LY38

© 03/2002 Boart Longyear Inc. Printed in Canada MKT1213

 LY 38 Diamond Core Drill System
Safety Identification and Safeguards
Read and understand all
safety instructions carefully before operating this
machine. Failing to follow these instructions
may result in serious personal injury or death.
Important Safeguards:
• Keep guards installed and maintained in good
working order.
• Keep clear of rotating equipment. Never wear any
loose clothing which could become tangled in the
machine.
• 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 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 the operator, and may void your warranty.
• Use only qualified service technicians. Failure to do
so could cause severe damage to the machine or
the operator, and may void your warranty.
• Never climb on top of the machine.
• Ensure that the drill and accessories fully comply
with applicable local safety and health regulations.
• Do not exceed rated capacity of any piece of
equipment.
NOTE: See following page for safety decals that appear on the
machine.
Printed in Canada MKT1213
• 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.
• Do not adjust the hydraulic system before
consulting a Boart Longyear Technician.
• Ensure that all commissioning checks and
adjustments have been thoroughly carried out
before operating the machine.
• Do not change or alter the drill, its components,
optional equipment or accessories without prior
approval from Boart Longyear 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.
• For additional information on training or start up,
contact your Boart Longyear representative.
© 03/2002 Boart Longyear Inc.
 LY 38 Diamond Core Drill System
Safety Decals

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 LY 38 Diamond Core Drill System
Table of Contents

Main Drill Components

1 Recommended Practices for Maintenance and 5 Hydraulic Explanation

Use of Masts
01 Drive Source
01 Safeguards
02 Hydraulic Swivel Head
01 Routine Checks
03 Hydraulic Chuck
02 Visual Inspection of Masts

6 Drill Operations
2 Drill Introduction
01 Force on Diamond Bit
01 General Information
01 Bit Pressure Table
01 Ordering Parts
01 Returning Parts
7 Accessory Attachments
02 Safety Warning
01 Wireline Hoist - Mechanical
03 Standard Warranty
01 Hydraulically Driven Water Pump

3 Operator’s Instructions
8 General Maintenance
01 Important Reminder
01 Drill Specifications and Capacities
01 Power Train
01 Drill Servicing Instructions
01 Power Units
02 Lubricant Chart
01 Throttle Control (Gasoline and Diesel Power
Units Only)
01 Main Drill Clutch
02 Four Speed Transmission
02 Bit Speed Selector (Main Gear Case)
02 Hoist or Draw Works
03 Hoist Functions - General

4 T-Style Mast
01 Installation of Raising and Lowering Sections
02 Raising the Mast
03 Lowering the Mast
03 Folding the Mast

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.
 1-01 Recommended Practices for
Maintenance and Use of Mast
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 enviromental conditions.)
Make copies of the checklist for each inspection.
The checklist should be signed and filed for future
reference.
Safeguards:
Operator shall be familar with the equipment and its
proper care. If adjustments or repairs are neces-
sary, 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 isn’t
advised. These modifications could result in
weakening the strength of the mast and may cause
failure.
Printed in Canada MKT1213
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.
• 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.)
• Steel becomes brittle when operating in low
temperature conditions. EXTREME CAUTION
must be exercised when operating at or below
-25°C (-13°F) as the mast may no longer hold the
rated load. Frequent visual inspection of mast
members and welds is even more critical at these
temperatures, see page 1-02.
• Ensure support legs are located on a solid footing
and tied back to a solid anchoring point.
© 03/2002 Boart Longyear Inc.
 1-02 Recommended Practices for
Maintenance and Use of Masts
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 druing 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 Warped OK
Grooves Worn OK
Spacers or Seals Bad OK
Grease Fitting Missing OK
Crown Frame Bent Flanges Bent Webs OK
Cracked Welds OK
Comments: Rusty Needs Repair
Needs Painting Other:
2. Vertical Members:
A. Front Leg, Driller’s Side
Condition:
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
Safety Pins Missing OK
B. Front Leg, Off Driller’s Side
Condition:
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
Safety Pins Missing OK
C. Rear Leg, Off Driller’s Side
Condition:
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
Safety Pins Missing OK
D. Rear Leg, Driller’s Side (Not applicable for “T” style mast)
Condition:
Bow Slight Bad OK
Pin Connection Bad OK
Pin Hole Bad Cracked Welds OK
Safety Pins Missing OK
Comments: Needs Repair Other:
3. Bracing
Condition: Slight Damage Badly Damaged Needs Repair OK
4. Adjustable Support Legs and Feet
Condition: Damaged Cracked Welds Corroded
Worn Pins/Hole Needs Repair

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 1-03 Recommended Practices for
Maintenance and Use of Masts
5. Working Platform
Condition:
Racking Platform
Frame: Damaged Cracked Welds OK
Pin Connections Worn OK
Safety Pins Missing Worn OK
Fingers Damaged Needs Repair OK
Working Platform Damaged Cracked Welds OK
Handrails Damaged Needs Repair OK
6. Guyline Anchorage
Condition:
Guyline Damaged Needs Adjusting Needs Replacing OK
Cable Clamps Loose Needs Repairing OK
Turnbuckles Damaged Needs Replacing OK
Anchor and Deadman Replace OK
7. 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 visual inspected and spot checked for tightness and no further OK
bolt tightening or repairs necessary.
8. Substructures for Mast
Damages: Minor Major OK
Corrosion: Minor Major OK
Condition:
Connections Worn Cracked Welds OK
Safety Pins Missing OK
9. Mast Raising and Angling Cylinders:
Condition: Oil Leaks Hose/Tubing Damage
10. Summary of Inspection
Appearance: Good Fair Poor
Repairs Needed: None Minor Major
Number of Missing Parts:
11. List of work to be completed:

