchaser’s expense; provided, however, Boart Longyear

will reimburse the Customer for an amount equal to the

reasonable expenses incurred by the Customer andattributable to the removal and shipment of any defective

goods. Boart Longyear reserves the right to reimburse

Purchaser for an amount equal to the purchase price

of any defective goods in lieu of providing repaired

or replacement goods. Anything contained herein to

the contrary notwithstanding, in no event shall Boart

Longyear be liable for breach of warranty or otherwise in

any manner whatsoever for:(i) normal wear and tear; (ii)

corrosion, abrasion or erosion; (iii) any goods, components,

parts, software or services which, following delivery or

performance by Boart Longyear, has been subjected to

accident, abuse, misapplication, modication, improper

repair, alteration, improper installation or maintenance,

neglect, or excessive operating conditions; (iv) defects

resulting from Purchaser’s specications or designs or

those of its contractors or subcontractors other than Boart

Longyear; (v) defects associated with consumable parts or

materials, the lifetime of which is shorter than the warranty

period set forth in this Section; (vi) defects associated

with Purchaser’s specications or designs or those of its

contractors or subcontractors other than Boart Longyear;

(vii) defects resulting from the manufacture, distribution,

promotion or sale of Purchaser’s own products; or (viii)

accessories of any kind used by the Purchaser which are

not manufactured by or approved by Boart Longyear.(d)

Sourced Goods. If the defective parts or components are

not manufactured by Boart Longyear, the guarantee of

the manufacturer of those defective parts or components

is accepted by the Purchaser and is the only guarantee

given to the Purchaser in respect of the defective parts

or components. Boart Longyear agrees to assign to the

Purchaser on request made by the Purchaser the benet

of any warranty or entitlement to the defective parts or

components that the manufacturer has granted to BoartLongyear under any contract or by implication or operation

of law to the extent that the benet of any warranty or

entitlement is assignable.

Boart Longyear

Global Headquarters

10808 South River Front Parkway

Suite 600

South Jordan, Utah 84095

United States of [email protected]

Tel: +1 801-972-6430

Fax: +1 801-977-3374


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DB525_OM_20081002D

1-4Introduction

3 In the interests of its technical development, Boart Longyear reservesthe right to modify the drill rig and the data in this manual without priornotication.

DELTABASE 525 Operating Manual

General Description

1 This manual is a general description of the operation and maintenancerequirements of DELTABASE 525 heavy duty Drill Rigs with the optionalReverse Circulation DB525RC drillhead and Trailer system.

2 Pictures, descriptions and technical data may therefore not match your

drill rig in every aspect.

3 REMEMBER!4 You are the one who is responsible for your personal safety when

operating the DB525 / DB525RCdrill rig.5 This manual is only a general guide to essential operating procedures,

safety precautions, etc.6 The procedures described in this manual do not relieve you of your

responsibility to exercise caution and common sense.7 You must comply with all safe working procedures and instructions

relevant to your drill site at all times!

Warnings

1 This manual describes the BOART LONGYEAR DELTABASE 525series drill and outlines its operational and maintenance procedures .It also includes a number of procedural hints.

2 The Manual set includes a spare parts catalogue depicting and describ-

ing the individual components of the rig.


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DB525_OM_20081002D

1-5Introduction

DELTABASE 525 Drill Equipment

General DescriptionThe Deltabase 525 is a compact, lightweight multi-purpose drill rig especiallydesigned for :-

• Wireline and conventional coring

• Undisturbed sampling and testing• Geological and geophysical work• Ground consolidation drilling• Water well drilling

• Auger drilling

• Reverse Circulation drilling

Apart from a compressor or water supply (for ushing purposes) the

DELTABASE 525 drill rigs are designed to operate fullyindependently, and are therefore suited to all types of drillingapplications, in a variety of ground conditions.

The mast can be positioned horizontally as well as vertically. Thisfeature, in combination with two articulating swivel joints (option),allows for perfect alignment of the drill, even in areas of restrictedaccess.

CONTROL PANEL

DRILL MAST

BREAK CLAMP

AND

HOLD

CLAMP

DRILLHEAD

GUARD


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DB525_OM_20081002D

1-6Introduction

Fire Extinguisher

Winch

Lube-oil Filler(behind)

Fuel-oil filler(behind)

Engine SpeedControl

TrammingControl Panel

Water/Mud Pump

Main ControlPanel

Auxiliary ControlPanel

Stabiliser ControlPanel

Stabilisers - one eachcorner

Hydraulic oil

Cooler


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DB525_OM_20081002D

1-7Introduction

Stabilser Jacks

Trailer option

Trailer

Centrifuge(RC Cyclone) and Sample collector (RC Splitter)

Storage Compartment Spare Wheel

Towing Hitch

Cyclone DoorOpen/Close

Stabilser Wheel

Jack

Cyclone lift and

slew controls

Air and Oil connections

Water Reservoir


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DB525_OM_20081002D

1-8Introduction

Percussion Drifter option

Percussive DrifterOption

Rod Clamp/Breaker for small diameter Rods

Control Panel forPercussive Drifter


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DB525_OM_20081002D

1-9Introduction

The main power source is an air-cooled diesel engine, which drives theopen-centre hydraulic circuit. (Maximum operating pressure: 250 bar). Thehydraulics power all operating functions, tramming, set-up, and drilling.

The drill mast carries a DELTABASE series drill head, together with the

entire drill string. The drill mast is attached to the mast carrier by means ofadjustable guide Slippers.

Holding and thread breaking clamps allow for rapid rod changes.

All control and monitoring elements of the fully hydraulic crawler drillDELTABASE 525 are conveniently positioned. Self-explanatory graphicsymbols are used to indicate control functions.

The crawlers are operated remotely from the Radio Remote or from thecontrol pendant. Both options have two levers (left and right track sections)to activate and steer the crawler undercarriage.

The control pendant is stowed at the rear of the machine and the RadioRemote is kept in the rig storage box.

On the right-hand side of the machine are the control levers for positioning,setting-up and alignment of drill mast.

The drilling control panel is mounted on a slewable arm on the right handside of the machine. All of the control and monitoring elements for drillingfunctions are mounted on this panel.

During transport and tramming the control panel is stowed parallel to thebase frame of the rig and within the width of the machine. During drilling,the control panel is swung out, then angled and positioned to afford thedriller optimum visual observation of the bore.

Emergency STOP switches are tted on the control panel, inside the meshguard (see next paragraph), on the Front Left Hydraulic Jack and on theRadio remote tramming panel.

The operator is protected from the rotating drilling elements by a wire meshguard with an emergency stop interlock which fully encloses the accesiblearea. If local regulations permit; a lanyard pull-wire can be tted along thelength of the mast in place of the wire mesh guard. Activating any of these

switches immediately stops all drilling and tracking functions.

The diesel engine can be tted with an optional soundproof cover whenoperating in areas with stringent noise regulations.

