700rc Ops Manual

KWL700RC
Operations and
Service Manual
and
Parts List
PRINTED IN AUSTRALIA
© 2009 Boart Longyear Pty Ltd Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice.
Equipment Record
Rig serial no.:
Location of Manufacture:
Engine Manufacturer:
Engine model no.:
Rotation Pump serial no.:
Feed Pump serial no.:
Water Pump serial no.:

TABLE of CONTENTS
Section 1 General Introduction
1-2 General Information
1-3 Hazard Signal Words
1-4 Boart Longyear Limited Warranty
1-6 Ordering and Returning Spare Parts
1-7 Safety
Section 2 Drill Introduction

2-2 General Drill Arrangement
2-3 KWL700RC Tech Data Sheet
Section 3 Drill Components

3-2 Base Frame Assembly
3-3 Vee Pack Cooler
3-4 Triple Drive and Pump Group Assembly
3-6 Power Pack and Compressor Assembly
3-8 Hydraulic Reservoir
3-10 Mast Arrangement
3-12 Drive Head Gearbox
3-14 Traverse Chains
3-15 Hose Reeler
Lighting
Air Dump Valve
3-16 Control Panel
3-18 Upper Auxilliary Control Valves
3-19 Centre Auxilliary Control Valves
3-20 Lower Auxilliary Control Valves
3-21 Feed System Control
3-22 Main Control Valves
3-24 Torque Controller
Table of Contents (cont’d)
Section 4 Drilling Operations

4-2 Introduction
4-4 Visual Inspection of Masts
4-6 Pre-Start Procedure
4-7 Emergency Alarm System
4-8 Safety Systems
4-10 Engine Operation
4-11 Drill Rig Setting Up
4-14 Water Pump
4-15 RC Boom
4-16 RC Winch
4-17 Survey Winch
4-18 Hydraulic Drill Rod Make / Break Tool
Hydraulic Slips
4-19 Air Compressor
Section 5 Hydraulic Explanation

5-2 Hydraulic Circuit Overview
5-3 Hydraulic Circuit Diagram
5-5 Hydraulic Pumps
Section 6 Drill Rig Maintenance

6-2 General Maintenance
6-4 Engine Maintenance
6-5 Lubrication Points
6-6 Filtration
Section 7 Start Up Procedure

7-2 Cooling System Bleeding Procedure
7-3 Pre-Start Requirements
7-11 Control Panel Pre-Start Check List
7-12 Settings
7-17 Raising the Mast
7-18 Cooler Fan Settings
7-19 Standby Settings
Section 8 Electrical System

Details still to be supplied
Section 9 KWL700RC Parts List

The KWL700RC Parts List is located at the rear of the Operations
and Service Manual.
The contents list for the Parts List appears on pages 9-2 to 9-5.
SECTION 1
General Introduction
1-2 General Information
1-3 Hazard Signal Words
1-4 Boart Longyear Limited Warranty
1-6 Ordering and Returning Spare Parts
1-3 Safety
Safety Awareness
General Introduction 1-2
General Information
The purpose of this manual is to furnish the operator with detailed information
which will enable him to achieve the maximum operating performance
from his drill. It will also give information necessary to perform preventative
maintenance and make minor repairs and adjustments.
Parts Lists, with corresponding views to aid in ordering parts, are also
included.
Boart Longyear is backed by over 100 years of experience in the design,
manufacture and operation of core drilling equipment. Many of the accepted
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 questions arise.
Important Note
Do not start or operate the drill until you have read this manual and
understand its contents.
Hazard Signal Words

Hazard signal words are used throughout this manual. They appear in the
narrow left-hand column of numerous pages and, with their additional text
description, are intended to alert the reader to the existance and relative
degree of a hazard.
DANGER indicates an imminently hazardous situation which, if not avoided,

will result in serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided,

could result in serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided,

may result in minor or moderate injury.
Boart Longyear Limited Warranty

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.
Capital Equipment. Boart Longyear warrants that the capital equipment
manufactured by it is free from defects in materials and workmanship for a
period equal to the lesser of (i) one (1) year after the date of shipment, or (ii)
the initial 1,000 operating hours. Boart Longyear warrants for a period of six
(6) months after the performance of related services that such services are
performed in a professional and workmanlike manner.
General Terms. Boart Longyear further warrants that, to the extent applicable,
as of the date of shipment or performance, all goods manufactured by it and
services performed shall conform to the written specifications agreed between
the parties. THIS IS BOART LONGYEAR’S ONLY WARRANTY. BOART
LONGYEAR MAKES NO OTHER WARRANTY, INCLUDING WITHOUT
LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE. As a condition to Boart Longyear’s warranty
obligations, any goods claimed to be defective under the foregoing warranty
must be returned to the facility designated by Boart Longyear, which return
shall be made promptly upon Purchaser’s discovery of the alleged defect.
With respect to consumable products purchased through an authorized Boart
Longyear distributor, the party making the warranty claim must also deliver
to Boart Longyear reasonable evidence of the date of purchase. Boart
Longyear shall perform its examination of the goods so returned by Purchaser
and shall report the results of its examination to Purchaser within thirty (30)
days following its receipt of such goods from Purchaser, or, if longer time is
required to complete such examination, within such time as would be required
through the exercise of reasonable diligence. As a further condition to Boart
Longyear’s obligations hereunder for breach of warranty, Purchaser shall
offer its reasonable cooperation and assist Boart Longyear in the course of
Boart Longyear’s review of any warranty claim. If requested by Purchaser,
Boart Longyear will promptly repair or replace at Boart Longyear’s expense
goods that are non-conforming according to Boart Longyear’s warranty as
set forth herein. All removal and installation of goods shall be at Purchaser’s
expense. Boart Longyear reserves the right to reimburse Purchaser for an
amount equal to the purchase price of any defective goods in lieu of providing
repaired or replacement goods. Anything contained herein to the contrary
notwithstanding, in no event shall Boart Longyear be liable for breach of
warranty or otherwise in any manner whatsoever for: (i) normal wear and tear;
(ii) corrosion, abrasion or erosion; (iii) any goods, components, parts, software
or services which, following delivery or performance by Boart Longyear, has
been subjected to accident, abuse, misapplication, modification, improper
repair, alteration, improper installation or maintenance, neglect, or excessive
operating conditions; (iv) defects resulting from Purchaser’s specifications
or designs or those of its contractors or subcontractors other than Boart
Longyear; (v) defects associated with consumable parts or materials, the
lifetime of which is shorter than the warranty period set forth in this Section;
(vi) defects associated with Purchaser’s specifications or designs or those
of its contractors or subcontractors other than Boart Longyear; (vii) defects
resulting from the manufacture, distribution, promotion or sale of Purchaser’s
own products; or (viii) accessories of any kind used by the Purchaser which
are not manufactured by or approved by Boart Longyear.
Sourced Goods. If the defective parts or components are not manufactured
by Boart Longyear, the guarantee of the manufacturer of those defective
parts or components is accepted by the Purchaser and is the only guarantee
given to the Purchaser in respect of the defective parts or components.
Boart Longyear agrees to assign to the Purchaser on request made by the
Purchaser the benefit of any warranty or entitlement to the defective parts or
components that the manufacturer has granted to Boart Longyear under any
contract or by implication or operation of law to the extent that the benefit of
any warranty or entitlement is assignable.
Boart Longyear Pty Ltd

919 Marion Road, Mitchell Park
South Australia 5043 Australia
Telephone +618 8375 8375
Fax +618 8377 0534
© Boart Longyear 2008

Ordering and Returning Parts

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, i.e. Parcel Post, Express, Freight; and for
Overseas shipment, Air Freight, Air Parcel Post, or Ocean Freight.
All parts are priced F.O.B., our factory and separate charge will be made for
transportation and export packing.
Returning Parts
1 If you desire to return parts, whether for repairs, replacement or warranty,
an email or a fax should first be sent to the Boart Longyear Sales Manager
in your region.
This should specify quantities and part numbers, and model and serial
number of the product, as well as the reason for requesting the return.
2 DO NOT ship parts until authorization and shipping instructions are
received.
3 All parts returned must be prepaid.
Safety
When operating and commissioning this drill rig bear in mind you will be
required to work in close proximity to:
• Rotating objects
• High temperature surfaces
• Pinch points and squashing areas.
Be prepared to work above and under steel platforms.
You will be required to:
1 Wear appropriate Personal Protective Equipment (PPE).

(Safety boots, glasses, hard hat, and earplugs must be worn.)
2 You must be familiar with the operations of the rig.
(Refer to Section 1 “Operations” of this Manual for full details of rig
operation.)
3 Ensure all personnel are trained in the lock out and tagging procedures,
and have their own lock out device and tag.
4 Have clear access to an eyewash station.
5 Barricade the drill rig and fit warning signs alerting personnel of
commissioning in progress.
Analyse Your Risk:

• Spinning drill rods can maim or kill
• Loose clothing has killed
• Unsecured air hoses have killed
• Falling components have killed.
Safety is Your Responsibilty

If you are unsure whether a particular task is safe or not stop ask
questions.
If you are unsure or do not understand any instructions in this manual
stop and ask questions.
Safety Awarness
• Rotating drill rods can be fatal.
• Power line contact can be fatal.
• Loose clothing can be fatal.
• Unsecured air hoses can be fatal.
• Falling components can be fatal.
• Never enter the acoustic cover with engine running as this is a dangerous
area.
• When entering the acoustic cover with engine stopped beware of heated
components.
• Please think safe and work safe. Assess your risk correctly.
• Beware — falling items can cause serious injury or death.