Signature : Date:
Ref No.:

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.
 2-01 Drill Introduction
General Information
The purpose of this manual is to furnish the opera-
tor 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. Parts Lists, with corre-
sponding views to aid in ordering parts, are also
included
Boart Longyear is backed by over 100 years of
experience in the design, manufacture and opera-
tion of core drilling equipment. Many of the ac-
cepted practices in use today were pioneered by
Boart Longyear.
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.
Printed in Canada MKT1213
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 sepa-
rate charge will be made for transportation and
export packing.
Returning Parts
1. If you desire to return parts, whether for repairs,
replacement or warranty, a letter should first be
sent to:
Boart Longyear Inc.
P.O. Box 330
North Bay, Ontario
Canada PlB 8H6
This should specify quantity and part numbers, and
model and serial number of the product, as well as
the reason for requesting return.
2. DO NOT ship parts until authorization and shipping
instructions are received.
3. All parts returned must be prepaid.
© 03/2002 Boart Longyear Inc.
 2-02 Drill Introduction
Safety Warning
Due to a wide variety of safety regulations existing
throughout the world, Boart Longyear Inc. can only
design its equipment to meet basic safety consid-
erations. The customer and/or operator is responsi-
ble for ensuring that his Boart Longyear drill and
accessories fully comply with all applicable local
safety and health regulations.
The customer is also responsible for taking the
necessary safety precautions for operating the drill
and accessories in a safe manner. Boart Longyear
will gladly assist the customer in this respect.
Following the general safety practices listed will
reduce exposure to potential hazards.
Printed in Canada MKT1213
1. Read this Operations and Service Manual carefully
and make sure you understand its content and
implications before you attempt to operate the
equipment. If you have any doubts or questions,
particularly in respect to safety matters, please call
for assistance.
2. Make sure all precommissioning checks and
adjustments have been thoroughly carried out.
3. Do not change or alter the drill, its components,
optional equipment or accessories without prior
approval from Boart Longyear.
Unauthorized alteration may void the warranty,
render the equipment unsafe or result in decreased
performance.
4. Before operating any controls, be certain you know
what function they control.
5. Use only replacement parts manufactured or
approved by Boart Longyear Inc. This includes
such items as cables, gears, hydraulic hoses and
components, as well as mechanical parts.
6. Do not change any of the factory settings on the
hydraulic systems without fully understanding the
system.
7. Do NOT exceed rated capacity.
8. Do not attempt repairs until you determine the
cause of the problem. Unless you know and
correct the cause, your repairs will be useless.
9. Make a list of probable causes and check the
simple ones first.
10. Do not attempt field repairs on complicated and/or
precision made parts such as hydraulic pumps and
motors. This may void your warranty. Complicated
repairs should be made by qualified personnel in
shops equipped with proper tools.
11. If you do not fully understand the equipment and
how it operates, DO NOT attempt adjustments or
repairs.
12. Keep guards installed and maintained in good
working order.
For additional information on training or start up,
contact your Boart Longyear Representative.
© 03/2002 Boart Longyear Inc.
 2-03 Drill Introduction
Standard Warranty
It is agreed that there are no warranties expressed
or implied made by Boart Longyear except its
following standard warranty and no others.
Boart Longyear Inc. warrants each new core drill
and related parts sold by it, to be free from defects
in material and workmanship under normal use and
service for ninety (90) days from date of first use,
but not to exceed six (6) months from date of
shipment.
The obligation under this warranty is limited to the
replacement or repair at the North Bay, Ontario
plant of Boart Longyear, or at a point designated by
it, of such part or parts as shall appear upon
inspection at this point to have been defective in
material or workmanship at the time sold, provided
that the part or parts claimed defective are returned
to the inspection point, transportation charges
prepaid.
Printed in Canada MKT1213
This warranty applies only to new and unused drills
and parts which, after shipment from the Boart
Longyear factory, have not been altered, changed
or repaired in any manner. This does not extend to
power units, pumps and other trade accessories not
manufactured by Boart Longyear, though sold or
operated with the Company’s drills, same being
subject to warranties of the respective manufactur-
ers thereof.
In no event shall Boart Longyear be liable for
consequential damages or liabilities caused by the
failure of any drill or parts to operate properly.
This manual contains all the information pertaining
to the LY 38 drill for equipment furnished on the
drill.
© 03/2002 Boart Longyear Inc.
Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.
 3-01 Operator’s Instructions
Your new Boart Longyear Core Drill has been
carefully inspected and tested at the factory.
Examine it closely for any damage due to ship-
ment. Claims for defective material or workman-
ship must be made in accordance with the war-
ranty.
Important
All lubricating oil, water, and hydraulic fluid has
been drained prior to shipment. Be sure to
replace these before initial operation of the drill.
Be sure all moving parts are lubricated accord-
ing to the Lubrication Chart. Also, check
battery. If it is dry charge type, fill it with the
electrolyte acid provided.
Power Train
Power from the engine is transmitted to the swivel
head and hoist through a dry disc clutch, a four
speed transmission and dual range hoist
transmission. Before starting the power unit on the
drill, be sure the clutch is disengaged and the four-
speed transmission is in neutral.
Power Units
The power unit manual pertaining to your particular
drill will be found at the back of this manual. Read
it carefully and follow the manufacturer’s
recommendations for engine break-in, operation,
maintenance, and servicing.
Throttle Control (Gasoline and Diesel
Power Units Only)
The throttle control is attached to the main
transmission case within easy reach of the operator
and is of the friction lever type. To increase the
engine speed, pull the lever away from the engine.
To momentarily increase the engine speed, pull on
the throttle chain. Adjust the throttle pivot bolt to
provide locking friction as desired.
Printed in Canada MKT1213
Main Drill Clutch
The clutch is used to stop rotation of the drill
mechanism without stopping the engine and
hydraulic oil pump. The clutch should be
disengaged when the engine is started and also
before the swivel head is opened.
Adjustment
After clutch is disengaged, turn clutch until
Adjusting Lock Pin can be reached. Placing a
sufficient size washer around Adjusting Lock Pin,
pull pin out and lock in position with a wire or small
nail pushed through the small cross drilled hole in
the lock pin. Then turn the Adjusting Yoke
clockwise one or two adjusting holes, or until the
clutch handle requires a distinct pressure when you
engage clutch. Release the Lock Pin and move the
Adjusting Yoke slightly until the Pin fits all the way
into a notch.
A new clutch or one with new discs may require
several adjustments before the discs are worn in.
SLOTTED HOLES
ADJUSTING YOKE
ADJUSTING LOCK PIN
CROSS DRILLED HOLE
ADJUSTING YOKE
8.00
© 03/2002 Boart Longyear Inc.
 3-02 Operator’s Instructions
Four-Speed Transmission Hoist or Draw Works
The transmission is a four-speed forward, syncro- The 38 Drill uses a planetary type of hoist clutch
mesh truck type transmission. The various speed and an extra large capacity brake which operate
ranges are shown on the shifting diagram on the independently of each other and gives the operator
drill per accompanying sketch. two lever control of the hoisting and lowering
operations. These clutch and brake levers pivot for
Gear Ratio
convenient positioning by the operator. A “Float
Low = 6.4 - l Spring” is provided on the back side of the clutch
HIGH 4 2nd = 3.09 - l
3 band and the back side of the brake band to
3rd = l.69 - l eliminate any “Brake Drag” and thus provide the
N High = l.00 - l “Free Spooling” operation so necessary when
lowering the hoisting plug. Spring tension should be
1 LOW 2 adjusted so that the top of the bands can be easily
moved back and forth by hand on their respective
The transmission also has a power take-off opening drums, when brakes are in the released position.
on the back side of the drill which is used with the The hoist drum itself, rotates on ball bearings and
built-in wireline hoist. The shifting mechanism for it anti-friction bearings are provided throughout the
is located in the Power Take Off housing and hoist and main housing to eliminated friction and
described with the wireline hoist. provide ease of bearing replacement.