The drill rig’s electrics are 12V DC.

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

• Rod holding and thread break-out clamp with adjustableclamping force

• Rotary head side shift• New generation diesel engine power supply

• Integrated control panel mounted on swinging arm

• Hydraulic mast raising with mast dump compensates foruneven drill site conditions


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DB525_OM_20081002D

1-10Introduction

Technical Data

DIMENSIONS AND WEIGHTS *Crawler Mounted Drill Rig Weight:Standard 6 500 kg (RC option 7500 kg)Consists of:• 4DEUTZ BF4L914 Power Unit Grp. -4.3 litre

4 cylinder (D914L04 as option)• Hydraulic Module• Main Hoist c/w Cable• Hydraulic Mast Raising (independant)• Lower Mast Assembly• Rotation Unit Group• Crawler Frame

• Battery• Levelling Jacks (hydraulic) - 4• Operator Controls• Holding Clamp and Breaking Clamp

CRAWLER CHASSIS STEEL TRACKSAxis distance 1715 mmLength 1900 mmWidth of track shoes 300 mmMax. ground pressure 0.053 MPaWeight 1035 kgMax. Driving speed 1.5 km/h

Max.Climbing ability 60% (30deg)

* Dimensions and weights may vary dependingon options and should be checked before cratingor lifting


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DB525_OM_20081002D

1-11Introduction

PRIME MOVERStandard DEUTZ BF4L914 air cooled DieselSwept volume 4.31 lPower maximum 72.4 kWRated rpm 2300 rpmSpecic Fuel consumption 225 g/kWh

ROTARY HEAD DD52 2 Gear with variable displacement motor RPM Torque (Nm)1st Gear 48 to 250 4890 to 9772nd Gear 140 to 740 1859 to 371Rotation Motor Danfoss hydraulic motor (variable/reversible - remote pilot)Mechanical Transmission (2 Speed) Ratio1st Gear 7.68:12nd Gear 2.92:1Bore inside dia. 62 mmFloating Spindle inside dia. 30 mmFloating Spindle stroke 60 mmDrive Flange 2 3/8”A.P.I.

Side shift 500 mm stroke hydraulicNote - The hydraulic motor ratings are at max. and min. displacement, primemover at 2200 rpm.

Alternative ROTARY HEAD HY 79Max torque and RPM low gear 6500/40 Nm/rpmMax torque and RPM high gear 300/800 Nm/rpmRotation motors DANFOSS TMT 315 +Parker 80Top drive ange 3 1/2” API IF .BoxAdaptor 2 3/8” API REG PinGear ratio 4.05:1Distance from drilling line to chain 435 mm

Reverse Circulation flushing attachments (optional)

Percussive Drifter (option) 2 Gear manual and 2 Electric Torque (Nm) RPMM1 296 daNm n1 = 87 minM2 148 daNm n2 = 174 minM3 72 daNm n3 = 360 minM4 36 daNm n4 = 720 minPercussion unit type 10 Frequency (f) = 3000 minWe = ... 180 NmShank: R38 female and H66 (RH) male thread

HYDRAULIC SYSTEMPrimary Pump Parker bent axis - xed displacementMax ow 66 lpm @ 2200 rpm

Max pressure 25 MPaSecondary pump - Casappa gear pumpMax ow (1st) 59 lpm @ 2200 rpmMax ow (2nd) 48 lpm @ 2200 rpmMax pressure (1st) 17.5 MPaMax pressure (2nd) 17.5 MPa

DRILL MAST AND FEED SYSTEM WITH FEED CYLINDERTotal Length 6.30 mFeed stroke 4mFeed speed -Up 12.5 m/min

- Down 18 m/minFast Feed speed - Up 31 m/min - Down 51 m/minPull down force 34 kNPull back force 55 kNDrilling Inclination 45 deg below horizontal to 90 deg vertically down


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DB525_OM_20081002D

1-12Introduction

WINCHMain Hoist Type Braden BG 6Line pull - Bare Drum 31.1 kN - Full Drum 23.1 kNRope speed @ 60 l/min

- Bare Drum 29 m/min - Full Drum 36 m/minFor Cable Dia14 mm 35 m

WINCH (option)Main Hoist Type SH220Line pull 20000 NRope speed @ 50 l/min 44 m/minFor Cable Ø12 mm

ROD CLAMPS Max. clamping diameter 220 mmMax. clamping capacity 175 kNMax. breaking torque 20.5 kNm

ROD CLAMPS - (option for Percussive application).Max. clamping diameter 140 mmCapable of handling down to 44mm diameter

OPTIONS MUD/WATER PUMPType DELTAPUMP - 200 with hydraulic motorWorking pressure 45 barContinuous delivery 200 l/min

WATER PUMP System (Option)Type Dynaset - HPW 200/30-45Water pressure (max) - 200 barSuction head (max) - 3 metreSuction connection - BSP 3/4”Complete with - Unloader valve, change-over valve for optional 150 litre reservoiror external water supply and quick connectors for Water Gun.

REVERSE CIRCULATION System (Option)Dual Swivel

Automatic Blow DownDeector BoxDriver SubSaver Sub - 3 1/2” Remet 3 1/2” Metzke

4” Remet

4” Metzke 4” Matrix

TRAILER System (Option)RC Cyclone 750 cfm

1100 cfmRC Splitter 3-Tier Splitter Cone Splitter

MAST EXTENSIONLength of rods 2 x 3 mTotal weight 140 kgFitted onto standard mast to pull 6 m rod lengths

WIRELINE HOIST

Line pull 6500 NRope speed @ 59 l/min 100 m/minFor Cable Dia 6 mm 250 mOptional Cable Dia 5,0 mm 350 m


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DB525_OM_20081002D

1-13Introduction

ACCESSORIES Crawler with rubber tracks, Crawler with rubber tracks and steel tipsRod and break-out clamps - 220 mmCentraliser for 220 mm rod clamps

Drill pipe storageHand held tachometer

Petol Tongue - breakout keyNight lightsDown the hole in-line oilerSpring shock absorbers on oating spindle for use with DTHConnecting ange 2 7/8 API threadConnecting ange HQ threadConnecting ange NQ threadConnecting ange NWY threadJaw plates for BW casingJaw plates for NW casing

Jaw plates for HWT casingTool box

DRILLING SYSTEMSThe gures in these tables have been calculated, based on eld experiences,and may be reasonably expected. Actual drilling capacity will depend on in-holetools and conditions, drilling techniques and equipment used.