SECTION 2
Drill Introduction
2-2 General Drill Arrangement
KWL700RC Tech Data
Drill Introduction 2-2
General Drill Arrangement
Vee Pack Cooler
Truck
Hydraulic Oil Tank
Mast Ladder
Right Hand Side
Mast Raise Cylinder
Head Assembly
Mast
Jack
Legs
Power Pack
Left Hand Side

Jack Legs Control Cabinet
KWL700 Drill
Technical Data Sheet
October 2007 - MKT1779 Page of 11
PRODUCT OVERVIEW
The KWL700 RC (Reverse Circulation) drill
is the largest of all Boart Longyear drills. Its
robust design features 40 000 kg (88,183 lb)
of pull back, a 38 m3/min at 34.5 bar (1,350
cfm at 500 psi) compressor, along with the
highest quality hydraulic pumps and motors
available in order to create a powerful and
reliable drill that can cope with the toughest
conditions. This rig delivers operational oil
flows at only 1500 rpm decreasing wear and
fuel consumption, while improving reliability.
The KWL700 also features the markets most
versatile RC Rod Handler.
DRILLING DEPTH GUIDELINES

Drilling capacities have been calculated from theoretical values to arrive at the above capacities. Therefore these values are
of the pull back system with 40% deduction for efficiency losses indicative only and depend on drilling conditions.
CAPACITY
RC ROD: 114.3 mm (4-1/2 in) METRIC SYSTEM U.S. CUSTOMARY SYSTEM
DEPTH 775 m 2,542.7 ft
RETRACT FORCE (max) 40 000 kg 88,183 lb
RETRACT SPEED (max) 930 mm/sec 36.6 in/sec
RAPID PULL DOWN FORCE 20 000 kg 44,100 lb
RAPID PULL DOWN SPEED 930 mm/sec 36.6 in/sec
OIL SUPPLY 765 lpm 202 gpm
ENGINE SPEED 1,600 to 1,850 rpm max
Boart Longyear is constantly striving to improve its products and must therefore, reserve the right to change designs, materials, specifications and price without notice. Copyright © 2007 BOART LONGYEAR CANADA
KWL700 Drill
TECHNICAL SPECIFICATIONS
METRIC SYSTEM U.S. CUSTOMARY SYSTEM

MAST
Design Open face SHS and RHS lattice frame with 2 mm (0.08 in) infill plates to rear face of mast
Overall Length 13.57 m 44.52 feet
Width 1 050 mm 41.34 inch
Depth 700 mm 27.56 inch
TRAVERSE ACTUATION
Feed Cylinder Dual 127 mm (5”) bore X 88.9 mm (3.5”) rod cylinders x 4 m (13 ft) stroke
Feed Cylinder Orientation Inverted compression when in retraction mode
Head Traverse Length 8 m 26.25 feet
Cylinder Rod Guards Sliding rod guards with nylon wear pads
Retract Speed (Fine Feed) 100 mm/sec 3.9 in/sec
Retract Force Hydraulic Pressure 310 bar 4,500 psi
Pull Down Hydraulic Pressure 207 bar 3,000 psi
Fine Feed Hydraulic Pressure 207 bar 0 - 3,000 psi
Fine Feed Control Infinite adjustment — feed down, hold back, feed up
Fine Feed Pull Down Force 16 000 kg 35,000 lb
Fine Feed Speed 193 mm/sec 7.6 in/sec
Pull Back Chain Tsubaki 180 DC
Chain Adjuster (Head Alignment) 100 mm (3.94”) adjustment
Pull Down Chain Tsubaki RS160HT
ROTATION DRIVE HEAD

Model Air drill rotation head
Gears Hardened and ground spur gears
Spindle Bore 75 mm 2.95 inch
Drive Motor Dual Danfoss OMVW 500
Drive Head Control Infinite (0 to 133 rpm) via friction lock joy stick
Forward Rotation: screw adjustable with 34.5 bar (500 psi) boost switch
Torque Controller
Reverse Rotation: screw adjustable
Drive Head Guide Cradle Heavy duty low friction nylon wear pads
Head Plate Alignment Adjustable nylon wear blocks at either end of each head slide plate (x4)
TORQUE AND RPM RATINGS

Speed infinitely variable: 0 to maximum rpm
Torque infinitely adjustable: 0 to maximum
Displacement Oil Flow Torque Output Speed
cm3/in3 US•gpm Nm lbft RPM
Engine Speed 1600 rpm 3.5:1 500/61 105 12 073 8,903 108
Engine Speed 1800 rpm 3.5:1 500/61 122 12 073 8,903 133
KWL700 Drill

DUMP MAST
Stroke 2.5 m 8.2 feet
Dump Mast Cylinders Dual 101.6 mm bore x 88.9 mm rod (4” bore x 3-1/2” rod)
BOOM WINCH
Drum Capacity 20 m 65.5 feet
Rope (1960 Caser High Capacity) 10 mm 0.39 inch
Minimum Breaking Load 9140 kg 89.6 kN
Aggregate Breaking Load 11 380 kg 111.6 kN
Hoisting Capacity (full drum) 750 kg 1,654 lb
Rope Length 19 m 62 feet
Rope Usable Length 15 m 49 feet
Static Braking Spring applied/hydraulic release
Dynamic Braking Over-center valve
Mounting Underside of RC boom arm
Rope Fixing Drum recess clamping
SURVEY WINCH
Drum Capacity 1 000 m 3,281 feet
Rope (Galvanised) 6 mm 0.24 inch
Minimum Breaking Load 2000 kg 19.6 kN
Aggregate Breaking Load 2570 kg 25.2 kN
Hoisting Capacity (full drum) 1 112 kg 2,451 lb
Hoisting Speed 4 m/sec 13 ft/sec
Static Braking Over-center valve
Dynamic Braking Over-center valve
Mounting Rear of RC boom
Hydraulic Motor SAI GM2
RC BOOM
Drum Capacity SWL 750 kg 1,653 lb
Boom Slew System Reduction gearbox with inbuilt brake
Slewing Degrees 330° (extra travel suit lifting acoustic pack)
Extension Distance From Mast Centre
4 m 13 ft
Line
Boom Retracted Length 750 mm 29.5 inch
Functions Slew, tilt (slew with automatic stops)
RC Haul Winch Mounted on RC boom
KWL700 Drill

ROD TROUGH
Drill Rod Alignment Guide Trough with adjustable heights
Mast Guide Collision Protection Rapid retract when control returned to neutral
ROD HANDLER
Model KWL rod handler
HOSE REELER
Suspends all drive head traveling hoses, keeping them away from operator and in tension to prevent
snaring and hose damage
BASE FRAME ASSEMBLY

Length 7.95 m 26 feet
Width 2.8 m 9.19 feet
Decking 2.5 mm flat plating
Mast Tilt Cylinders 152.4 mm bore x 88.9 mm rod (6” bore x 3-1/2” rod) Rod: 4140 grade dual heavy wall
Raise Cylinder Force 82 250 kg 180,955 lb
Mast Angle Locking Hydraulic cylinder locking system (hands free - vertical to 45°)
JACK LEG ASSEMBLIES

Style Encased RHS
Hydraulic Cylinders 107.95 mm (4.25”) bore X 1.2 m (3.94 ft) stroke
Lift Capacity (per leg) 19 950 kg 43,982 lb
Fixing Welded to main base frame
Locking Over centre valves
POWER PACK
Engine MTU 12V 2000 series
Configuration 90° V12 cylinder
Electrical System 24 volt
Displcement 23.9 L 1,458 inch3
Power (intermittent) @ 1800 RPM 634 kW 850 HP
Engine Speeds 1800 - 2100 RPM
Peek Torque 3 682 Nm 2,715 lb/ft
Control Display DDEC 1V electronic controls with auxiliary interface module
Estimated Fuel Burn 148 L/hr 39 gal/hr
Air Filtration Large dual Donaldson FVG16 with safety elements
Pre-Cleaners Centri turbo cleaners
Exhaust System Special low back pressure with low sound pressures — 250 mm (9.8”) outlet
Mounting Direct to base frame with 3 point pivot
KWL700 Drill

POWER PACK (cont’d)
Pump Group Gear products 38c triple pump drive 1:1 ratio
Pump Group 1 Denison P16 (rapid traverse – up), TD6CC triple vane (water pump, auxiliaries, fine feed)
Pump Group 2 Denison P16 (rapid traverse – up and down), Denison P07 (cooler fan)
Pump Group 3 Denison P16 (rotation), P05 (Rod Handler)
Pump Drive Coupling Centreflex 400 series with floating spigots (protecting crank end thrust)
Other Remote engine sump drain
Remote pump drive oil drain
Remote compressor oil drain
Fuel Primer Electric, mounted low on fuel tank
Engine Cooler Hose Silicon
CONTROL CONSOLE
Position L/H rear corner of rig base
Extension 1000 mm (39.4”) travel to facilitate visibility of work table whilst angle drilling
Yaw Cabinet slews 30° away from mast to facilitate visibility of work table
Engine ECM Display Mounted in console fascia
Pilot Control Levers Sigma TH7 spring centered
Gauges 100 mm and 65 mm (3.94” and 2.56”) gauges to monitor all hydraulic pressures
Console Access Hinged access doors both sides of console
Platform Fold up ‘jump up stand’ for operator
Cyclone Shutter Dual Norgren 5/2 valves
Lever 1: rapid feed, rotation
Pilot Control Lever Functions
Lever 2: winches
Auxiliary Valves Danfoss PVG 32 L/S
Main Load Sense Control Valve
Rapid feed Denison Lokomec CVG51
Rotation Denison Lokomec CVG31
Water Pressure Panel mounted — 0-69 bar (0-1000 psi)
Torque controller (multi-purpose) Forward rotation: screw adjustable with 34.5 bar (500 psi) boost switch
Reverse rotation: screw adjustable
Labels Stainless steel engraved and riveted to cabinet fascia
CENTRAL GREASE STATION

Location L/H side rear main base
Grease Points All stationary grease points (not traveling points)
KWL700 Drill

HYDRAULIC TANK ASSEMBLY
Capacity 600 L 145 US gal
Baffle / De-aeration Central baffle with lower corner oil flows
Filtration Return Single stand alone 5000 series pall flange mount — 1500 L (396 US gal) capacity
Material 4 mm (0.16”) aluminum grade 5005
Position Between cooler and compressor
Breather Pall tank top
Low Oil Level Engine shut down via DDEC – AIM module
Bleed Line Filtration Pall in tank suit total bleed lines
WATER PUMP
Water Pump FMC E0413H.D
Water Pump Pressure 69 bar 1,000 psi
Fluid Delivery 56 Lpm 14.9 US gpm
Maximum Pressure 103 bar 1,500 psi
Input 700 rpm maximum
Cylinders Four (4)
Hydraulic Drive Motor Danfoss LSHT
Water Flow Control Screw adjustment at operator’s console — 0 to maximum
Water Pump Outlets Water injection, dust suppression and washing down
HAMMER OIL
Brand KWL
Type Hydraulic pump delivery
Control Operator’s console
Flow Control Screw adjustment at operator’s console
Tank Capacity (Aluminium) 40 L 10.6 US gal
HYDRAULIC OIL COOLER

Brand/Model Dynaflow 32/15
Position Mounted in Vee Pack cooler
Hydraulic Oil Heat Rejection 45 kW 2,560 BTU/min
HYDRAULIC HOSES AND FITTINGS

Hose Type Aeroquip
Fittings (subject to availability) Aeroquip and Ryco
KWL700 Drill