Bit-Speed Selector (Main Gear Case)

The main housing contains a gear train which
divides the flow of power to either the swivelhead,
hoist, or cathead. The drive to the swivelhead has
(2) speed ranges; a high speed used normally for
diamond drilling, and a low speed used normally for
tricone bits, drag bits, etc.
This gives a total of eight speeds on the bit and
eliminates the need for various bevel gear ratios.
The high speed range is engaged by moving the
speed selector lever toward the swivel heads; the
low speed by moving the lever towards the hoist.
The center or vertical position is neutral and
permits operation of the hoist drum without rotation
of the spindle.
Care should be used when operating swivel head in
the low speed range. Rotation at low speed, which
is an advantage for drilling with rotary or drag bits,
will develop excessively high torque on the drill
spindle and may twist off the drill string if the bit
should happen to stick in the hole.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 3-03 Operator’s Instructions
Hoist Functions - General 1. Hoisting
The hoisting drum has several functions, as fol- The drum is stopped from rotating by pulling down
lows: the hoist brake lever and locking it over center. The
drum is caused to rotate for hoisting by pulling
1. To Hoist Rods down on the hoist clutch lever and releasing the
2. To Lower Rods hoist brake lever simultaneously.
3. To Move Drill Under Own Power If the drill is equipped with a hydraulic retraction
frame, the drill can be moved back without opening
4. To Drive Casing, etc. when Drill is not Equipped
the swivel head, thus clearing the hole area for
with Cathead
hoisting.
The lever NEAR the swivel head end is the hoist
brake lever. The lever NEAR THE POWER UNIT is
the hoist clutch lever. 2. Lowering
A Shifting Lever is not required on either the “34” or The hoist drum is allowed to rotate by lifting up on
the “38” Drill to engage the hoist, as the drum shaft the hoist brake lever only enough to let the drum
is continuously engaged with the gear train from the “Free Spool” at desired rate.
engine.

3. Driving Casing
The cathead with manila rope (See Accessory
Attachments Equipment for Cathead Operation) is
recommended for operating a drive hammer, but if
the cathead is not available on the drill, the hoist
drum with wire rope cable can be used as an
emergency measure. This will require a little
practice, but by intermittently engaging and disen-
gaging the hoist clutch lever, the drive hammer can
be operated.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.
 4-01 T Style Mast
1. Before mounting any part of the mast to the drill, Installing the Raising and Lowering
ensure that the drill is securely anchored to the Section
ground, the drill head is in a vertical position and
the bolts around the swivel clamp ring and hinge 1. Use five 5/8” UNC x 2-1/2” long, Gr. 8 bolts to
plate are tight. attach rear mast support to the drill. There are
three bolt holes on one side and two holes on the
2. Familiarize yourself with the assembly of the mast other. The side with the two bolt holes will face the
in the parts book and all instructions for mounting, operator’s side of the drill.
raising, lowering, and operation of the mast. If
there are any questions, Consult your Boart Mast Stop Bolt
Longyear Technician immediately.
3. Ensure that all heavy loads are lifted with
machinery.
4. Ensure a qualified individual is installing and
operating the mast.
5. Use the hardware provided with the mast. If
replacement of hardware is necessary, consult your
Boart Longyear Technician before doing so.
6. For the assembly of the mast to the drill, always
use a washer and a lock washer with each bolt,
unless specified otherwise.
NOTE: All fasteners are to be Grade 8 hardware
only.