STANDARD DRILLING SYSTEMSCore drilling Hole depth (metres) Hole depth (feet)

Core barrel:NQ/NQ2”/NV/NV/2” 310 m 1000 ftHQ/HV 220 m 710 ftPQ/PV 145 m 480 ft

SQ 90 m 290 ftReverse Circulation drilling 140 m 4 “ RC pipe 160 m 3 1/2 “ RC pipeRotary Drilling (Tricone)

Hole Dia - 216 mm (8.5”) 175 m 570 ftAuger Drilling

Hole Dia - 150 mm 15-20 m 49-65 ft

OPTIONAL DRILLING PACKAGESPT (Standard Penetration Test) Auto Hammer

Impact rate 1-30 bpmLength of Travel 762 mmHammer Weight 63 kgTotal Weight 180 kg

DTH Drilling package Max.size DTH Hammer: 98mm 3 7/8” Air requirement: 17,2m3/min @ 24bar max. Depth capacity: 290m max. 950 ft

Hole size - recommended: 115 mm 4 1/2”Hole size - max: 127mm 5”Recommended rod size: 76,1 mm 3”Note - The air compressor must be selected according to the hammer in use.In-line oiler and shock absorber are required for DTH drilling

RECOMMENDED SPARES KITS Basic kit (S)

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


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1-14Introduction

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

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

Mast Support in normal tramming position

Mast Support in Shipping

position with mast Slidecylinder fully retracted (in)


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1-15Introduction

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

depending on the transporter. Check that all transport bindings areremoved.

Offloading by Lifting the rig. Ensure that the lifting appliance is capable of carrying

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

Offloading by driving the rig. Before attempting to operate the rig for off-loading, read and un-derstand the instructions given in Sections 2 and 4 of this manual.The Crawler mounted DB 525 Drill Rig is an off -road vehicle andtherefore should not be driven on public roads

except for access to site. Always consult local laws.

Transport Dimensions.Length: 6500 mmWidth: 1900 mmHeight: 2310 mmWeight: 7000 kg (RC option 7500 kg)

Lifting Points

Plan View

Lifting PointsElevation

Tow Pin

Tow Pin


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1-16Introduction

Top Lifting Points

Location

Rear Towing PinLocation

Front Lifting PointsLocation

Rear Lifting PointsLocation

Front TowingPin Location


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[email protected] www.boartlongyear.com DB525 20081002D © 2012 BoartLongyear


SECTION 2

Table of Contents

2-3 Section 2 Safety Considerations

2-3 Location of Warning Signage

2-4 Typical Drillheads - Location of Warning Signage

2-5 Trailer (Option) Location of Warning Signage

2-6 Personal Protective Equipment

2-7 Jack-leg

2-7 Emergency

2-7 Stop Switch

2-7 Emergency STOPS 2-7 Guard Emergency Stop Switch

2-7 Control Panel Emergency Stop Switch

2-8 In the event of an Emergency Stop:

2-8 Mast/Drillhead Safety Guard

2-8 Safety Precautions

2-8 General

2-10 TRAILER (OPTION) SAFE SETTING-UP

2-10 Specic Safety Instructions for Drilling


2-12 SAFETY VALVES

2-12 HYDRAULICS

2-12 REPLACEMENT OF WORN PARTS

2-12 SAFETY DEVICES

2-12 STATIC COMPONENTS

2-12 DIRECTIVE OF APPLICATION

2-12 OPERATION

2-12 OPERATING INSTRUCTIONS

2-13 DANGER ZONE - 2.5 metres All round the Rig.

2-13 Danger Zone with Trailer (option)

2-13 SAFETY DISTANCE

2-13 TRANSPORT OF PERSONS

2-13 NOISE LEVELS


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2-2Safety Considerations

2-14 Fire Extinguisher Instructions

2-15 STABILITY

2-15 SECURING AGAINST FALL

2-15 TRAMMING AND OPERATING CRAWLER DRILL RIGS

2-15 SAFE TRAMMING SET-UP (with Trailer option)

2-16 SIGNALLING

2-16 UTILITY LINES

2-16 WORKING NEAR OVERHEAD LINES

2-16 OPERATIONAL INTERVALS

2-17 Extreme Environmental/Job Site Conditions

2-17 Extremely dusty Working Conditions.

2-17 Warm to Hot Ambient Air Temperature.

2-17 Extremely Cold Ambient Temperature.

2-17 Working At High Altitude (above sea level).

2-17 Working in Salty Atmosphere.


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Section 2 Safety Considerations

Location of Warning SignageMaintenance note - To ensure that all personnel are continually awareof the dangers of the rig, examine all signs during routine maintenanceand replace as required.

Mast Support adjust


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Typical Drillheads - Location of Warning SignageMaintenance note - To ensure that all personnel are continually awareof the dangers of the rig, examine all signs during routine maintenanceand replace as required.


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Trailer (Option) Location of Warning SignageMaintenance note - To ensure that all personnel are continually awareof the dangers of the rig, examine all signs during routine maintenanceand replace as required.


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Personal Protective Equipment

This list must be amended to meet YOUR on site require-ments.

Approved Hard Hat

Safety Boots

Working Gloves not Operator

Hearing Protection

Respiratory Protection *

Safety Glasses *

* Especially on applications creating dust, or when using com-pressed air for ushing!

DANGER ZONE


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Emergency STOPS

DELTABASE rigs are tted with various Emergency STOP switches.

Familiarize yourself with the position and operation of all the EmergencySTOP switches.Check the operation of the stop switches DAILY.

Guard Emergency Stop Switch

Control Panel Emergency Stop Switch

Green Button Jack-leg

Emergency Stop Switch


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In the event of an Emergency Stop:1 Immediately investigate the cause of the Emergency Stop2 In the event of personal injury, assist if you feel able to do so,

otherwise seek medical assistance or contact the emergency

services.3 If the stop was initiated to prevent mechanical damage, assess the

situation before continuing. If in doubt, seek advice from the SiteSupervisor.

4 If the cause of the stop was unknown, walk around the drill rig and check for any unsafe conditions before continuing.

Restarting after an Emergency Stop:1 Ensure all controls are in neutral.2 Turn the ignition switch to the OFF position3 Re-set the activated STOP buttons by pulling or twisting and pulling.4 Check the operation of all lights and warning devices.5 Report all defects to the Site Supervisor.6 Visually inspect and assess the work area for potential hazards.7 Re-start the engine.(See section 4-12 to 4-13).

Mast/Drillhead Safety Guard This is a guard which covers the Mast and Drillhead over the area withinreach of the operator. A special hinge on the guard is interlocked with theoperation of the Drillhead so that when it is opened the drill rotation and feedstop immediately, low speed rotation at low torque is obtained by pressing theGreen button on the main control panel. Closing the Guard restores normaldrilling settings. This green button also functions to energise the hydraulics

after initial start-up.

Safety PrecautionsGeneral Drilling operations frequently expose people to imminently

hazardous situations which, if not avoided, could result in deathor serious injury. The following safety precautions must be ob-

served at all times.1 Do not attempt to operate the drill rig unless you are fully familiar with

all rig controls, gauges, functions and operational sequences. Failureto comply with the detailed instructions contained in the

Operating Manual could result in physical injury or death.2 Always wear an approved helmet, safety shoes or boots, safety glasses, and hearing protection when near an operating drill rig. A Respirator

may be necessary in dusty operations, assess each situation.3 Keep hands, arms, legs and clothing away from all moving parts of the drill and its accessories. Failure to comply could result in physical injury or even death.4 Do not touch rotary heads, drifters, shank adapters, couplings, drill steels, casing, bits, and crowns with your bare hands during drilling. These parts usually get hot and a severe burn may result. Be sure to wear work gloves when you

are handling any of these components.