POWER BREAKOUT STD
Type Hydraulic cylinder
Tool Wrap around spanner
Size (diameter) 114.3 mm 4.5 inch
Operation Operator’s console
Adjustment Hydraulic vertical
AUTO POWER BREAKOUT

Brand Airdrill single unit
Parking Hydraulic rack back in rear of mast
Functions Extend-clamp make and break (3 lever control)
Size to Suit RC Drill Rod 114.3 mm 4.5 inch
Control Lever controls at operator’s console
Clamping Torque Screw adjustable at operator’s console with pressure gauge — 0 to maximum torque
DRILL ROD SPANNERS (2)

Rod Size (client to specify) 101.6 or 114.3 mm 4 or 4.5 inch
Controls Foot actuated
Actuation Air cylinders
Material Bisalloy 500
Spanner Action Top: foot pedal with spanner auto return
Bottom: foot pedal with detent positioning
SLIPS TABLE
Table Style Metzke
Opening (maximum) 305 mm 12 inch
Slips Hardened inserts
Control Hydraulically adjustable
AIR/FLUID MANIFOLD
Valves 50.8 X 50.8 mm (2 x 2 inches) Worchester valves with high temp seals
Size 50 mm 2 inch
Pressure 103 bar 1500 psi
Seals High Temperature
Air Inlets Auxiliary and booster
Location Below deck (where possible)
Activation Operator’s console
Positioning Left hand front corner of main deck
Terminations Restrained by wire socks and dual anchor points
Discharge Valve Air Flow Angles Vertically down (safety)
Airline Dumping Valve Lever operated
KWL700 Drill

ELECTRICAL SYSTEM
Voltage 24 volts
BATTERY (x2)
Type 12v N200
Position Enclosed steel case with removable side below rig deck
Isolators Dual pole at battery
Access Easy access in emergency
Type Key activated
Locking Gang padlocking
COMPRESSOR
Brand Sullair oil flooded screw
Flow 38.2 m3/min 1,350 cfm
Air Pressure 34.5 bar 500 psi
Air Pressure Control Console Switching — 14.5/24.1/34.5 bar (210/350/500 psi)
Receiver Tank Large Sullair tee tank
Gear Ratio 2.61:1
Power Draw 474 kW 636 hp
Filtration Dual Donaldson FVG 16 with pre-cleaners
Inlet Valve Poppet style
VEE PACK COOLER

Style Vee Pack
Core Material Aluminum cad plated
Hydraulic Fan Drive Motor Volvo F12 axial piston
Fan Blade Multi-wing 630 mm (24.8”) diametre
Heat Displacement @ Max Power Draw 46,435 BTU/min
Air Discharge Vertical
Fan Speed Control Thermal — L/S Denison P07 piston pump
FINISH
All steel sand blasted to white metal
Undercoat and topcoat - polyurethane two pack paint
All components painted prior to assembly
ROD BIN
Standard 3 tilting plates to suit load and unload position with hinged head and toe boards
KWL700 Drill

FIRE SUPPRESSION
Description Auto heat activation plus manual activation at console and RHF jacking leg
Two (2) hand held fire extinguishers at front and rear of rig platform
ADDITIONAL SAFETY FEATURES

Emergency Stop at operator’s console and two at front corners of rig base
Hose socks on all high-pressure air hoses fixed to anchor points
Access steps mounted into rig base (2 locations)
Mast traveling air hose has hard sheath cover and full S/S safety sock covering full hose length
AIR SWIVELS
Air Swivel/Blowdown System Westrod top air swivel and blowdown system
Sample Pipe Fabricated with sacrificial wear points
MANUALS ????????????????
Operators (x2) Standard operating and safety procedures
Spare Parts (x2) Boart Longyear manufactured components and hydraulic circuits
WARRANTY
Six (6) months against faulty workmanship
Individual manufactures warranty on all componentry as per our terms and conditions of sale
COMMISSIONING
Upon commencement of normal drilling operations, BL to coordinate on-site commissioning with
client
Travel and accommodation costs at clients expense
KWL700 Drill
October 2007 - MKT1779 Page 10 of 11

OPTIONS
Acoustic Cover
Location Encloses engine and compressor
Access Large removable doors for maintenance
Air Flow Large air inlets with roof mounted sucker fan - hydraulic driven
Material Aluminum frame with dense foam filling
Fuel Tanks
Capacity 1 080 L 285 US gal
Type Dual aluminum round
Mounting Below drill rig base one per side
Fuel Level Gauge at operator’s console and truck instrument panel
Slips Table
Table Style Metzke
Opening (maximum) 405 mm 16 inch
Slips Hardened inserts
Control Hydraulically adjustable
Ladder Mounted on right hand side of mast
Fitted with lanyard rope that allows a harness to be attached for ascending mast when vertical
Note: may not be available with some rod handler configurations
Cyclone Pivot Frame
Position Mounted to left hand rear jack leg outer
Valving Dual hydraulic valves suit cyclone raise and splitter slewing
Cyclone Supplied by client and mounted by KWL
Frame Folding Hydraulic cylinder
KWL700 Drill
October 2007 - MKT1779 Page 11 of 11
DIMENSIONS AND WEIGHTS*
WEIGHT
Weight = 30 000 kg (66,000 lb) approx. Consisting of:
Mast with Rod Handler
Hydraulic Module c/w Control Console
Boom and Survey Winch and RC Boom
Engine Power Group and Pump Group
Rotation Drive Head
Base Frame and Jack Leg Assembly
Compressor and Vee Pack Cooler
Hammer Oiler
Water Pump
DRILL - TOP VIEW
a = 2 796 mm (110.08 in)

b = 2 665 mm (104.92 in)
c = 7 950 mm (312.99 in)
a
d = 2 938 mm (115.67 in)
b c d
DRILL - SIDE VIEW
a = 13 553 mm (533.58 in)

b = 3 288 mm (129.45 in)
c = 751 mm (29.75 in) b
d = 1 250 mm (49.21 in)
Jack Leg extended
e = 7 245 mm (285.24 in)
f = 350 mm (13.78 in) c
d
f e f
a
Rig Carrier (by Client) The standard KWL700 drill is designed to suit a Mercedes Actros 4144 8x8 truck. Selection of an alternate car-
rier should be done in conjunction with the above diagram to ensure wheels, fuel tanks, transmission, suspen-
sion and other ‘furniture’ will not foul with the rig jack legs. A minimum chassis specification will need to be met
prior to the rig being mounted to it. Additionally, care should be taken that weight and dimensional envelopes
are in accordance with local statuary vehicle guidelines. In some instances, permits may be required. There is a
nominal provision to fit the rig to an Actros that includes allowances for mud guards and clearance lights and tail
lights.
NOTE: Mounting the rig to tracks is non-standard, please contact your Boart Longyear representative.
* Dimensions and weights may vary depending on options and should be checked before crating or lifting.
This page is intentionally blank.
SECTION 3
Drill Components
3-2 Base Frame Assembly
3-3 Vee Pack Cooler
3-4 Triple Drive and Pump Group Assembly
3-6 Power Pack and Compressor Assembly
3-8 Hydraulic Reservoir
3-10 Mast Arrangement
3-12 Drive Head Gearbox
3-14 Traverse Chains
Lighting
3-15 Hose Reeler
Air Dump Valve
3-16 Control Panel
3-18 Upper Auxilliary Control Valves
3-19 Centre Auxilliary Control Valves
3-20 Lower Auxilliary Control Valves
3-21 Feed System Control
3-22 Main Control Valves
3-24 Torque Controller
Drill Components 3-2
Base Frame Assembly
Vee Pack Cooler
Left Front Jack
Left Rear Jack
KWL700RC Base Assembly (viewed from left rear)
Levelling Jacks
Included in the design of the Base Frame Assembly are four mechanical
levelling jacks, which are welded to the main base frame.
These independently-operated levelling jacks are equipped with a hydraulic
locking drill set.
Vee Pack Cooler

The Vee Pack Cooler consists of five cooling cores.
When viewed from the operator’s console end of the rig, the core layout is
as follows:
Left hand side

Outer core small core Fuel cooler
Inner cores High pressure compressor (500 psi)
Right hand side

Outer core Hydraulic oil cooler
Centre core Engine induction air Intercooler
Inner core Engine water jacket
A 1200 mm diameter fan blade is positioned between both core groups at

the top of the Vee Pack frame, drawing air through both cores.
The Left and Right hand core groups extract heat from all core groups.
Heated air then passes through the fan blade and is expelled vertically. This
ensures the heated air does not reenter the cooler faces under any wind
direction conditions. It also does not come into contact with any personnel
working around the drill rig. It also limits the noise levels around the drill rig.
Fan blade diameter 1200 mm

Maximum fan blade rotating speed 1250 rpm
Air volume 30,000 m³ / m
Number of blades 6
Fan blade pitch 40 degrees
Fan blade drive Hydraulic motor
To minimise noise and fuel burn levels, the hydraulic fan drive motor has an
automatic speed adjusting circuit which is controlled by two thermal valves:
Never operate the Vee Pack • one is mounted at the engine water jacket outlet; and
with its fan safety guard • one is mounted at the compressor thermal valve cooler outlet port.
removed.
These valves sense the operating temperature and will vary the fan speed
Never place any items in a to maintain constant temperatures required.
spinning fan blade.
Water jacket 75°C
Never place any part of your Compressor oil 85°C
body in the heated air blast.
Cooler cores must be regularly cleaned to maintain correct cooling

parameters. This is your responsibility.
Triple Drive and Pump Group Assembly
Triple Drive and Pump Group

Triple Drive and Pump Group

1 Triple Pump Drive - DS38 - 700RC G.D. - DS38-1:1-E4E4E4BB2
2 Pump Rear Mount
7 MTU2000 Triple Drive Coupling
8 Triple Drive Mount
20 Relief Valve R5V10-493-12-A1
21 Hydraulic Pump P16H-3R1D-L10-D0
22 Hydraulic Pump T67DCC-B20-B14-B14-3R**-A100
23 Hydraulic Pump P07-3R1C-L10-NO
24 Hydraulic Pump P05 3R1C L10 M0
25 Funk Box Extension Adaptor
26 Hydraulic Pump P16H-3R1D-L10-C0
Power Pack and Compressor Assembly
Power Pack and Compressor Assembly

2 Triple Drive and Pump Group Assembly
3 Front Engine Mount Regular
4 Pump, Engine and Compresor – Rear Engine Mount
12 MTU Detroit Diesel Engine
24 Front Engine Mount (Long)
25 1350/500 Sullair Drill Compressor
32 Isolator
59 Circuit Breaker and Solenoid Label
63 Water Pump Housing Cover (Modified)
68 Air Receiver Check Valve – Sullair
Detroit (MTU 2000 series) Engine