Refer to drawing
#104173 (Mast
Mounting Group) in Two bolt holes will face operator’s side .
your Parts manual 2. Loosen the six 3/8” capscrews around the two
for assembly. piece retaining ring. Remove the clamp ring from
the raising and lowering section.

Clamp Ring Two-piece Retaining Ring

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 4-02 T Style Mast
NOTE : Do not lose the hardware once it is 5. To mount the lower Clamping Blocks
removed. section of the
mast, loosen the
3. The mounting and raising section can now be
bolts on the
attached to the hinge plate and the rear mast
clamping blocks.
support. Fasten the mounting and raising section
Using a lifting
to the hinge plate with four 5/8” UNC x 2” long,
device, slowly
Gr. 8 bolts.
position the lower
section so the
holes line up and
Bolts (4) the pin can be put
Hinge Plate through the mast
and the clamping
blocks. Tighten
the bolts on the
clamping blocks. Side View - Pin
Top View - Pin

Rear View Side View

4. The mounting and raising
section should rest on the
The mast should
machined ring of the rear
now rest on the
mast support. Once this
pieces of channel
is done, replace and
as indicated in the
secure the clamp ring
picture.
with two 3/8” x 2-1/2”
long, Gr. 8 bolts. Then
tighten the retaining ring
to the rear mast support
which it is attached to.
Adjust the mast stop bolt
until it touches the
mating area on the
rear mast support. 3/8” x 2-1/2”, Gr. 8 bolts

3/8” x 1-1/2”,
Gr. 8 bolts

Clamp Ring

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 4-03 T Style Mast
6. The raising cylinder must be mounted to the 7. To mount the angling cylinder, attach the bracket to
mounting and raising section and the lower section the skid of the drill. Use the 3/4” UNC x 1” long,
of the mast (item 1). Slide the cylinder end ,which Gr. 8 bolt for the hole closest to the cylinder itself.
doesn’t have a rod end adjustment, into the Use the two 3/4” x 2” long, Gr. 8 bolts for the other
bracket. Insert the pin and ensure that the cotter two holes.
pins are in both ends of the pin. To secure the
other end to the lower section, loosen the jam nut
and adjust the end until the pin can be put through.
Remove the pin and stroke the cylinder to extend 3/4” UNC x 1” long,
and retract several times. This is to remove any air Gr. 8 bolt
in the cylinder or lines. Retract the cylinder,
replace the pin and tighten the jam nut. Ensure
that cotter pins are put in both ends of the pin.
(item 2)