5 Dry Nitrogen is the only gas used to charge accumulators on drifters and rotary heads. Never use Oxygen to charge accumulators because a mixture of Oxygen and Oil may ignite to produce an explosion.


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6 Make sure that accumulators are always in perfect condition. Inspectregularly and thoroughly to ensure that accumulator components haveno cracks or signs of excessive wear.

7 When pressurised, damaged accumulators could burst,

scattering metal fragments throughout the area, and severely injuring personnel.

8 Be sure to bleed the accumulator before attempting to disassemble it, and only replace with accumulators that have been tested and approved.9 Always operate the drill rig from the operatorís position.10 Make sure all other persons are clear of the drill rig before moving or starting any drilling operation.11 Tram only with the jacks fully retracted, the mast fully retracted and resting on its support bracket. The drill head should be centred in the middle of the mast.12 Use extreme caution when tramming or setting up on uneven ground.

13 Always ensure that the stability of the rig is not impaired.14 Drills have many moving components. Keep yourself and all other persons clear of moving drill heads, feed mechanisms, drill strings, and moving tools.

15 Know where you are drilling! Make sure you do not drill into any utilities, such as buried electric cables, gas, or water mains.16 Use only purpose-made craneage lugs and/or lifting holders when

lifting the rig.17 Do not remove or disable protective guards and safety devices under any circumstances.18 Pay particular attention to the accident prevention devices and ensure that they are always fully functional. Defective devices may

delay stopping rig functions, and may therefore cause severe personal injury or even death.

19 Exhaust fumes from internal combustion engines are deadly. Be sure to only operate the drill rig in well ventilated areas.20 If you must operate the rig in a conned area, consult your occupational health and safety representative to ensure safe drill operations at all times.21 Noise and Vibration levels -

The A weighted sound power level at the operating position is 104dB. Appropriate hearing protection is required while operating

the Rig.


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Specific Safety Instructions for DrillingDrilling operations frequently expose workers to imminently

hazardous situations which, if not avoided, could result in deathor serious injury. The following safety instructions must be ob-

served at all times.1 While tramming the Rig do not walk alongside, even for short distances. You could tram the Rig over your own feet.2 Always check that all helpers are well clear of the

tramming and swing radius of the drill rig prior tomoving or setting up.

3 When using level or angle indicator to make the nal adjustment of mast

TRAILER (OPTION) SAFE SETTING-UPThe Trailer Stabiliser Jacks must always be applied on stable ground beforeraising the Cyclone Bracket. Additionally - during transport the Cyclone mustbe in the transport position and the Sample hose must be secured by the

Blockades (see pictures below)

Sample Hose

Blockade secure

Sample Hose

Blockade secure


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rake, only allow helpers to enter the area after the drill mast has beenaligned and inclined to the approximate degree required.

4 Be sure that all hoses (e.g. for ushing - grouting) are cleared from the path before moving the drill rig.5 Care must be taken when handling drill string sections. They are often

cumbersome and very heavy (especially Duplex Strings).6 Always ensure there are adequate foot holds (mud-sludge).7 Special care is required when placing Duplex Drill String Sections

(casing and inner rods) on the drill mast. The inner string threads mustbe connected rst.

8 Keep the casing section firmly secured to prevent it from sliding down and squashing ngers during this process.9 Care must be taken when flushing with compressed air

because pressurised air can drive cuttings with extreme force and great velocity. Reverse Circulation 0ption - this high volume compressed air system is supplied with Whip-checks and anchors; these must

always be applied and maintained.10 Ensure that all persons are at a safe distance and that

whip-checks are applied before opening air to the drill string.11 Always relieve the pressure on the ushing medium in the drill string

during steel changes (i.e. extending the drill string and tripping-out the hole).12 When using DHD drill tubes (API, etc.) always ensure that clamps

are placed directly alongside couplings (joints).13 DHD tubing is manufactured using relatively thin-walled tubes, which may deform or be damaged by hydraulic pressure.14 When using spanners to break and uncouple threaded joints on drill strings, always comply with the following:

a) Note the direction of rotation to break joints b) Select the correct size spanner to suit the ats c) Place the spanner securely on the ats d) The spanner must rest against the drill mast in the direction of rotation required to break the joints e) Do not hold the spanner by hand f) Keep the spanner in position with a safety rope g) Stand behind the drill mast.15 Never stand beneath drill bits when inspecting for wear and

removing plugs when ushing holes.16 Plugs may be forced out by flushing pressure, or the bit may drop out causing severe injury.17 Use a mirror for inspection if the bit cannot be removed for checking.18 Do not hit drill bits with a hammer when cleaning strings of concrete

residue. Carbide inserts may break and cause severe injury.

19 Remember that some cleaning solvents used for removal of oil and grease develop dangerous fumes when they vapourise. Be sure to use solvents only in well-ventilated areas. 20 The operator must never leave the control panel while drilling

is in progress.21 The rig must be secured against inadvertent and unauthorised

movement prior to each operational interval.

22To avoid inadvertent or unauthorised start up once the engine is stopped, ensure the starter key taken out of the ignition lock and all covers, doors and lids are locked and secured.23 If the drill rig is parked on a slope or incline, the crawler tracks must be


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

Safety Requirements Drilling operations frequently expose workers to imminently hazardous

situation which, if not avoided, could result in death or serious injury.The following safety requirements must be observed at all times.

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

HYDRAULICS The hydraulic components of the drill rig must be checked regularly.

Always use original Boart Longyear parts to replace worn components.For safety reasons this specic requirement must be complied with.

It applies to: - hydraulic hoses and other components.

- all static and bearing components, e.g. screws, bolts, springs and washers, boom components, drill mast components and undercarriage components.

REPLACEMENT OF WORN PARTS Repairs and replacement of worn parts can only be carried out by qualiedpersonnel.Standard maintenance and service intervals must be complied with.If in any doubt, contact your nearest Boart Longyear service centre.

SAFETY DEVICES The safety devices on the drill rig must only be changed by or with the per-mission of Boart longyear approved personnel.

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

Safety devices and protective equipment incorporated withinmoving machine components must only be opened, removed,or disabled with the rig’s engine stopped and secured againstinadvertent or unauthorised start up. (Safety devices includeengine covers, lids, caps, doors, gratings and panels.) All safetydevices and protective equipment must be reinstalled after

completing maintenance service and repairs.