• Develops 850 BHP (641 Kw) @ 1800 RPM.
• Engine low idle speed is 1400 RPM, due to compressor lubrication.
• Engine oil to be changed to manufacturer’s specifications.
Drain engine oil when warm from drain ball valve mounted below rig
base on L1H side of rig
• Replace engine oil filters at manufacturer’s specifications.
• Refill engine with Mobil Delvac MX 15W-40 grade
(or equivalent high quality oil)
• Batteries: dual N200 12V mounted below rig deck
(L1H front of drill rig base)
• Engine voltage: 24V
• Inspect battery water levels every 3 days.
Add distilled water only if required
• BATTERIES MUST BE ISOLATED BEFORE REMOVING BOX LID
• BATTERY ACID FUMES CAN BE IGNIGHTED BY SPARKS CAUSING
BATTERIES TO EXPLODE RESULTING IN VERY SERIOUS BURNS
• Clean battery terminals as required.
Smother with thin layer of grease.
Tighten terminal leads to prevent terminal damage and battery
explosion.
• Engine coolant must be full at all times.
Use NALCOOL PREMIX 4100.
Caterpillar Diesel Engine 3412

• Develops 850 BHP (641 Kw) @ 1800 RPM.
• Engine low idle speed is 1400 RPM, due to compressor lubrication.
• Engine oil to be changed to manufacturer’s specifications.
Drain engine oil when warm from drain ball valve mounted below rig
base on L1H side of rig
• Replace engine oil filters at manufacturer’s specifications.
• Refill engine with Caterpillar Diesel Engine Oil (15W40)
(or equivalent high quality oil to OEM specification)
• Batteries: dual N200 12V mounted below rig deck
(L1H front of drill rig base)
• Engine voltage: 24V
• Inspect battery water levels every 3 days.
Add distilled water only if required
• BATTERIES MUST BE ISOLATED BEFORE REMOVING BOX LID
• BATTERY ACID FUMES CAN BE IGNIGHTED BY SPARKS CAUSING
BATTERIES TO EXPLODE RESULTING IN VERY SERIOUS BURNS
• Clean battery terminals as required.
Smother with thin layer of grease.
Tighten terminal leads to prevent terminal damage and battery
explosion.
• Engine coolant must be full at all times.
Use NALCOOL PREMIX 4100
Hydraulic Reservoir
Hydraulic Reservoir
1 Drop In Diffuser Housing 19 Mk II Hydraulic Tank (990 L)
2 Valve Butterfly 20 Hydraulic Tank Stand
3 Oil Return Manifold #1 27 3/4 Low Pressure Ball Valve
11 Hydraulic Sight Glass 29 Case Drain Filter Assembly
12 Oil Level Cut Off Switch 30 Thermowell
13 Tank Lid 34 Tank Filter Breather
16 Case Drain Filter Manifold 36 Vacuum Indicator
17 Filter Diffuser
Hydraulic Tank
• The hydraulic oil must be correct type and viscosity.
• The correct oil level must be maintained at all times.
• All hydraulic oil must be filtered.
• When adding oil to the hydraulic reservoir it must go through the PALL
return filter port.
• The hydraulic reservoir suctions have no internal strainers, so never
allow dirt or loose particles to enter as it will result in immediate hydraulic
pump failure.
• The control cabinet end of rig base must never exceed more than 10
degrees above front of base as serious cavitations and pump group
failure will result.
• The hydraulic reservoir is fitted with a low oil sensor that will shut the
engine down when hydraulic oil level drops below the sensor height. It
will show on the engine display unit (EDU) as a code 26 failure.
• The hydraulic reservoir has a oil capacity of180 US gallons (680
Litres).
• Dual 5” (127 mm) suction lines carry 30 US gallons (114 Litres) and the
hydraulic circuit carries approximately 53 US gallons (200 Litres).
The engine must not be started • The total volume of circulating oil is 263 US gallons (994 Litres), with a
with suction valves closed. average oil lapse time of 0.5 minutes.
Serious hydraulic pump • Dual 5” (127 mm) suction butterfly valves are fitted.
damage will occur. • The hydraulic reservoir has a PALL breather mounted at the top of
reservoir
• All returning oil into the reservoir passes through a diffuser to assist in
aeration of the circulating oil.
Mast Arrangement
KWL700RC Mast Assembly (9m Stroke)

Mast Components
1 Mast Structure – 9m
6 Dump Cylinder Assembly
8 Hydraulic Pipe and Stauff Assembly
11 Rod Trough Assembly
18 Breakout Assembly
30 Vertical Adjustable Breakout
31 Rod Handler
32 Cylinder
34 Dump Plate Assembly
40 Feed System Assembly
41 Hose Reeler and Rail Assembly
45 Rod Spanner and Slip Assembly
46 Mast Foot Rest
Drive Head Gearbox
KWL700RC Drive Head Assembly

Drive Head Gearbox

The Drive Head Gearbox is a single speed heavy duty unit with dual hydraulic
motor inputs.
Drive head spindle speed @ 1800 engine rpm set to deliver = 122 rpm.
Maximum drive head spindle speed @ 1400 engine rpm = 90 rpm.
Gear ratio 3.5:1

Hydraulic motors OMVW 500
Bottom spindle thread 4½” API REG
Spindle bore 75 mm (2.95”)
Maximum output torque 11831 Nm (8725 Lb/ft)
Max rpm 122 rpm
Maintenance
Oil change 1000 hours
Oil type Mobl Gear 630
Drive Head Components

1 Rotary Drive Head 75mm Bore Splined Shaft
2 KWL700 Drive Head - Input Pinion (18 tooth)
3 Washer, Retainer
4 OMVW-500 High Torque Rotation Head Motor - Splined Shaft
5 Air Swivel (to suit Air Drill Drive Head and West Rod Blowdown)
6 Adapter Plate - Rotary Head To Swivel - RC Sample Pipe
7 Adapter Flange - Blowdown To Swivel - RC Sample Pipe
8 Slip Flange - Verdi Sample Pipe - RC Sample Pipe
9 Primary Sample Diverter - RC Sample Pipe
10 Horizontal Pipe With Dust Supression - RC Sample Pipe
11 Case Drain Extension
Traverse Chains
This drill rig is equipped with a traverse system that consists of dual Tsubaki
RS180DC pull back chains and dual Tsubaki RS160HT pull down chains.
Keep clear of travelling chains Each chain has an adjuster bolt at the mast termination points with a lock
and sprockets at all times. nut.
The upper chains travel over a timing axle with half sprocket tooth timing
stagger.
Adjust the chains to align drive head assembly within mast beams.
Drive head alignment

1 Loosen side wear pads of traverse frame (4 off).
2 Position mast vertically with 6 m drill rod attached.
3 Loosen bottom chains.
4 Adjust top right hand chain turn buckle (10 links above drive head) for drill
rod to be central with work table.
5 Adjust top chains with rear adjusters for even droop of rear chains.
6 Lower mast to horizontal position with drive head in lowest position.
7 Adjust lower adjusters evenly until a measurement of 100mm (4”) from
top face of mast to top chain link centre pin is achieved.
8 Reposition mast vertical. Recheck drill rod for alignment and adjust lower
chains slightly if required.
9 Readjust side wear pads for light contact only to mast beam.
10 Traverse chains are now aligned and tensioned.
Lubrication
It is recommended that the chains be wiped regularly with oil to assist with
their lubrication.
The pull down chains in particular operate in a very harsh environment, so
lubrication will extend their life considerably.
Lighting (If fitted)
There are four overhead work lights mounted at the top of mast structure plus
one mounted on the control cabinet.
Fitted into the electrical circuit is a press button circuit breaker.
If the circuit breaker does not reset, this indicates overloading caused by
possible short circuiting.
The circuit breaker protects all the electrical systems, so do not bypass the
fault and have it rectified.
Hose Reeler
The hose reeler system is designed to control all mast traveling hoses and
extensively increase hose life. It requires no operator input as it is attached
to the traverse system which automatically controls its operation.
The system will require activation rope tensioning when hoses loosen. This
is achieved by positioning the mast horizontal, loosening rope grippers at the
feed cylinder rod clevis position, and then tightening the ropes.
Ensure that all three grippers per rope are tightened correctly with the clamp
clip on the live side of the rope.
Maintenance
Inspect the stainless steel ropes weekly for any sign of damage. If damaged
replace immediately
Replace ropes every 2000 of operations.
Hose reeler ropes are 316 grade stainless steel to resist unseen corrosion.
The hose reeler track system has an inbuilt deceleration and bump stopper
system on the lower section to prevent unforeseen rope failure damage.
Air Dump Valve
36
The air dump valve is activated via a cable from the control cabinet using the
control knob [K-36].
It allows air trapped in the rod string to be dumped to atmosphere.
Air Dump Valve Control Knob [K-36]

Knob out Opens Rod String Air to Atmosphere
Knob in Closes Rod String Air to Atmosphere
Control Panel
KWL700RC Control Panel

Control Panel controls

Control Description Control Description
L-01 Main Air Valve K-41 Throttle
L-02 RC Boom Extension G-42 Compressor Interstage Temperature
L-03 RC Boom Slew G-43 Compressor Discharge Temperature
L-04 RC Boom Raise G-44 Hydraulic Oil Temperature
L-05 Break Out Extension K-45 Dust Supression On / Off
L-06 Break Out Clamp K-46 Dust Supression Flow
L-07 Break Out Rotate K-47 Hammer Oiler On / Off
L-08 Splitter Swing K-48 Hammer Oiler Flow
L-09 Slips Table K-49 Rotation Forward Low / High Torque
L-10 Mast Tilt K-50 Rotation Reverse Torque
L-11 Dump Mast K-51 Clamp Pressure
L-12 Break Out Cylinder K-52 Feed Down Pressure
L-13 Rod Trough K-53 Feed Hold Back
L-14 Spare K-54 Feed Up Pressure
L-15 Left Front Jack K-55 Mast Lock
L-16 Right Front Jack K-56 Compressor Start / Run
L-17 Left Rear Jack K-57 Compressor Pressure Settings
L-18 Right Rear Jack K-58 Blow Down
L-19 Cyclone Raise / Lower K-59 Blow Down Air Swivel
L-20 Cabinet In / Out G-60 Rotation Pressure
L-21 Cabinet Yaw G-61 Down Feed Pressure
L-22 Cyclone Slew G-62 Feed Hold Back Pressure
L-23 Rapid Feed G-63 Down Hole Air Pressure
L-24 Rotation G-64 Compressor Receiver Pressure
L-25 Survey Winch G-65 Clamp Pressure
L-26 RC Winch G-66 Vee Pack Cooler Pressure
L-27 Fine Feed G-67 Inter Stage Air Pressure
L-28 Cyclone Shutter Top G-68 Rig Fuel Capacity
L-29 Cyclone Splitter G-69 Water Injection Water Pressure
K-30 Rotation Torque Forward G-70 Hammer Oiler Pressure
L-31 Rig Washdown Water 71 Control Cabinet Frame Complete
L-32 Water Injection 72 Left Door
K-33 Water Pump Flow 73 Right Door
K 34 Water Pump On / Off 74 MTU Display Panel
K-35 Break Out Raise and Actuate Divertor CAT Display Panel
K-36 Air Dump Valve
E-37 Emergency Stop
E-38 Fuel Primer
E-39 Ignition / Starter
E-40 Start Overide
Upper Auxiliary Control Valves