3/4” UNC x 2” long,

Gr. 8 bolts

Put the pin through

the cylinder and
(item 1) ensure that cotter
pins are in both ends
of the pin. Fully
extend and retract the
angle cylinder several
times to remove any
air in the cylinder or
lines. To mount the
top of the cylinder,
extend the cylinder
until the holes line up
and the pin can be
inserted. Ensure that
cotter pins are in both
ends of the pin.
Refer to drawing
#104120 (20 ft “T”
Style Mast) in your
Parts manual for
hardware and
(item 2) assembly.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 4-04 T Style Mast
8. At this point, the lower section of the mast should Raising the Mast
be mounted to the mounting and raising section,
which in turn should be mounted to the drill. Ensure the mast will not
9. The upper section of the mast has two weld-in pins interfere with any over head obstruction.
which interlock to the lower section. Using a lifting Ensure that the lower and upper mast sections
device, pin the upper section to the lower section. are securely fastened together.
Once this is complete, ensure that cotter pins are
Ensure that no one is underneath the mast as it
properly installed in the end of the pins. The two
is being raised or lowered, and that all hoses
sections must be bolted together with the six 5/8”
are correctly connected to the mast raising
UNC x 2-1/2” long, Gr. 8 bolts (dwg. no. 103814).
cylinder.
10. Fasten the Crown Block Assembly to the upper
Ensure that the angle hole cylinder is attached
mast section with the four 1” UNC x 3” long, Gr. 8
to the raising and lowering section at all times.
bolts. The correct orientation is shown on the mast
assembly in the parts books (dwg. no. 104120).
11. Bolt the Rod Rack to the mast. Use two 3/4” UNC
The operator whom is raising
x 9” long, Gr. 8 bolts and one 3/4” UNC x 6” long,
the mast must read the mast raising procedure
Gr. 8 bolt to fasten it. Once this is secure, attach
and be familiar with the operation of the drill
the helper’s platform and railings to the Rod Rack.
before proceeding.
Attach the stiff legs to the platform.
1. Ensure the mast is installed according to the
12. Attach the rod slide to the rod slide brackets.
previous section. Unfold the mast and attach the
Ensure the slide is attached with the small flare at
rod basket and stiff legs to the mast.
the bottom or the drill head can not be fully raised.
NOTE: If a separate hydraulic valve is being
Refer to drawing #104172 in your Parts Manual for
used downstream from the main control valve
hardware and assembly.
(head circuit) to raise the mast, hydraulic oil will
only be available when all spools in the
upstream valve are in the neutral position.
2. Slowly raise the hydraulic valve lever to begin
raising the mast. Adjust the needle valve to adjust
the speed of raising the mast. Avoid jerky or
erratic motions of the lever or mast. As the mast is
being raised, ensure that the stiff legs from the
mast do not become obstructed by the ground and
the mast doesn’t interfere with any overhead
obstructions.
3. Raise the mast to the vertical position and lock it in
place with the stabilizer bars. Disconnect the
hydraulic hoses from the mast raising cylinder at
the quick-disconnect couplers.
4. Ensure the angling cylinder is connected to the
mast. Connect the hydraulic hoses to the mast
angle cylinders with the matching quick couplers.
Loosen the bolts around the swivel clamp ring and
the retaining ring. Angle the cylinder to the desired
angle. Tighten the swivel clamp ring and retaining
ring bolts. Ensure the stiff legs are chained back to
a solid anchoring point.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 4-05 T Style Mast
Lowering the Mast
1. Loosen the swivel clamp ring and retaining ring
bolts. Raise the mast back to the vertical plane
with the mast angling cylinder. Tighten the swivel
clamp ring and retaining ring bolts. Connect the
hoses to the mast raising cylinder. Remove the
stabilizing bars from the mast. Slowly push the
hydraulic valve lever to begin lowering the mast.
Avoid jerky or erratic motions of the lever or mast.
Printed in Canada MKT1213
Folding the Mast
1. Ensure the mast is in the horizontal plane.
Remove the Helper’s platform and stiff legs. Undo
the six 5/8” UNC x 2-1/2” long, Gr. 8 bolts holding
the two sections together. Slowly, swing the top
section around until it comes in contact with the
bottom section. Chain the two sections together so
that they can not come apart.
Always transport the drill with
the mast down and folded together.
© 03/2002 Boart Longyear Inc.
Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.
 5-01 Hydraulic Explanation
Hydraulic System PRESSURE ADJUSTMENT
SCREW LOCATION
1. General Operation of Hydraulic System
The hydraulic system consists of an oil reservoir
complete with return filter. Oil is routed from the
reservoir to hydraulic pump. The pump pressurizes
the oil and forces it to a four-way, three-spool valve
which directs oil to the swivel head cylinders for
either lowering, raising or feeding the drill string. A
return line carries the low pressure oil from the
control valve back to the return filter in the reser-
voir.
WEIGHT OF
RODS 4-WAY VALVE PUMP
FAST RETRACT Figure 1 - View from Rear of Pump
PRESSURE 3. Recommended Hydraulic Pressure
GAUGE
RETURN
FILTER
Hydraulic pressure should be adjusted to a mini-
mum required, which is normally in the 300 -
HYDRAULIC CYLINDER 500 PSI (2l to 35 kg/sq. cm) range. Although the
3.5” BORE 24.5” STROKE
(2 CYLINDERS) FEED CONTROL hydraulic system is rated for pressures up to
VALVE
l,000 PSI (70 kg/sq. cm.), it is recommended to
Head Cylinder Hydraulic Schematic adjust pressure below 750 PSI (53 kg/sq. cm.) to
avoid excessive oil heating and premature pump
2. Hydraulic Oil Pump wear. 750 PSI (53 kg/Sq. cm.) will be required if
the drill is equipped with an automatic chuck.
The hydraulic pump is a variable displacement type
which maintains a constant preset pressure but
provides only as much flow as is needed by the 4. Hydraulic Fluid Reservoir and Recommended
drilling operation. This eliminates unnecessary Hydraulic Fluid
pump effort and reduces heating of the oil.
The oil level in the hydraulic reservoir should be to
A pump drain line allows a small circulation of oil the top of the sight gauge.
back to the reservoir when no flow is being used by
the hydraulic system. Therefore, this line must The filter hand pump must always be used to fill the
never be disconnected or plugged as stoppage of reservoir as this forces the hydraulic fluid through
this oil low would be extremely injurious to the the filter to assure a contaminate free system.
pump. ANTIWEAR HYDRAULIC OIL
To increase oil pressure, turn pressure- adjustment Hydraulic System Operating ISO VISCOSITY
screw clockwise (figure 1). Decrease pressure by
turning pressure-adjustment screw counter-clock- Temperature Range* Grade
wise. 20°C (68°F) 32
To check the pump pressure, move hydraulic valve 25°C (77°F) 46
lever to the “RAISE” position and allow the head to
come to its top position. Let the system pressure 30°C (86°F) 68
stabilize (about 3 to 4 minutes). The actual pres-
sure setting of the pump can then be read on the Table l: Recommended Oils
gauge. (See Lubrication Chart for complete details)
Do NOT adjust this pressure higher than the Foaming of oil in reservoir indicates air in the
actual drilling conditions require. system or improper type of oil. The air may be
bled from the system by loosening a union fitting.
This union must then be tightened again when all
the air is out.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 5-02 Hydraulic Explanation
5. Hydraulic Fluid Filter
A “10” micron full-flow hydraulic fluid return filter is