DIRECTIVE OF APPLICATIONBoart Longyear drill rigs must be used only as directed and described in theOperating Manual. The drill rig must not be used for :- Towing other ma-chines, lifting parts other than for the the drilling duties, carrying passengersor materials other than drilling tools, or for clearing debris from the drill site.

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

OPERATING INSTRUCTIONS Operating instructions must be complied with for all operations, maintenance,service, repairs, and transport.A copy of the current operating instructions (with all approved amendments)

must be retained on the working site.The contractor is obliged to amend safety regulations to meet local require-ments.


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DANGER ZONE - 2.5 metres All round the Rig.

Be sure that no one is within the Danger Zone of the drill rig. This is the areaaround the drill rig, within which persons may be endangered by slewing therig or moving any of its operational components.

The operator can work the rig only if no-one is within the Danger Zone. Ifsomeone enters the Danger Zone the operator must immediately give appro-priate warning signals. These are usually made with horns, but pre-determinedhand signals can be used to warn other people if on-site noise is liable todrown audible signals.The operator must immediately terminate all operations if other people donot leave the Danger Zone, despite having been warned.

Danger Zone with Trailer (option)

SAFETY DISTANCEA safety clearance of 0.5 metres must be kept from buildings, scaffolding,and other equipment to prevent the danger of being squashed.

At all times keep in mind the rigís slewing requirements.If the safety distance can not be complied with the area must be cordonedoff.

TRANSPORT OF PERSONS Using the rig to transport persons is strictly forbidden.

NOISE LEVELS The Maximum noise level measurements are:Lwa = 104dbLpa = 85db

Ear defenders must be worn


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Fire Extinguisher Instructions

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


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STABILITYThe crawler drill rig must only be operated when it is in a stable position. The

rig’s stability may be impaired by:- Excessive load

- High Winds

- Unsecured ground

- Incorrect drill mast position- ‘Jerky’ acceleration and stopping during tramming,- Slewing movements, and

- Operating on slopes and inclines.The maximum allowable Gradients are:-

Parking - 20deg

Drilling with jacks down - Lateral 19deg - Longitudinal 11degTramming with Mast level - Lateral 19deg - Longitudinal 10deg

The operator is responsible at all times for the rigís operation and must modifyprocedures to allow for any likely instability and ensure a safe work area.

SECURING AGAINST FALLTo avoid the danger of falling and crashing, the crawler rig must always keepa safe distance from ledges, pits and slopes.It is the contractorís responsibility to assess the ground bearing capacity andstate a safety distance for the rig.

Check the bearing capacity of bridges, oors and any structures prior tomoving the rig onto them.

TRAMMING AND OPERATING CRAWLER DRILL RIGS Independent and unassisted operation and maintenance of the crawler drillrig must only be entrusted to persons who:

- Are at least 18 years

- Have been instructed in operating and maintaining the crawler drill rig andhave demonstrated their ability to the contractor.

- Can be expected to perform responsibly and are designated for the job bythe contractor.

SAFE TRAMMING SET-UP (with Trailer option)

Mast StowedCyclone Stowed


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SIGNALLINGIf the operatorís vision is impaired during tramming and working, someonemust give signals for assistants or the tramming/working area must be cor-doned off.

Only reliable persons should be designated to give signals. They must receiveinstruction and be aware of this responsibility.Communication must be co-ordinated and exclusively used between theoperator and the signaller.The signaller’s attention must not be diverted by any additional tasks.

UTILITY LINES The contractor is responsible to determine if utility lines are buried on the drillsite, and the site owner is obliged to supply this information.If utility lines are present their location must be clearly marked. Plans clearlydetailing the location (run and depth) of utility lines must be kept for referenceon the working site.The operator must stop working immediately and inform the site manager ifa utility line or its protective cover is detected.Uncovered utility lines must be secured against swaying or slipping.

WORKING NEAR OVERHEAD LINES Unless local or national stipulations require otherwise, the following minimalsafety distances must be complied with. Rated Voltage ProximityIf working near overhead power lines: Up to 1000V 1 metre Above 1KV 3 metres Above 110KV 4 metres Above 220KV 5 metres

If rated voltage unknown 5 metresFor overhead tram lines: Up to 1000 V AC / 1500 V DC 1 metre Above 1000 V AC / 1500 V DC 1.5 metres

OPERATIONAL INTERVALS The operator must park the drill rig on bearing and level ground, stop the drillrig engine, and secure the equipment against inadvertent or unauthorisedmovement prior to leaving the drill rig. The drill mast and drill string shouldbe resting on the ground.The operator must set all operating levers in the ‘O’ position prior to leavingthe control panel. Furthermore, the operator must not leave the site if anydrill rig tools are not secured.

If the drill rig must be parked on a slope or incline, the crawler tracks must besecured with wedges in addition to the failsafe hydraulic brakes.Drill rigs should be parked only where they do not impede the public or anysite trafc. If necessary the rig must carry a warning triangle, signalling linesand/or warning lights when visibility and lighting conditions are poor.These shutdown procedures must be performed before each operationalbreak and at the end of each working day.Proir to re-starting the rig check that the mast and drillhead alignment areas required.


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Extreme Environmental/Job Site ConditionsExtremely dusty Working Conditions.In order to extend the service life of the standard air lter for the Deutz diesel

engine with extreme dusty conditions, we recommend the use of a cyclone.Thus air is pre-ltered of the rough dust particles. The cyclone should betted outside the sound proof enclosure and before the air lter. To ensureoptimum maintenance; the performance of the cyclone must be monitoredduring the normal daily drilling schedule.Please contact Boart Longyear

Warm to Hot Ambient Air Temperature.If the drill rig is required to operate for extended periods in an ambient tem-perature of more than 40 degrees C, we recommend the installation of a largerdimensioned hydraulic oil cooler, otherwise the machine will overheat. Inaddition to a larger cooler, the hydraulic oil viscosity could be changed. Further

more the cooling performance of the diesel engine must be inspected.Please contact Boart Longyear regarding a ‘Desert version’ engine capableof operationg to +60 C, 5000m Above sea level

Extremely Cold Ambient Temperature.If the drill rig is required to operate for extended periods in an ambient tem-perature below 0 degrees C, and/or occasionally under 10 degrees C, thenwe recommend the installation of heating systems for the powerpack.The diesel engine is equipped with a pre-heating unit, in order to work howeverat extremely low temperatures, an additional block heater can be tted.Futhermore the hydraulic oil can be warmed up by an oil heater integratedinto the tank.

Also the hydraulic oil may be changed to HLP46(-5 to 10 degrees C) orHLP30(-10 to 0 degrees C).Please contact Boart Longyear

Working At High Altitude (above sea level).For any operation at high altitude the hydraulic tank must be modied and aninspection and check on the power of the diesel engine is necessary.The standard air lter unit must be inspected and eventually replaced with altration system under charging pressure.Please contact Boart Longyear

Working in Salty Atmosphere.When working in a salty atmosphere the hydraulic cylinder rods in particularmust be protacted. Furthemore the machine, especially the chassis. must becoated with a defensive laquer against corrosion. The hydraulic oil radiatormust also be provided with a protective laquer nish, and in extremely saltyenvironments (offshore for instance) the radiator must be replaced with astainless steel model.Please contact Boart Longyear

See also the Prime Mover manual.