Control Cabinet lever positions
1 2 3 4 5 6 7
Main Air Valve [L-01]

Lever up Closes the air valve
Lever down Opens the air valve
NOTE: The air tap is fitted with a restrictor which will only allow the air to
be turned on slowly but it will close quickly.
Winch Boom Extension [L-02]

Lever up Retracts the RC Boom extension
Lever down Extends the RC Boom extension
Winch Boom Slew [L-03]

Lever up Slews the RC Boom clockwise
Lever down Slews the RC Boom anticlockwise

Winch Boom Raise [L-04]
Lever up Raises the RC Boom
Lever down Lowers the RC Boom

Breakout Extension [L-05]
Lever up Moves the breakout back into the mast
Lever down Moves the breakout into the centre of the rod string

Breakout Clamp [L-06]
Lever up Opens the breakout jaws
Lever down Closes the breakout jaws

Breakout Rotate [L-07]
Lever up Turns breakout to make tool joint
Lever down Turns breakout to break tool joint
Centre Auxiliary Control Valves

8 9 10 11 12 13

Splitter Swing [L-08]
Lever Activates the splitter swing
Slips Hydraulic [L-09]

Lever up Closes the slips
Lever down Opens the slips
Mast Raise / Lower [L-10]

Lever up Raises the mast
Lever down Lowers the mast
Dump Mast [L-11]

Lever up Raises mast on dump plate
Lever down Lowers mast on dump plate
Break Out Cylinder [L-12]

Lever up Retracts the cylinder
The Break Out Cylinder must Lever down Extends the cylinder
always be parked with the raise/
lower cylinder at full extension,
or damage will occur when the
Break Out Cylinder Raise / Lower [L-12]
rod handler is slewed into the Lever up Raises the break out cylinder
mast. Lever down Lowers the break out cylinder
NOTE: Lever [L-12] has dual functions:
— break out cylinder operations, and
— raise and lower of tool height alignment.
Knob [K-35] switches operational modes.
Lower Auxiliary Control Valves

14 15 16 17 18 19 20 21 22
Spare [L-14]
Lever Spare motor spool section
Left Hand Front Jack [L-015]

Lever up Raises the Jack
Lever down Lowers the Jack
Right Hand Front Jack [L-016]

Left Hand Rear Jack [L-017]

Right Hand Rear Jack [L-018]

Cyclone Raise / Lower [L-19]

Lever up Raises the Cyclone
Lever down Lowers the Cyclone
Control Cabinet In / Out [L-20]

Lever up Retracts the Control Cabinet
Lever down Extends the Control Cabinet
Control Cabinet Yaw [L-21]

Lever up Slews the Cabinet in line with the Mast
Lever down Slews the Cabinet 30 degrees away from the Mast
Cyclone Slew [L-22]

Lever up Slews the Cyclone Arm behind the Control Cabinet
Lever down Slews the Cyclone Arm out 90 degrees to the Base
Feed System Control

Lever[L-26] Activates the Fine Feed system
Lever[L-27] Down lowers the Drive Head
Lever[L-27] Up raises the Drive Head
52 53 54
27
26

The fine feed controls consist of three cartridge valves mounted in operators
console to adjust the following functions …
Fine Feed Down Pressure [K-52]

Screw Knob Adjusts hydraulic force required
in feed cylinders down
Hold Back Pressure [K-53]

Screw Knob Adjusts hydraulic retract force in feed cylinders
Fine Feed Up Pressure [K-54]

Screw Knob Adjusts fine feed up pressure
Operation to start feed system

1 Move control lever [L-27] into the Neutral position
Hold back pressure is indicated only when in neutral position
2 Move control lever (L26) into the Down position
3 Adjust hydraulic force required in feed cylinders down
Adjust feed down knob [K-5] to increase the down pressure
(to max 1500 psi).
4 Adjust hold back knob [K-52] to required feed rate and force.
Adjust Fine Feed Up Pressure

1 Move control lever [L-27] into the Up position
2 Adjust the fine feed up screw knob [K-54] inwards to increase the pull back
pressure in fine feed only (0 – 3000 psi).
Main Control Valves

There are 2 main high flow control valves.
Feed Valve CVG50
Feed Valve [V23]

This is a load-sensing CVG50 valve that supplies the dual traverse hydraulic
cylinders with oil from zero flow through to maximum retract / lower speed
of 1 m/sec.
The pilot control valve lever [L-23] (rapid feed), when moved to the maximum
forward / back position, will cause maximum speed of the traverse system in
either direction, and proportional to lever movement through the range.
Lever forward Raises the Drive Head
Lever back Lowers the Drive Head
Up pressure is set at 4500 psi, and down pressure is set at 2500 psi.
23
Lever [L23]
Rotation Valve CVG50
Rotation Valve [V21]

This is a load-sensing CVG30 valve that supplies the head rotation with oil
from zero flow to maximum oil flow. It is activated by the pilot control lever
[L-24].
The pilot control valve lever, when moved to the maximum forward /
back position, will cause the drive head to rotate at maximum speed, and
proportional to lever movement through the range.
Lever forward Rotates the drive head spindle in the Drilling direction
(i.e. clockwise)
Lever back Rotates the drive head spindle in the Unthreading
direction (i.e. anticlockwise).
24
Lever [L24]
Torque Controller
Torque control operates in forward rotaton only.
50
30
49
The torque controller [K-30] is a manual screw adjuster mounted in the

operators console to set the rotational energy supplied to the drill rods. It can
be adjusted from zero to maximum energy by screw action adjustment.
The recommended setting is 300–500 psi above the operating rotational
pressure indicated by the rotation pressure gauge at any time.
When set it limits the torque rise being induced by down hole friction, therefore
protecting the drill bit and string.
Turn knob [K-49] horizontal to automatically increase forward rotation torque
by 500psi (Hi / Lo)
Screw knob [K-50] in to increase reverse rotation torque 145 – 3800 psi.
Screw torque control knob in to increase the energy (torque) from the drive
head spindle.
SECTION 4
Drill Operations
4-2 Introduction
4-4 Visual Inspection of Masts
4-6 Pre-Start Procedure
4-7 Emergency Alarm System
4-8 Safety Systems
4-10 Engine Operation
4-11 Drill Rig Setting Up
Jacking the Base
Raising the Mast
Lowering the Mast
Dumping the Mast
Rod Trough
4-14 Water Pump

4-15 RC Boom
4-16 RC Winch
4-17 Survey Winch
4-18 Hydraulic Drill Rod Make / Break Tool
Hydraulic Slips
4-19 Air Compressor
Sullair Model 20/12 Drill Compressor
Operator’s Manual and Spare Parts List
Drill Operation 4-2
Introduction
The following are recommended guidelines and practices to help prolong
the life of your newly obtained Boart Longyear mast.
Enclosed is a checklist for a visual inspection which should be done
every 1000 hrs of operation. (Inspections may have to be done more often
when operating in extreme environmental conditions.) Make copies of
the checklist for each inspection. The checklist should be signed and
filed for future reference.
Safeguards
• Operator shall be familiar with the equipment and its proper care.
• If adjustments or repairs are necessary, or if any damage is known, the
operator shall report the details promptly to an appointed person and shall
notify the next operator upon changing shifts.
• In mast erecting and lowering operations, ensure that the drill is securely
anchored first.
A slow practical operating speed should be used during this function at
all times.
• There is no way of judging the remaining strength of a rusty cable. When
detected, rusty cable lines must be immediately replaced.
Areas adjacent to end connections should be examined closely for any
evidence of corrosion.
As a standard operating procedure, cables must be replaced at least every
12 months (or more frequently if required).
• Design modifications or welding to the mast weldments is prohibited.
These modifications could result in weakening of the mast members and
therefore, possibly causing a structural failure later.
Drill Operation 4-3
Routine Checks
Routine checks should include:
• Inspection of welds in the 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 commencing the 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.
Check bolts for correct torque 48 hours after initially erecting the mast.
• Ensure that the Load Rating and Warning decals are installed on the mast
and are in good shape/clearly visible.
• Steel becomes brittle when operating in low temperature conditions.
Frequent visual inspection of mast members and welds is even more
EXTREME CAUTION must be critical at these temperatures, see pages 4-4 and 4-5.
exercised when operating at or
below -25°C (-13°F) as the mast • Ensure support legs are located on a solid footing and tied back to a solid
may no longer hold the rated anchoring point.
load.
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.)
Drill Operation 4-4
Visual Inspection of Masts

The following is a checklist for a visual inspection of the mast.
Ensure that the inspection is performed by an individual with knowledge of all mast operational
procedures during erection or relocation of mast.
Each section has a pass or fail choice. If there is a problem, it should be noted and corrected
immediately.
Make copies of this checklist and file completed check lists 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
C. Rear Leg, Off Driller’s Side
Condition:
Bow Slight Bad OK
D. Rear Leg, Driller’s Side (Not applicable for “T” style mast)
Condition:
Bow Slight Bad OK
Comments: Needs Repair Other:
3 Bracing
Condition: Slight Damage Badly Damaged OK
Needs Repair
Drill Operation 4-5
4 Adjustable Support Legs and Feet

Condition: Damaged Cracked Welds OK
Worn Pins/Hole Needs Repair
Corroded
5 Working Platform (not applicable)
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 visually 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
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.:
Drill Operation 4-6
Pre-Start Procedure
This drill rig must be operated only by experienced operators who have
been instructed on how all the functions are to be used.
This machine can kill.
Inspect/check the following before starting the drill rig:

• Engine oil level
• Engine coolant level
• Hydraulic reservoir oil level showing at centre site glass
• Hydraulic suction valves open (Lever forward)
• Compressor reservoir oil level
• Emergency Stops set to engine run position
• Fire extinguishers checked
• All hydraulic control valves positioned to neutral
• Engine stop control deactivated
• Engine throttle set to low idle position
• Check the drill rig deck is clear of personnel
• Check all acoustic pack doors are closed
• Press over-ride button (E-40) and hold in until beeper stops then
release
• Engage engine starter and start engine
• Idle engine at 1400 RPM for approximately 10 minutes
40
Drill Operation 4-7
Emergency Alarm System

The KWL700 RC drill rig is fitted with an Engine Display Unit (EDU) that
digitally displays all engine functions. Hydraulic oil temp, Hydraulic oil level
and Compressor discharge temp are indicated by code 26 only. Compressor
inter-stage temps appear on analog Murphy gauges that signal the ECM/EDU
for engine shut down when required.
Functions controlled with Shut Down Set Values

Engine Coolant Temperature ECM controlled
Engine Oil Pressure ECM controlled
Hydraulic Oil Temperature Code 26 Set @ 80°C,
ECM controlled
Compressor Discharge Air Temperature Code 26 Set 127°C,
ECM controlled
Compressor Inter-stage Air Temperature Code 26 Set 115°C,
ECM Controlled
Hydraulic oil level Set level 50%
capacity,
ECM controlled
Normal Operation Values

Engine Water Temperature 85°C
Engine Oil Pressure @ low idle speed 40 psi (276 kPa)
Engine Oil pressure @ Max rated RPM 110–140 psi
(758–965 kPa)
Drill Operation 4-8
Safety Systems
Inspect and ensure the following are functional:
• Three Emergency STOPs. One is located on each front corner of the drill
rig base, and one is in the control cabinet at item [E-37]
• Two Fire extinguishers. One is located adjacent to each front jack leg.
Safety System Locations (See “Figure 2” below)
Item 3 Ladder Fall Arrestor Cable

Item 4 Emergency Stop
Fire Extinguisher
Fire Suppression Activation Point
Fire Extinguisher
Item 8 Fire Suppression Activation Point
Engine Check Locations (See “Figure 3” above)
Item 1 Engine Radiator and Intercooler Header Tanks with

radiator caps to check and top up coolant levels
Item 2 Pump Tri-drive Dipstick
Item 6 Compressor Oil Level Indicator (inside Acoustic Pack)
Item 7 Engine Oil Dipstick and Engine Oil Filler Location
Drill Operation 4-9
Emergency Equipment Base Locations

• Emergency Stops
• Fire Extinguishers
• Fire Suppression Activation Points
Top View
LHS View
RHS View
Drill Operation 4-10
Engine Operation
Pre-Start Checklist
Check the following before starting the engine:
• All operational control valves to be in Neutral position
• Throttle is at low idle position
• Turn the Start switch to first position and alarm beeper will sound
• Depress the bypass button fully and hold depressed
• Turn the Start switch fully clockwise. The engine will start, then release
the Start switch
• Continue to depress the bypass button until alarm beeping stops, then
release the button
• Visually check oil pressure has risen and all other gauges are indicating
correctly
• Should the engine or any engine gauges indicate an incorrect situation
immediately shut the engine down
• Run the engine at 1400 RPM unloaded for approximately 10 minutes
before loading at1800 RPM
The drill rig engine is now ready for normal operations.

Note: The drill rig engine is designed to operate between 1400 and 1850 RPM.
When shutting engine down
always idle for approx. 5 minutes
to allow turbo charger to slow with
lubrication.
Drill Rig Setting Up
Look Up and Live - Beware of

power lines at all times.
10
IMPORTANT
Always lift the front or rear

jacks as a pair to avoid
severe twisting of the rig base
structure. Typically raise 55
the fronts 300mm then raise
the rear jacks 300mm or all
together.
15 16 17 18
Before raising drill rig mast Jacking the Base

CHECK FOR POWER LINES
or any other obstruction that Lower all four jacking legs onto stable ground using levers [L15], [L16], [L17],
could cause injury or damage. and [L18] to raise drill rig base to the required height.
Ideally, the truck wheels should just be touching the ground.
Note Set the drill rig base level.
The mast raise cylinders can
generate in excess of 77 tones of
force, so operate with care. Raising the Mast
The dump plate locking cylinder’s Remember the mast locking system
minimum mast angle is 45°.
1 Ensure drill rig base is level before proceeding with any mast lift.
Attempting to lower the mast
past this angle while the
2 Set the Engine to low idle.
dump plate locking cylinder is 3 Position knob [K55] at the 3 o’clock position. The mast locking cylinder is
engaged will result in serious in the Unlock position
damage.
4 Push Lever [L10] up to raise mast to the vertical position.
When lowering the mast,
hydraulic pressure is only 5 Position knob [K55] at the 9 o’clock position. The mast locking system will
required to move mast automatically drop over anchoring shaft at the bottom of the dump mast
approximately 5° then mast plate. The mast locking system is now secured to the dump assembly,
will free fall. and the drill rig mast is now locked at three positions.
When the mast is stopped by
locking cylinder, DO NOT hold
mast raise/lower lever down as MAST LOCK
damage will occur.
LOCK UNLOCK
6 Lower mast to desired drilling angle by pushing down on Lever [L-10].

The mast is now locked.
Lowering the Mast

Remember the mast locking system
1 First raise mast fully vertical lever [L10] up
MAST LOCK
LOCK UNLOCK
2 Position knob [K55] at the 3 o’clock position. This will automatically lift the
mast locking cylinder off the dump locking shaft assembly positioning the
mast locking cylinder in the Unlock position
3 Push Lever [L10] down to begin lowering the mast to the Park position.
4 Before the mast is fully lowered the mast is to be fully extended up on the
dump mast assembly to align the mast with the mast rest frame. Lift lever
[L11] up to clear truck cabin.
5 Lower the mast lever [L10] onto the mast rest frame at the front of the rig
base.
6 Ensure the mast is dumped correctly to prevent the mast rest fouling with
piping on the underside of the mast when it is fully lowered.
IMPORTANT Dumping the Mast

The dump system is designed
Dumping the mast is required to make the mast structure contact the ground.
solely for elevating and
This allows all loads applied to the mast during drilling (i.e. drive head pull
lowering the mast to achieve
contact with the ground to
back, using winches, etc.) to be transferred directly to the ground. This reduces
relieve stress from the rig base,
the stresses on the A-frame, rig base, and jacks legs.
jack legs, rig carrier, etc.
1 Once the desired mast angle is set, push lever [L-11] down to allow the
It MUST NOT be used for any mast base to contact the ground.
other purpose, e.g. jacking the
rear of the rig up, assisting in
2 Push Lever [L-11] up to raise the mast off the ground.
rod pull back.
Park Position: When lowering mast, position the mast dump in the fully up
Note: position to achieve correct rest position for travel.
Dump mast average working
pressure is 2000 psi.
10 11 13
55
Rod Trough [L-13]
When carrying out these Lever up and held Raises the rod trough.
adjustments follow all Lever down Lowers the rod trough.
relevant safety procedures. This function does not require activation as the rod
trough will automatically retract when the lever is
released.
The rod bin is designed to be raised with the lever in the up position
and held.
When lever is released the trough will automatically retract to its Park
position.
The speed of the trough raising is set by an adjustable needle valve. This is
set at the factory and it is recommended not to increase the extension speed
as this will cause excessive wear of keyways and bushes.
The pressure of the rod trough is preset to support the weight of a drill rod
only. Any other load applied the trough will not raise or push down if extended.
This is designed for collision with drive head.
Mounted at the top edge of the trough are two nylon adjustable blocks to align
the drill rod with to drive head spindle centre line.
Height adjustment is achieved by a screw and lock nut at the motor arm ends
of the trough.
Water Pump
The Water Pump is a high pressure, 4-cylinder, positive displacement unit
that can deliver both high pressure and flow suitable for normal RC drilling
Safety guard must cover drive conditions.
coupling at all times It can also be used for washing down, and is controlled from the operator’s
console.
• Fluid Flow 15 USGPM (57 Litres) max.
• Fluid Pressure 1000 psi (169 Bar) max.
Refer to FMC Pump Owners The Water Pump is driven by the drill rig’s hydraulic system.
manual for further information.
• The fluid relief valve is preset to 1000 psi (169 bar)
• Use Knob [K-34] to turn the fluid pump On/Off
• Adjust the fluid flow with Knob [K-33] to the required flow at operators
console. Unscrew the knob for maximum flow
• When fluid flow is set use the On/Off Knob [K-34] when changing drill
rods and flow will return to set flow. Flow is infinitely variable
• A 1” (2.5 cm) min. diameter suction hose is required for fluid delivery
rates greater than 15 USGPM
• Suction fluids require straining to eliminate any possibility of valve
malfunction
• Water outlet via a check valve prevents reverse flow air pressure
• Pump suction must be fully primed before starting to avoid pump
damage.
34
33
RC Boom
Operating the RC Boom
RC Boom Slew [L-03]

Lever up Slews the RC Boom clockwise
Lever down Slews the RC Boom anticlockwise

RC Boom Raise [L-04]
Lever up Raises the RC Boom for slewing clearance
Lever down Lowers the RC Boom
When removing the RC boom from the transport position always raise
the RC boom fully before slewing or damage will occur to the RC winch
and the RC boom raise cylinders.
When slewing have the RC boom fully raised (if possible). The RC boom has
a total slew of 303 degrees.
When the RC boom is in line with the spindle it will slew 105 degrees clockwise
and 198 degrees anticlockwise.
3 4
RC Winch
• The RC winch is mounted on the RC boom at the mast crown
• The RC winch drum carries 17 m of 10 mm Cassar Eurolift, with a minimum
Only use rope recommended breaking load of 8330 Kg giving a SWL of 10:1
to maintain winch lift
• The winch rope tail is inserted into a hole within the winch drum and held
specifications
in position by a clamping screw.
Should a replacement brand • There must always be three friction turns on the drum before usable rope
rope be used, winch capacity
is available.
must be derated to suit rope
SWL
• The RC winch has a max SWL of 750 Kg.
• The RC winch has factory preset pressure setting to ensure that the safe
working load is adhered to. Under no circumstances may this pressure
setting be adjusted.
Operating the RC Winch
RC Winch [L-26]
Lever up Raises the RC Winch
Lever down Lowers the RC Winch
26
Survey Winch
• The survey winch is mounted on the rear of the RC boom at the mast
crown
Only use rope recommended • The survey winch drum carries 100 m of 6 mm diameter rope, with a
to maintain winch lift minimum breaking load of 1900 Kg (18.7 kN)
specifications
• The winch rope tail is inserted into a hole within the winch drum and held
Should a replacement brand in position by a clamping screw.
rope be used, winch capacity
• There must always be six friction turns on drum before usable rope is
must be derated to suit rope
available.
SWL
• When fitting a new rope be sure to pack each row tightly together as this
will then assist the rope to spool evenly across drum when hauling and
allow full rope capacity of 1000 m to be stored on the winch drum.
• Never let rope be foul on any part of drill mast as this alters rope fleet
angle causing bad spooling on drum.
Operating the Survey Winch from the RC Boom Park Position
RC Boom Slew [L-03]