installed in the return line from the 4-Way Valve.
This filter continually removes dirt which may get
into the hydraulic system. When the pointer enters
the “red” area on the filter gauge, the filter is be-
coming clogged with dirt. Replace the filter element
when this occurs.
6. Hydraulic Control Valve
A three-spool, four-way hydraulic valve which
controls the raising and lowering of the drill rod is
furnished as standard equipment. The second
spool section of this valve is to be used to operate
the hydraulic chuck when it is furnished. The third
spool section is to be used to operate the hydraulic
retraction or hydraulic wireline when they are
furnished.
For additional illustrations, refer to the Parts List on
this valve in the Parts Section of the owner’s kit.
7. Feed Control Valve and Swivel Head Hydraulic
Cylinders
Instructions for these valves and cylinders are
included in the section on “Hydraulic Swivel Head.”
8. Hydraulic Piping
The hydraulic piping is by means of pipe fittings
and flexible hydraulic hoses. The hoses should be
inspected occasionally for wear due to rubbing on
metal parts and deterioration from grease or other
elements.
Any leak that occurs in the piping can usually be
stopped with a commercial high-pressure pipe
thread sealant applied to the threads and tight-
ening the connection firmly.
Printed in Canada MKT1213
Hydraulic Swivel Head
1. Hydraulic Swivel Head - General Explanation
The hydraulic swivel head incorporates a drive rod
and a three jaw Hydraulic Chuck (or a Mechanical
Chuck), which are raised and lowered by two
hydraulic cylinders. Two swing bolts clamp the
head rigidly to the hinge and clamp ring so that the
bevel gears are in alignment for drilling. After
loosening the lock nuts, the swivel head can be
swung aside to provide clearance for pulling the
rods, or for other operations. The speed range
selector lever located on the main gear case has a
neutral position which allows the drive rod rotation
to be stopped while hoisting.
CAUTION: Do NOT attempt to open the swivel
head while the chuck is rotating. DO NOT pull
the rods through the swivel head.
The swivel head has two functions:
i. To rotate drill rods
A wide range of drive rod rotation speeds is
provided by the speed range selector, thus
eliminating the need of more than one set of
bevel gears.
ii. To advance the rods as they rotate
The drill rods are advanced by hydraulic
pressure applied above the pistons in the
hydraulic cylinders. A feed-control valve in the
piping leading from the bottom of the cylinders is
adjustable to regulate or stop the advance of the
bit.
The top and bottom of the cylinders are piped to
a four-way valve which determines the
downward and upward movements of the
pistons. They hydraulic valve lever controlling
the raising and lowering of the head has four
positions:
RAISE
NEUTRAL
LOWER
FLOAT
When the lever is moved down the LOWER
position, the chuck is forced downward. When
the lever is moved to FLOAT position, the
weight of the rod string will provide the bit force.
© 03/2002 Boart Longyear Inc.
 5-03 Hydraulic Explanation
Cylinder piston ring installation instructions
a. Clean piston with solvent and dry. Inspect
groove and end of piston for nicks or burrs which
could damage the expander or piston rings.
b. Lubricate expander ring with a compatible
lubricant for easier installation.
CAUTION: Make sure that expander is not
twisted or distorted in the piston groove.
c. Install the piston ring onto the piston body and
into the groove in a single motion as quickly as
possible.
CAUTION: Do NOT use pry bars, screw
drivers, knife blades, or any other metal
object to install piston ring.
d. Check cylinder bore for burrs, sharp edges or
foreign materials.
e. After installation of the piston rings, carefully
guide the piston into the chamfered cylinder
bore. If bore is not tapered, use a smooth,
lubricated and tapered piston ring compressor to
facilitate installation.
f. To remove a worn piston ring, carefully cut
through the teflon ring and remove it. Do not cut
into the expander unless it is to be replaced
also. Use care not to damage groove walls and
create burrs or sharp edges.
2. Hydraulic Feed Control
To feed the rods downward, place the four-way
valve in NEUTRAL and close the feed control
valve. Then, clamp the rods in the chuck.
With the pistons in the upper position, the chuck is
tightened and the rods rotating, the downward
drilling stroke is started by moving the handle of the
four way valve down and adjusting the feed control
valve to obtain the desired rate of bit advance.
For deeper drilling operations, the weight of the rods
in the drill string can provide enough bit force for
drilling. The four way valve can then be placed in
FLOAT and the feed control valve adjusted to
obtain the desired rate of bit advance.
Printed in Canada MKT1213
3. Fast Retract Control
This fast retract feature is for the singular purpose
of quickly retracting (raising) the UNCHUCKED
crosshead and drive rod as performed when re-
chucking on a drill string. The ball shut off valve is
to be closed (handle horizontal) at all other times.
This ball shut off valve is located on the swivel
head near the pressure gauge.
To fast retract the UNCHUCKED crosshead, and
drive rod, place the head four way control valve in
the DOWN position and place the ball shut off valve
handle in the OPEN (Upright) position.
CAUTION: Do NOT open the ball shut off valve
when the swivel head is holding rod weight as
with hung rods. The rods will either DROP if
the four valve is in the UP or FLOAT position or
EXCESSIVE pressure may occur in the hydrau-
lic cylinders and if the valve is in the NEUTRAL
or DOWN position.
4. Bevel Gear Adjustment
In the event that the Bevel Pinion Gear be replaced
or a new head installed, the bevel gears must be
adjusted to ensure even tooth mesh.
The adjustment should be made in the following
manner:
a. Put the bit speed selector in neutral.
b. Open the head and clean the bevel gears.
Close the head and tighten the swing
bolts.
c. Remove the inspection plate to allow
access to the gears.
d. Insert the measuring device through the
inspection opening and between the gear teeth.
Manually turn the drive rod in order to draw the
measuring device into the gears. Turn the drive
rod in the opposite direction, in order to retrieve
the measuring device.
e. The recommended backlash is .007-.010". If
the measured backlash is greater or less than
this value, the gear mesh should be adjusted.
This is done by removing the bearing cap bolts
on the top and on the bottom of the swivel frame
to expose the shims under the bearing caps.
From this point in meshing the gears, any shims
removed from the top or the bottom must be
placed in the opposite end to maintain proper
end play in the quill bearings.
© 03/2002 Boart Longyear Inc.
 5-04 Hydraulic Explanation
f. If the backlash is greater than that specified,
move a shim from the bottom of the frame to the
top. Replace the bearing covers and again
measure the backlash. Continue until the proper
backlash is obtained.
NOTE: The measuring device could be a
plastic shim or ordinary writing paper. If the
paper is used, the gears should mark three
layers severely and four layers of paper
should not go through.
grease that will stick to the teeth of the gears each
time the head is opened.
When the swivel head is open for a long period of
time, the bevel gears should be covered to protect
them from sand, grit or other foreign matters. If
sand or grit does come in contact with the bevel
gears, they must be thoroughly cleaned and new
grease applied. They should be checked and
cleaned regularly to prevent excessive wear.