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Boar t Longyear is constant ly s t r iv ing to improve i ts products and must therefore, reserve the r ight to change designs, mater ia ls , specif icat ions and pr ice without not ice.

SECTION 3


Table of Contents

3-2 Section 3 Drill rig components

3-2 Drill Rig Complete

3-4 Optional Radio Control

3-6 Drilling Mast

3-10 General rules for Feed chains:

3-13 Drillhead Sideslide - DD52

3-14 Alternative Rotary Drill Head - HY79

3-15 Drillhead Sideslide - HY79

3-16 Reverse Circulation Swivel (option)

3-17 Percussive Drifter (option)

3-18 Clamping and Breaking Device

3-19 Clamping and Breaking Device (option)

3-20 Automatic SPT (option)

3-21 Oil Liner DTH Lube system (option)

3-24 High Pressure Water Pump (option)

3-25 Vice (Option)

3-26 Vandal Covers (option)

3-27 Main Hoist

3-28 Wireline Winch

3-29 Crawler Tracks


3-31 Water/Mud Pump

3-32 Air Compressor and reservoir (Option)

3-32 Reverse Circulation (Option) Air Hose

3-32 Whip Check Connections

3-33 Hydraulic circuit


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3-2Drill Rig Components

Rotary Drill Head

Enginecompartment

Drill Mast

Drill Rig Complete

Water Pump

Hold clamp andBreakout clamp

Section 3 Drill rig components

Oil coolerGuard

Levelling Jacksat each corner

Engine ControlPanel

Set-up ControlPanel

Dri l ler ControlPanel


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Drill Rig Complete

Engine controlpanel

Set-up functionsxed panel

Drilling functionsswivelling panel(open for use)

Alignment functionspanel

Drilling functionsswivelling panel(Open for use)


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Read all instruc-tions prior to tram-

ming the rig.

Drill Rig Complete

Pendant Tramming controls(stowed)

Radio RemoteReceiver

Radio RemoteTramming

Control

Driving StartButton

Driving Stop But-ton

Emergency StopSpeed selector

Optional Radio Control


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Drill Rig Complete

Wireline Winch

Main Hoist


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The frame of the drill mast is fabricated from rolled steel section,and is capable of drilling from vertical to horizontally forwards.

The travel of the rotary head is innitely variable in forwarddrilling mode and features fast feed and return. The drillheadrotational speed is manually adjustable for low and high speedsand is innitly variable in both ranges.The drillhead assembly, complete with side shift, is traversed

up and down the mast by a hydraulic cylinder acting through aleaf-chain and pulley system. All pulleywheels are roller bearingmounted. All chains and pulley wheels are made from high gradesteel.The drill mast is raised and lowered by hydraulic cylinders

equipped with load control valves.The drill mast is designed to handle full strings of casing and drillpipes.The hydraulically controlled feed system allows full control of thedrilling speed and bit weight.

The drillmast has a facility to advance towards the ground toposition the break-out device on the drill string.The mast is locked in the upright position by clevis pins.

Drilling Mast

Mast Assembly

Safety Guard

Rod Clamps

Rotary Drill Head


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Drilling Mast

Low FrictionSliders

Lateral alignmentrollers

The rotary head is held ontothe drill mast with low frictionsliders. Lateral alignment of

the rotary head is controlledby four rollers with eccentricshafts (Lateral alignment roll-ers on the photo below).The up and down movementof the Rotary Head is control-led from the swing-out panel(see section 4), by activatingthe hydraulic cylinder chainand pulley system.


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Locking pins(one each side

The Mast is raised to vertical by two Lift cylinders which are com-plete with over centre counter balance valves to lock the cylindersin the event of hose failure. There are two manually inserted lock-ing pins which maintain the mast in the vertical position during longworking cycles.

Finger trap hazard,do not enter dangerzone until mast isfully raised, themast must be staticwhen the pin is

inserted.


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Drilling Mast

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

Chain adjuster Bolts


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General rules for Feed chains:The chain pulleys are mounted on roller bearings.

Feed chains have to be checked daily for cracks and ssures.Pins and links with wear marks and grooves or mechanicaldeformations must be replaced. Feed chains have to be checkedweekly for elongation.

Excessive lengthening of the chains should be avoided. Theyshould be adjusted by tightening the adjuster bolts at the end ofthe mast assembly. As a general rule, the useful life of chain iswhen the percentage extension reaches 2 per cent (160mm on

each piece of chain), then the chain should be replaced.Elongation test procedure:The gauge distance must consider at least 17 double-links in the

working range of the chain and should be done as follows:• Fix the total length of 17 double-links of a new chain within the

pitch distance (roller to roller / link to link)• The test procedure compares the total length of the new chain

and the used chain and if the used chain shows increasedlengths of 161/2 double-link gauge, the chain must bereplaced.

Nominal length values of chains:(For example) Type 24 B-2 -1 double link 38,1 mm

17 double links 647,7 mm


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The load applied to the drill head is proportionally regulated fromthe Swivelling Panel

The maximum thrust is 34 kN.The maximum pull back is 55 kN.A special valve in the hydraulic system automatically balancesthe load applied to the up and down movement of drill head.

Drilling Mast

Retract Chain

Feed Chain

Drillhead

Chain adjuster Bolts


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The high torque / high speed rotary head is equipped with ahollow drive shaft mounted between conical roller bearings andball bearings.

The rotary head has two speed ranges, manually selected at theDrillhead gearbox (position 1 below).

The Drillhead is powered by a high torque - variable displacementhydraulic motor which is hydraulically controlled from theswivelling control panel.

The head output speed and torque are innitely variable beingcontrolled from the swivelling control panel.

The head is equipped with a water swivel (position2)and a topsub shaft extension adaptor for connection to the drill pipes.The head has lateral side shift to allow passage of drill string andfor wireline extraction.For easy coupling of the drill pipe the rotary head is equippedwith a oating spindle (position3)allowing axial movement.Drill tools are manually connected to the rotary head.The oating spindle is a thread saver and is important during

making up and breaking out drill pipe connections (i.e. whenscrewing and unscrewing).

Gear selector(position1)

Floating

spindle(position3)

Water swivel

(position2)


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Drillhead Sideslide - DD52The drillhead can be moved sideways 500 mm to clear the wayfor rod extraction/insertion and wireline operations.

Drillhead movedsideways 500 mm

IMPORTANT NOTE STOP rst and ONLY switch the gear stages at stop.