Lever up Rotates the RC Boom clockwise to centralise the
survey winch to the mast face

RC Boom Raise [L-04]
Lever up Raises the RC Boom for slewing clearance

Survey Winch [L-25]
Lever back (i.e. towards the operator) lowers the rope
Lever forward (i.e. away from the operator) raises the rope
Lever central rope is stationary
Lever movement infinitely varies the rope speed
3 4
25
Hydraulic Drill Rod Make / Break Tool

Operating the Hydraulic Make/Break Tool to Break a Tool Joint
1 Move Lever [L-05] down to extend the tool from the Park position to the
drill rod centre line.
2 Move Lever [L06] down to clamp the tool to the drill rod.
3 Move Lever [L07] down to rotate and break the drill rod thread.
4 Move Lever [L06] up to unclamp the tool from the drill rod.
5 Move Lever [L07] up to rotate the tool back to the central position.
6 Move Lever [L05] up to retract the tool to the Park position
Clamp Pressure [K-51]

Screw knob in to increase tool clamping pressure
Screw knob out to decrease tool clamping pressure
Should the tool jaws slip on drill rod, increase the clamping pressure.
Adjust the tool pressure slightly above the non slip zone.
Beware of rod crush when
making this adjustment.
51
5 6 7
Hydraulic Slips
The hydraulically adjustable slips are designed to guide and align drill rods.
They must not be used to suspend rods.
Doing so may result in damage to the unit.
Air Compressor
Air Compressor
This drill is equipped with a Sullair 2-stage 1350 cfm x 500 psi air compressor
that is directly coupled to the rear bell housing of the MTU engine.
Based on advice from Sullair (the Compressor OEM), the engine should
never idle lower than 1400 rpm as compressor lubrication will stop,
resulting in compressor failure.
The Sullair Model 20/12 Drill Compressor Operator’s Manual

and Spare Parts List are included at the back of this manual.
To Operate the Compressor

• Position Knob [K-56] to the Start position.
• Set engine speed to 1800 rpm.
• Allow the engine to reach its operating temperature.
• Close all air valves on output air circuits.
• Position Knob [K-57] to 175 psi position.
Air pressure will rise to 175 psi on gauge [G-64].
• The inter stage pressure gauge [G-67] will indicate 60 psi.
• Reposition the Knob to the required air pressure 350–500 psi.
• Working pressure selected will be indicated on gauge [G-64].
• Steadily open the main air valve using [L-01].
• The compressor start producing an air flow rising to 1350 cfm.
• Start drilling.
• Stop drilling.
• Close main air valve using [L-01].
Air flow will cease and selected pressure will remain.
• When main air valve closes, pull [K-36] to release air pressure held within
the drill rod string.
Air flow must always be circulating through the drill string, not directly
to atmosphere.
64
56
67
57
36
1
SECTION 5
Hydraulic Explanation
5-2 Hydraulic Circuit Overview
5-3 Hydraulic Circuit Diagram
5-5 Hydraulic Pumps
Hydraulic Explanation 5-2
Hydraulic Circuit Overview

The KWL700RC drill rig utilizes five load sensed, pressure compensated
Denison open loop piston pumps, and one triple vane pump:
Drive head spindle speed

@ 1800 engine rpm is set to deliver 122 rpm.
Maximum drive head spindle speed

@ 1400 engine rpm 90 rpm.
Hydraulic oil temperature

operating in a 55 degree ambient 75°C (approx.)
Maximum flow off the complete hydraulic circuit

with all flows combined 450 USGPM
(1700 Lpm).
This will only occur for a period of nine seconds

when traversing the Drive Head in rapid feed.
In Drilling mode the flow in the hydraulic circuit

will be (approx.) 230 USGPM
(870 Lpm).
The KWL700RC Hydraulic Circuit appears on the facing page.

No DESCRIPTION PART No
1 TRI BOX 230-02466
2 P16 PUMP 450-01970
2A P16 PUMP 450-01976
3 P07 PUMP 450-01977
4 P05 PUMP 450-01384
5 T6DCCM PUMP 450-01978
6 RELIEF SET PRESSURE 2200 PSI 450-00235
7 PRIORITY FLOW CONTROL 230-02372
8 CASE DRAIN FILTER 400-05330
8A ELEMENT 400-04197
9 MAIN RETURN FILTER 400-04192
9A ELEMENT 400-04193
10 BREATHER 400-00209
11 DIFFUSER 450-00221
12 GATE VALVE 450-04240
13 CASE FLUSH FILTER 400-04689
13A ELEMENT 400-04195
14 FLOW CONTROL CARTRIDGE 270-01948
14A BODY 230-02374
15 CHECK VALVE 450-01973
16 ENGINE THERMAL VALVE 450-01452
17 COMPRESSOR THERMAL VALVE 450-01453
18 MAIN COOLER FAN MOTOR 280-00589
19 MAIN COOLER FAN MOTOR OVER RUN RELIEF 280-02373
20 2" 36psi BSPP CHECK VALVE 450-00757
21 ROTATION VALVE 450-01974
22 ROTATION MOTOR 140-01468
23 RAPID FEED VALVE 450-01975
24 DUEL PILOT CETOP 3 450-02497
24A SUBPLATE 450-02029
25 FEED CYLINDER 150-03552
26 FINE FEED VALVE 270-02256
27 MAIN HOLDBACK RELIEF CARTRIDGE 230-02375
27A BODY 230-02376
28 MAIN HOLDBACK RELIEF PILOT CARTRIDGE 450-02183
28A BODY 450-02184
28B KNOB 450-02175
29 1/2" CHECK VALVE 450-02026
30 HOLDBACK GAUGE 270-01712
31 PILOT OPERATED VALVE 2 SECTION 270-02261
32 CONTROL VALVE 300-04337
33 RC WINCH MOTOR 131-01359
34 RC WINCH BRAKE 110-01335
35 RC WINCH OVERCENTRE VALVE CARTRIDGE 450-01476x2
35A BODY 450-01477
36 SURVEY WINCH MOTOR 110-01362
37 OVERCENTRE VALVE CARTRIDGE 450-01476
37A BODY 450-01480
38 CETOP 3 SINGLE PILOT 450-01518
38A SUBPLATE 450-02029
39 TILT CYLINDER 200-00026
40 OVERCENTRE VALVE CARTRIDGE 450-00253x2
40A BODY 450-02748
41 MAST LOCK CYLINDER 190-01558
42 MAST LOCK ACTUATOR CYLINDER 190-00708
43 SPLITTER SWING CYL SUPPLIED BY CLIENT
44 PILOT OPERATED CHECK VALVE CARTRIDGE 450-00831
44A BODY 450-00720
45 DUMP MAST CYLINDER 190-01497
46A BODY 450-00254
47 BREAKOUT IN/OUT CYLINDER 180-05019
48 BREAKOUT UP/DN CYLINDER 180-01686
49 SIX PORT DIVIRTER 450-01795
50 ROD TROUGH MOTOR 450-01726
51 3/8" NEEDLE VALVE / FREE FLOW REVERSE CHECK 420-02412
52 CROSS LINE RELIEF CARTRIDGE 450-00259x2
52A BODY 450-00260
53 CYCLONE SLEW CYLINDER 110-00696
54 CABINET IN/OUT CYLINDER 270-02148
55 CABINET YAW CYLINDER 270-01686
56 CYCLONE UP/DN SUPPLIED BY CLIENT
57 JACK CYLINDER 220-00628
58A BODY 450-00256
59 HYDRAULIC SLIPS TABLE 182-02177
60 NINE SECTION VALVE 270-02259
61 SIX SECTION VALVE 270-02258
62 SEVEN SECTION VALVE 270-02260
63 3500 PSI GAUGE 270-00403
64 AIRDRILL BREAKOUT ROTATE CYLINDER
65 AIRDRILL BREAKOUT CLAMP CYLINDER
66 DUAL PILOT OPERATED CHECK VALVE
67 BREAKOUT EXTEND CYLINDERS 180-01440
68 RC BOOM LIFT CYLINDERS 110-00696
69 RC BOOM SLEW MOTOR 130-01071
70A BODY 450-01479
71 RC BOOM EXTENSION CYLINDER 130-01346
72 FEED UP RELIEF CARTRIDGE 450-00179
72A BODY 450-01628
72B KNOB 450-02175
73 FEED PRESSURE RELIEF CARTRIDGE 450-02022
73A BODY 450-01628
73B KNOB 450-02175
74 REVERSE ROTATION TORQUE CARTRIDGE 270-01946
74A BODY 450-01628
74B KNOB 450-02175
75 ROTATION TORQUE CONTROL 270-00239
76 ROTATION HI/LOW TORQUE CARTRIDGE 450-02023
76A BODY 450-01692
77 1/4" 2 WAY WHITEY BALL VALVE 650-01563
78 1/4" 3 WAY WHITEY BALL VALVE 650-01562
79 NEEDLE VALVE 270-02185
79A NEEDLE VALVE PANEL MOUNT NUT 270-02186
80 WATER PUMP MOTOR 650-01870
81 1/2" 145 PSI CHECK VALVE 420-02713
82 PRIORITY FLOW VALVE 230-02371
83 NEEDLE VALVE 270-02187
83A NEEDLE VALVE PANEL MOUNT NUT 270-02188
84 HAMMER OILER MOTOR 805-01394
85 PRESSURE REDUCING VALVE CARTRIDGE 450-03157
85A BODY 450-00720
86 JOYSTICK FEED/ROTATION 270-00765
87 JOYSTICK SURVEY/RC WINCH 270-00248
88 AIR ON/OFF CYLINDER 550-00352
89 1/4" NEEDLE VALVE / FREE FLOW REVERSE CHECK 420-002710
90 BLOW DOWN SYSTEM SUPPLIED BY CLIENT
91 HYDRAULIC COOLER CORE 280-02875
92 ROD BIN CYLINDER 250-00620
93 CLAMP PRESSURE CARTRIDGE 450-00179
93A BODY 450-01692
93B KNOB 450-02175
94 ACOUSTIC PACK FAN MOTOR 240-02150
95 LOGIC ELEMENT CARTRIDGE 450-03493
95A BODY 450-03494
96 SHUTTLE VALVE 450-00917
97 DIVIRTER VALVE 450-01990
98 COUPLING 21/2" 410-02290
99 HIGH PRESSURE BALL VALVE 620-02714
100 RELIEF VALVE CARTRIDGE 450-00179
100A BODY 450-01692
101 OVERCENTRE CARTRIDGE 450-04662
102 ROTARY ACTUATOR 300-04017
103 OVERCENTRE VALVE CARTRIDGE 450-06731
103A BODY 450-05071
104 RODHANDLER RAISE/LOWER CYLINDER 300-04280
105 ACCUMULATOR (SET 2000PSI) 300-04044
106 MANIFOLD ACCUMULATOR CHARGE VALVE 450-04586
107 VALVE CARTRIDGE 450-04587
108 HYDRAULIC MOTOR 805-01393
109 CARTRIDGE VALVE CHECK 450-00831
110 JAW CYLINDER 300-03936
111 MANIFOLD BLOCK (JAWS) 300-03668
112 MANIFOLD BLOCK 300-04399
113 MANIFOLD BLOCK 300-03637
114 GAUGE 1400 PSI 270-00649
115 CHECK VALVE 3/8 BSPP 0.5 BAR 450-01798
116 PUMP (HAMMER OILER) 805-01394
117 FUNK COOLER 280-04453
118 FUNK COOLER PUMP 450-04409
119
120
121
122
123
124