5. Chucking
Hydraulic Chuck
To open the chuck jaws, move the chuck operating
control handle to position OPEN so that the hood
rises. Lock the hood in RAISE position by return-
ing the control handle back to NEUTRAL position.
To close the chuck jaws, move the handle to
CLOSE position and hold in this position until
chuck cylinder comes to a rest. Return control
handle to NEUTRAL position.
NOTE: Never actuate chuck while it is rotating.
Never rotate spindle with chuck open. Drill
pump pressure must be set at 750 PSI (53 kg/sq.
cm) to open chuck.

6. Lubrication
Grease fittings are provided so bearings and
running parts can be properly lubricated. See
LUBRICATION CHART in on pages 8-02 and 8-03
for recommended greases and location of fittings.
The bevel gears should be coated with a good

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 6-01 Drilling Operations
Force on Diamond Bit Bit Pressure Table
Note - If the drill is equipped with accessory Off Pressure Downward Force on Bit
instrumentation kit, see operation of bit weight
indicator in accessory attachment section. PSI (mPa/Sq Cm) Pounds (N)
The force exerted on the diamond bit while drilling 100 0.9 1,920 8 540
is approximately equal to the weight of the rods and 200 1.4 3,840 17 081
the down force exerted by the hydraulic cylinders. 300 2.1 5,760 25 621
This force id difficult to measure directly but can 400 2.8 7,680
easily be found by the following 500 3.5 9,600 34 162
OFF PRESSURE” method: 600 4.2 11,520 51 244
700 4.8 13,340 59 784
1. First, suspend the rods with the hydraulic swivel
head
2. As the rods are lowered, and the bit makes contact,
the amount of the pressure reading decreases and
can, for convenience, be called the “OFF
PRESSURE”.
NOTE: The four way valve control handle must
be in the same position and the engine should
be operating at approximately the same speed
while reading the OFF PRESSURE.
3. The OFF PRESSURE multiplied by the effective
area of the hydraulic cylinders (19.2 sq. in 124 sq.
cm.) for both 3” and 3 7/8” heads) will give the
downward force exerted on the diamond bit.
Example:
Hydraulic Pressure with rods suspended
400 PSI (2.8 mPa/sq.cm)
Hydraulic Pressure with bit fed into rods
300 PSI (2.1 mPa/sq.cm)
Off Pressure is the difference
100 PSI (0.7 mPa/sq.cm)
Total force on bit =
19.2 sq.in x 100 PSI 1,920 lbs
(124 sq.cm) x (0.7 mPa/sq.cm) (8540 N)

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.
 7-01 Accessory Attachments
Wireline Hoist - Mechanical
The wireline hoist is used for spooling the light wire
cable used in retrieving the wireline core barrel inner
tube from the hole. It may also be used for handling
testing and surveying equipment in the hole. The
wireline hoist is furnished with a power take off that
fits on the side of the four speed transmission.
The control levers for operating the hoist are
located on the operator’s side, midway between the
engine and drill main gear case. One push/pull knob
engaged (out) and disengaged (in) the PTO gears.
Always disengage the main drill clutch when
engaging the PTO gears. Avoid unnecessary wear
by disengaging the PTO, when the wireline hoist is
not in use. The levers for operating the spool are
side by side with the brake lever on the swivel head
side. Either lever is actuated by pulling toward the
operator.
Printed in Canada MKT1213
Hydraulically Driven Water Pump
The water pump is driven by a variable displace-
ment hydraulic pump complete with load sensing.
The Load Sensing Pump Provides the exact flow
and pressure required to run the system. When no
flow is required, the pressure drops to 250 PSI. the
result is a fuel efficient hydraulic system.
Pressure Settings
The recommended setting for the pump pressure is
1200 PSI.
A pressure gauge is inserted between the pump
and the flow control valve and the flow is blocked at
the hydraulic motor.
The pressure compensator adjustment screw (see
page ??) is turned clockwise to increase pressure
and counter clockwise to decrease pressure.
Note : The maximum pressure setting for this
pump is 3000 PSI. However, operation at this
pressure will reduce the life of the pump.
© 03/2002 Boart Longyear Inc.
Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.
 8-01 General Maintenance
Drill Specifications and Drill Capacities Drill Servicing Instructions
Engine and Drill Capacities Battery Servicing (Diesel and Gasoline Units
Only)
For fuel tank, radiator and crankcase capacities,
see engine manufacturer’s catalogue. Check water level in battery once weekly, and if
necessary, fill to proper level with DISTILLED
Note: An additional quart of oil is required on WATER.
all the above engines when the filter is replaced.
Four Speed Transmission 3.8 L (4 Quarts)
Oil Capacity Hydraulic System Servicing
Hoist Transmission 6.6L (7 Quarts) 1. Hydraulic Fluid - Maintain the oil level in the
Oil Capacity Main Gear Case hydraulic reservoir to the top of the sight gauge.
See section 1.4 for recommended hydraulic fluid.
Hydraulic Reservoir 15 L (40 U.S Gallons)
Oil Capacity 2. Hydraulic Fluid Filter Element - Replace fluid filter
element whenever pointer enters the red area on
the pressure gauge.