SERIOUSMALFUNCTION

OR EVENCONSIDERABLEDAMAGE WILL BECAUSED IF THISWARNING IS NOTADHERED TO


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Gear selector

Oil Level

Water swivel

Alternative Rotary Drill Head - HY79The high torque high/low speed rotary head is equipped with ahollow drive shaft mounted between conical roller bearings and

ball bearings. The head is powered by one high torque - variabledisplacement hydraulic motor and one xed displacement motor.The head output speed is manually set to High or Low rotationand is innitely variable in either High setting or Low setting.Control is from the pivoting panel.

The head is equipped with a water swivel and a top sub shaftextension adaptor for connection to the drill pipes. For easycoupling of the drill pipe the rotary head can oat 50mm axiallyThe oating facility is a thread saver and is important during

making up and breaking out drill pipe connections (i.e. whenscrewing and unscrewing).Drill tools are manually connected to the rotary head.

The correct oil level is 3/4full showing on the levelglass on the rotation gearbox, with the rotary head inthe drilling position.


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Gear selector

The HY79 drillhead has a manual change two

speed facility for changing from higher to lowerspeed drilling operations. It is important to followthe steps below to change gears.1 - STOP the engine.2 - Turn the Gear Change Stick Changing from Low to High - 1 turn ccw. Changing from High to Low - 1 turn cw.3 - Rotate the Drill Spindle until engagement isfelt through the Gear Change Stick.4. IMPORTANT - If the Gear Change Stick is not

turned one full turn, return to original position,rotate the Drill Spindle through a small angle,then try again.

Drillhead Sideslide - HY79The drillhead can be moved sideways 500 mm to clear the wayfor rod extraction/insertion and wireline operations.

Drillhead moved

sideways 500 mm

Do not start the engine to rotate by the hydraulic motors until theGear Change Stick is turned fully in or fully out.Serious damage will be caused.If it is not possible to align the teeth manually:Reengage the original gear and rotate with the hydraulics, thenrepeat the process.


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Reverse Circulation Swivel (option)The HY 79 Rotary Head is tted with a special Water/Air Swivel

arrangement when Reverse Circulation is required.

RC OutletWear plate accessBlowdownair inlet

Blow-down system

Drilling airinlet


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Boar t Longyear is constant ly s t r iv ing to improve i ts products and must therefore, reserve the r ight to change designs, mater ia ls , specif icat ions and pr ice without not ice.

SECTION 3


Percussive Drifter (option)The Eurodrill H1006 Rotary/Percussive Drifter is tted as an

option.

Manual Rotationspeed change

H1006 PercussiveDrifer


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Clamping and Breaking DeviceThis device is for holding, making up and breaking out the drillpipes, core barrels and casing tubes. It includes:-

1. Holding Clamp - for holding the drill string during thread makingor breaking.2. Breakout device - with a clamp for gripping the upper drill pipethen a breakout cylinder for breaking the thread by rotating up to

30degrees.Standard clamps have a capacity of 50-133mm Dia. Optional sizecapacity of 60-220mm Dia can be supplied.Both holding and unscrewing clamps can be open front type soas to facilitate installing and extracting rods, core barrels andcasings.If the clamps are closed front type (with pinned gate), tofree the area remove the pin on one side and open the gate.

BreakoutClamp(position2)

HoldingClamp(position1)


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Clamping and Breaking Device(option)This device is for holding, making up and breaking out smalldiameter drill rods generally applies when usig a Rotary/ Percussive Drifter.

Breakout

Clamp(position2)

HoldingClamp(position1)


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Automatic SPT (option)The rig is equipped with automatic, hydraulically operated SPT(Standard Penetration Test). The weight of the drop hammer is

63Kg, and the free fall height is 75 cm.

SPT in workingposition

Sideslide activated


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Oil Linerreservoir(DTH Lube)

Oil Liner ControlPanel (DTH Lube)

Isolation Valve

Oil Liner DTH Lube system (option)A reservoir and electric control for the automatic lubrication ofDTH.

On/Off/AutoSelector Switch

Red Light (see next

page for function)

Green Light (see nextpage for function)


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AIR LINE OIL LUBRICATION SYSTEM MANUAL

The Air Line Lubrication System functions in two operating modes selected by means of S1

switch (ON-MANUAL / OFF / ON-AUTOMATIC). When the MANUAL mode is selected the red H20

LED is on indicating the E3 electrovalve (lubrication pump) is energized all the time. When AUTO

mode is selected the green H10 LED is on and the red H20 LED is turning on and off periodically as

the E3 electrovalve gets energized and disenergized.

The H20 flashing frequency (corresponding to the periods the lubrication valve E3 is with or

without electric power supply) can be adjusted by means of the two timer relays (K10, K20) fitted

inside the control panel of the Lubrication System. Use the dial on the top of the K10 and K20 relays to

adjust respectively the delay time and the time for the E3 electrovalve to be energized (working time).

If the time scale of the timers needs be changed use the first three dip switches from left and set themaccording to the below given time scales diagram.

Both the timers time scales are set to 0,5…10s by default.

S1 H10 H20


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A – LED diodeB – Time adjustment dialC – Time scale / function selection

Workingtime relay

Delay timerelay


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Water pump/PTO Change over valve

High Pressure Water Pump (option)

High pressureLanceconnectoror to Dust Deec-tor (RC option)

Externalwater suctionconnection

Optional Water tank- 150 litres

Water level indicators

Position of 3-Way Valve Flow to Collector

Position of 3-Way ValveFlow to Gun and Dust Deector(RC option)

Dust Deector (RC option)

Water/Mist PumpValve positioningdetails.


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Vice (Option)


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Lift off Control panel

Vandal cover

Vandal Covers (option)Lockablle covers to prevent damage to controls by vandals.

Tramming Con-trol Vandal cover(closed)

Tramming Con-trol Vandal cover(open)


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Main HoistThe main hoist is used for handling the rods and pulling the drillstring during conventional coring operations.

Main Hoist Type Braden BG 6Line pull - Bare Drum 31.1 kN - Full Drum 23.1 kNRope speed @ 140 l/min

- Bare Drum 30 m/min - Full Drum 40 m/minFor Cable Dia13 mm 30 mBrake - Failsafe with overcentre valve capable of withstanding 1.3

times the winch capacity

Fitted with a limit switch to prevent reeling off of the rope, this

cuts out the rig hydraulics which must be re-set with the green re-set button on the xed control panel.

See Main Hoist section for full specication and Parts list.


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Wireline WinchThe Wireline winch is used for retracting the core barrels from thehole.

Wireline WinchLine pull 6500 NRope speed @ 59 l/min 100 m/minFor Cable Dia 6 mm 250 mOptional Cable Dia 5,0 mm 350 m

Brake - Failsafe with overcentre valve capable of withstanding 1.3times the winch capacity

See Wireline Winch section for full specication and Parts list.


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Crawler Tracks

Crawler Tracks

The rig is equipped with a hydraulically powered TrackOneCrawler Tracks type 070221. These comprise of a Left and Right

hand pair. See section 10 at the back of this manual.