Lubrication of Drill
See Lubrication Chart for Specification of
Lubricants. Refer to Lubrication Chart (next page).

Hydraulic Chuck
Refer to Automatic Chuck Service Manual at end of
Parts List.

Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.

 Item Description Location Number of Lubricant Lube Quantity Change Level Check
Lube Points Type Method (U.S.) Interval (hrs) Interval (hrs)
8-02

1 Power Unit See Manufacturer’s Operation and Service Manual 8

2 Bevel Gears Inside Swivel Head 1 MPG Pack, Hand or Brush Cover Teeth 4 4
3 Drive Rod Hydraulic Head 6 sides MPG Pack,Hand or Brush Sparingly **4 4
4 Roller Chain Wireline Hoist Wireline Hoist 1 Engine Oil Brush or Can Sparingly 4 4
5 Brake and Clutch Linkage Wireline Hoist 12 Engine Oil Can Sparingly 8 4
6 Quill Bearing Hydraulic Head 2 MPG Grease Gun 2-3 Shots 8 8

Printed in Canada MKT1213

7 Cross Head Bearings Hydraulic Head 1 MPG Grease Gun 2-3 Shots 8 8
8 Planetary Gear Teeth Inside Clutch Drum 2 MPG Grease Gun 2-3 Shots 8 8
9 Planetary Gear Bearings Inside Clutch Drum 2 MPG Grease Gun 1-2 Shots 8 8
10 Gear Shaft Bearings Main Hoist 1 MPG Grease Gun 2-3 Shots 8 8
11 Clutch Actuating Bearing Inside Clutch Housing 1 MPG Grease Gun 1-2 Shots 24 24
12 Drive Shaft Bearing Clutch Housing 1 MPG Grease Gun 1 Shot 50 50
13 Cam Follower Operators Side of Drill 4 MPG Grease Gun 1 Shot 50 50
14 Fairlead Roller and Guide Rollers Side/Front of Drill 6 MPG Grease Gun 2-5 Shots 50 50
General Maintenance

15 Guide Rails On Retraction Frame Retraction Rails 6 MPG Grease Gun 2-4 Shots 50 50
16 Fairlead Sheave Underside of Drill 1 Engine Oil Oil Can Sparingly 50 50
17 Shaft - Clutch Clutch Housing 2 Engine Oil Oil Can Sparingly 50 50
18 Case-Main Gear Case-Main Gear 1 Gear Oil Change 7 Quarts (6.6 l) 400 24
19 Transmission 4 Speed Under Hoist Drum 1 Gear Oil Change 4 Quarts (3.8 l) 400 24
20 Shaft Bearings -Wireline Hoist Wireline Hoist 2 Sealed For Life
21 Pilot Bearing- Cutch Shaft Clutch Shaft 1 Sealed For Life
22 Hoist Drum Bearings Hoist Drum 2 Sealed For Life
23 Drive Shaft Assembly Engine to Clutch 3 MPG Grease Gun 2 Shots 50 50
24* Hydraulic Reservoir Hydraulic Module 1 Hyd Oil Change 38Gals (144 l) 8 months 8 months

Options
Hydraulic Wireline Hoist Flange Bearing 1 MPG Grease Gun 2-3 Shots 60 168
Water Pump* See Pump Manufacturers Specifications
Mud Mixer* Separate 2 MPG Grease Gun 2-3 Shots 60 168
Rod Clamp* Base of Drill 2 MPG Grease Gun 2-3 Shots 60 168
Auto Chuck* Head - See Automatic Chuck Service Manual
Crown Block Assembly T Mast Top Of Mast 4 MPG Grease Gun 2-3 Shots 8 168
Lower Mast/ Draw Works Pivot Near Control Panel 2 MPG Brush/Hand Coat Shaft Upon Assembly 168

* Not Shown
** (Every hr during 1st wk of break in)

LUBRICATION CHART
LY 38 DRILL ASSEMBLY
SHEET 1 OF 2

© 03/2002 Boart Longyear Inc.

 © 03/2002 Boart Longyear Inc.
Lubricant Code
Winter Summer Hot Climate
Start Up Temp Low -26° C -22° C N/A
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 .
Colder Start - up preheat engine and hydraulic oil in a safe manner (No Open Flames)
Operating Temp High 20° C 25° C 30° C
Engine Oil - SAE Grade See Engine Manufacturer’s Specifications
Hydraulic Oil - ISO Grade 32 46 68
- Imperial Oil Nuto H32 Nuto H46 Nuto H68
- Shell Tellus T32 Tellus T46 Tellus T68
- Chevron AW MV 32 ISO VG 46 ISO VG 6846
- Mobil DTE13M DTE15M DTE16M
Not Affected by Temp
Gear Oil -SAE Grade 80W90
- Imperial Oil GX-80W90
- Shell Spirax80W-90
- Chevron Delo 80W-90
- Mobil Mobilube HD 80W90
MPG (Multipurpose Grease)
- Imperial Oil Unirex EP 2
- Shell Darina XL EP 2
- Chevron Ulti-Plex EP2
General Maintenance

- Mobil Mobilux EP2

Mobilith AW 2
Filter Reference Chart
Item Filter Description Filtration Filter Element Qty Service Remarks

Printed in Canada MKT1213

Part Number
1 Main Return Filter 10 Micron 37874 2 Change element when visual
Bypass Valve indicator displays to do so or
@ Hydraulic oil change. LUBRICATION CHART
Indicator #060364.
LY 38 DRILL ASSEMBLY
8-03

SHEET 2 OF 2
Printed in Canada MKT1213 © 03/2002 Boart Longyear Inc.