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Trailer (option)The rig may be coupled to a trailer for Reverse Circulationoperations

Cyclone and Sampler Manual Stabiliser Jacksat each corner

Cyclone door operatorWater ReservoirStoragecompartment

Hydraulic and air

connectors

Cyclone Slew and

Lift positioner valves

Hose stowage

Brackets


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Water/Mud PumpThe Water/Mud pump is a hydraulically driven triplex mud pump. It is deckmounted and driven from the hydraulic system which is powered by the

diesel engine.The pump is supplied complete with all accessories.All controls are positioned close to the operator.Maximum pressure: 50 barMaximum working pressure: 35 barMaximum ow: 90 litres/minThe output ow of the pump is variable to suit site conditions.

Accumulator

Pressure Regulator(manual re-set) Pump


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Air Compressor and reservoir (Option)

Air Reservoir

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

Reverse Circulation (Option) Air HoseWhip Check Connections

When the Rig is equipped for Reverse Circulation duties involvinghigh volume Compressed air, the hose system is protected by theapplication of Whip checks and anchors. These safety items mustalways be utilised and must be monitored regularly for wear anddamage - replace any item that shows signs of wear or damage.

Typical Whip Checks and Anchors


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Hydraulic circuitThe pumps are mounted directly on the diesel engine.In the complete version of the drilling rig there are 2 pumps.• A bent axis xed displacement pump powers the crawler tracks, the

drillhead and main hoist• A 2 stage gear pump actuates all auxiliary movements and feed.

All pumps are protected against excessive pressure by safetyvalves mounted before the distribution valves. The xed pressurerating must not be changed.

The Oil Tank is tted with the following:-

1. Oil level and temperature sensor which shuts down the systemif the temperature exceeds 80 degrees

2. Oil lter with electric signal device, which lights a warning lamp positioned on the engine instrumental panel. When this

happens, the lter cartridge must be replaced.The lter grade is 10 micron. We recommend using 17/15/13class oil (ISO 4406).

ATTENTION!!During cold weather starting (when the temperature of theoil is low and therefore the viscosity is high), the lamp maylight due to the high resistance the oil meets when owingthrough the lter element. This does not necessarily meanthat the lter is clogged.After the oil has circulated for a certain time and becomeuid, if the lamp does not extinguish then the lter cartridgeshould be renewed.

3. A lling tap with breather and pre-lter.

4. Three ball-valves to close the oil circuit in case of a shutdownor repair, avoiding the loss of oil.

5. One heat exchanger incorporated in the return circuit andtted with one electric fan that is automatically actuated by athermostat in the oil tank when the oil temperature has risen tothe value indicated. A lamp on the engine control panel lightswhen the fan is running.

The thermostat is set to 60 degrees C.

All the control and monitoring elements of the drill are assembledin the control panels.


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SECTION 4

Table of Contents

4-2 Section 4 Operations

4-3 Introduction

4-3 Equipment Description and Identification

4-4 Component Location

4-6 Diesel tank and Hydraulic tank location

4-7 Flushing Control valves

4-8 Flushing Control valves (circuit with RC option)

4-9 Auxiliary Controls

4-10 Main control panel description

4-10 Engine controls

4-11 Alignment controls

4-12 Swivel panel controls

4-13 Fixed panel controls

4-14 Tramming Control Panel Description

4-15 Crown Block control description

4-16 Pre-start checks

4-16 Prior to Start-up

4-17 Initial Start-up

4-18 Tramming (Tracking)

4-18 Transport Support

4-18 Tramming control hoses

4-18 Mast in Tramming Position

4-18 Radio Control (Option)

4-19 Drilling Methods

4-19 Hints for Optimum Application


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[email protected] www.boartlongyear.com Prepared by TSG - Printed in Poland - Issue level DB525 20081002C © 2010 BoartLongyear Sz o.o.

4-20 Drilling Operations

4-20 Calculating Bit Weight

4-21 Down Hole Drilling

4-22 Up Hole Drilling

4-23 Horizontal Drilling

4-24 Bit Weight Table

4-26 Flushing

4-26 Blow Down (option)

4-26 Reverse Circulation / Blow Down (Option) Air Hose

Whip Check Connections

4-27 Blow Down circuit (option)


Section 4 OperationsSECTION 4


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4-3Operations

The DELTABASE 525 is configured for:• DTH drilling of holes from 4” to 61/2”• Geothermal wells• Water wells

• Drilling with casing• Reverse Circulation (Option)

Equipment Description and Identification

Introduction

Filler Pump (hydraulic reservoir) - this pump is used to pump hydraulicuid into the reservoir and is permanently connected through the mainreturn line lter.

Main Frame Enclosure - contains the main hydraulic directional control

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

pressures at any time while the machine is running. Hydraulic Reservoir - has a total oil capacity of 200 litres, and is tted with

an indicator to show hydraulic oil level and temperature. Lifting Eyes - assist with lifting and slinging the Drill Rig. Oil Cooler - provides cooling of hydraulic oil by electric driven fan blowing

air across Heat Exchanger. Hydraulic Filters - maintain continual particle ltration through 10 micron,

beta-rated elements. A visual clogging indicator is tted, which changescolour to warn of an element servicing requirement, the Return lter hasan electrical connection to a warning light on the insrument panel.

Electric Starter - refer to section 4-13 to 4-14 for further details startingprocedure.

Fuel Tank - has a capacity of 60 litres, and is tted with a fuel gauge on theStarter panel. The tank is lled via a

llercap on the mid left side of the rig. Engine and Pump - The diesel engine and close coupled Hydraulic Pump

are situated in the Engine Compartment. The speed of the diesel engineis controlled by accelerator lever mounted to the right of the main controlpanel.

The pictures on the following pages locate the main components of the DB

525.Note: The hydraulic reservoir can be lled with a wide range of oils. See theOil Selection Chart in section 5 to determine the oil most suited to yourconditions.

Important - The personnel responsible for operating the DB525 must besufciently trained and be aware of all the safety rules in this manual.If there is anything you are not sure about, contact the Boart Longyear,Technical Support Group.

Contact information :- European Service Manager

T.S.G.(Technical Support Group) BOART LONGYEAR Arrowmax Buildings

Langwith Road Langwith Junction Manseld Notts NG20 9RN England Tel: +44(0) 1623 747898


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Operations 4-4

Component Location

Rotary Drill Head

Engine compartmentDrill Mast Water Pump

Hold clamp and

Breakout clampOil coolerSafety

Guard

Levelling Jacks ateach corner

Control panelsBattery compartment


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4-5Operations

Engine speed

control

Hydraulics Acti-

vate button

Engine controlpanel

Set-up functionsxed panel

Drilling functionsswivelling panel(Stowed)

Alignment functionspanel

Drilling functions

swivelling panel(Open for use)

High/Low sp

perforadora diamantina db525_om_20081002d

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