Hydraulic Pumps
P16 No 2
P16 No 3
P09
Triple Vane Pump
P16 No 1
P05
In the above photo ...

• P16 No 1 — Supplies oil flow for Rotation via an L/S pilot operated control
valve.
• P16 Nos 2 & 3 — Supply oil to rapid feed circuit when in retract mode
with a single P16 used when in feed down mode, this pump combination
allows 930mm per second in both retract & feed down modes.
• PO9 — Delivers oil flow to the Vee Pack cooler fan motor. Two thermal
valves are fitted to cooler fan circuit:
— Thermal valve 1 senses the engine coolant temperature, and
— Therrmal valve 2 senses the air compressor oil temperature.
These thermal valves will control the Vee Pack hydraulic motor speed
which constantly adjusts the air flow through the cooler cores to maintain
the correct operational temperatures and ensure minimum horsepower is
consumed at all times.
On start up when cold the cooler fan pressure will be approx. 500 psi
(35 bar).
As the engine and compressor temperatures rise the fan speed
automatically increases until operating temperatures are reached. The
fan then adjusts its speed to maintain these temperatures. The extent of
this adjustment will vary, depending on several variables (e.g. ambient
temperature, horsepower being consumed, core cleanliness).
Fan pressure will rise and fall as loads on the engine and compressor
come on and off (e.g. while drilling a rod the cooler fan pressure may
slowly rise, then while adding another rod the fan pressure may drop back
off). The maximum speed of the fan is 1550 rpm which equates to approx.
1900 psi (131 bar)
• PO5 — Supplies oil flow for the rod handler and rod bin only. No other
functions affect or are affected by use of the rod handler.
• Triple vane pump:
— Front section supplies oil flow for the acoustic pack fan thru a priority
flow valve and the excess flow is used for the water pump thru a load
sense priority valve.
— Middle section supplies oil flow for the auxiliary functions thru a load
sense priority valve.
— Rear section supplies oil flow for the fine feed thru a load sense priority
valve.
SECTION 6
Drill Rig Maintenance

6-2 General Maintenance
Routine Maintenance Procedures
6-4 Engine Maintenance

6-5 Lubrication Points
6-6 Filtration
Drill Rig Maintenance 6-2
General Maintenance
Owners/operators should be particularly vigilant towards ensuring that bolt
fasteners are correctly tightened throughout the drill rig. Movement and
‘settling’ of the new drill rig and paint between contact surfaces can result
in bolts coming loose which may cause in serious structural damage. It is
recommended that they adhere closely to the routine maintenance procedure
schedule below.
Bolts not listed specifically in the following table should be checked for
tightness every three months of operation.
Routine Maintenance Procedures
Inspection Frequency
Week Month Periodically
Required Inspection 2 4 6 8 10 12 4 5 6 3-Monthly
Inspect rig for cracking in Inspect monthly if no cracks Inspect every 3 months
the vicinity of the A-frame X X X X X X are detected at end of if after 6 months no
and cylinder lug Week 12 cracking is found
Inspect all bolts connecting

Inspect monthly to ensure bolts
the rig base to the chassis X X X X X X
are maintaining pre-torque
and re-torque
Torque Gr 8 5/8” UNC bolts to 250 Nm
Inspect all other critical

bolted components X X X X X X Inspect monthly if after Week 12 no problems are found
Refer to manual for bolt torque details
Notes:
In addition to the bolts connecting the rig base to the carrier chassis other
important bolted connections which require routine checks include:
• Engine mount bolts
• Funk drive mount bolts
• Mast pivot block bolts
Engine Maintenance
• The KWL700RC drill rig is fitted with a MTU 12V 2000 series diesel engine
that develops 850 bhp (641Kw) @ 1800rpm.
• The low idle speed is set to 1400 rpm to ensure that the compressor
maintains lubrication at all times.
• The engine oil and filters must be changed to manufacturers specifications.
The oil should be changed when the engine is warm via the drain ball
valve mounted below the rig base on the left hand side of the drill.
• Recommended engine oil is Mobil Delvac 15W-40 grade or equivalent.
• There are dual N200 12V batteries mounted on the left hand side of the
drill rig. The engine voltage is 24V.
• Inspect the battery water level every 3 days and add distilled water only
if required.
THE BATTERIES MUST BE ISOLATED BEFORE REMOVING THE
BOX LID.
BATTERY ACID FUMES CAN BE IGNIGHTED BY SPARKS CAUSING
BATTERIES TO EXPLODE.
• Clean battery terminals as required and smother with a film of grease to
prevent terminal damage.
• Engine coolant tank must be full at all times.
Use NALCOOL PREMIX 4100.
MTU 12V 2000 Series Diesel Engine

Lubrication Points
Item No. of Frequency Amount Completed Signature
points (interval) by
Grease
R/C Boom pivot pin Mast
Lower idler central 7 days 2 x pumps
sprocket bearings grease
stations
Mast locking Base

cylinder bush central 7 days 2 x pumps
Tilt cylinder grease
lower bushes station
Trolley sheave wheels 2 14 days 1 x pump

Dump mast pins 4 7 days 2 x pumps
(upper and lower)
Dump plate 2 7 days 2 x pumps
(upper and lower)
Mast pivot bushes 2 7 days 1 x pump
Lift cylinder pin upper 2 7 days 1 x pump
Cabinet slide arms 2 7 days light
smear
Survey winch 1 28 days 1 x pump
outrigger bearing
Other Lubricants/Fluids
Drive head gearbox 1000 Mobil 630
hours
MTU 12V 2000 Engine Delvac
MX
15W40
Engine coolant Nacool
4100
Hydraulic oil Mobil DTE
25
Compressor oil Aircol
SR46
Drive head Mobil
Gear 630
Down hole fluid pumps 2000 SAE 30
hours Grade
(3.7 Litres)
FMC Water Pump 3 12 2 x pumps
plunger seals months
REMEMBER, change the oil if it is “milky”

Filtration
Oil Filtration
This drill is equipped with one of the finest brands of oil filters available (PALL)
and does not require element changes on a regular date, but only when the
filter indicator is red.
The filter element indicators are a pop-up style that require finger pressure
to reset.
The indicators will not be operate at temperatures less than 27°C.
If the red indicator button rises, reset it by pressing it in when the drill is
operating with warm oil.
Should indicator rise immediately, the filter element is due to be changed.
New oil must always be added via the hand pump suction hose, as this will
filter the oil before it enters the hydraulic tank.
Compressor Air Filters
Oil Hand Pump
Main Hydraulic Filter
Air Filtration
Engine air filtration: dual Donaldson FVG160587 filtration system.
Compressor air filtration: dual Donaldson FVG 160587 filtration system.
Main filter element P18 2049
Safety filter element P11 6446
Inspect all induction lines regularly for airline leaks which will cause dusting
and serious engine/compressor failures
SECTION 7
Start Up Procedure
(When Commissioning or Pressure Setting components)
Note: When necessary, refer to the Hydraulic Schematic
(see page 5-3) whilst following these procedures.
7-2 Cooling System Bleeding Procedure

7-3 Pre-Start Requirements
Bleeding Points
Valve Adjustments
P16
P05
6
14
85
27
76
Compressor Valves
Testing the Low Air Pressure Circuit
7-11 Control Panel Pre-Start Check List

7-12 Settings
Cooler Fan Pump
Pilot Pressure Valve (85)
Control Panel Auxilliary Valve Bank
Valve 62
Valve 61
Valve 60
Cabin Yaw and Cyclone Slew
Rod Trough Counterbalance/Flow Control Valve
Mast Dump
7-17 Raising the Mast

Jacking the Base
7-19 Cooler Fan Settings

7-20 Standby Settings
P16 Pump
Rotation Circuit
Feed Circuit
Lower Feed Pump
Upper Feed Pump
Rod Handler Circuit
Acoustic Fan and Water Pump Circuit
Fine Feed Circuit
Start Up Procedure 7-2
Cooling System Bleeding Procedure

Fill the cooling system with water only in first instance for commissioning
purposes.
Open the bleed screws as shown until all air is removed from the system.
Bleed Screws located inside Engine enclosure
Bleed Screws on Cooler Pack
NOTE: If Bleed Screws are not fitted as above then ensure

a Bleed Hose has been fitted to the system.
Pre-Start Requirements
Refer to the hydraulic schematic on page 5-3 to identify all KWL700RC
valves.
In the hydraulic pump suction system there are 6 bleeding points that are
required to be bled until all signs of air in system has been expelled.
Left hand side manifold bleed points

Right hand side suction manifold bleed points
Bleeding triple vane pump (No. 5)
Crack off the fittings in 3 places on pump outlets to expel air

from the system.
Pressure cut off adjusting screws (P16)
Screw out (3 turns) until loose.
Valves PO5 and PO7
Screw out the pump cut off adjusting screws PO5 and PO7
(one turn each) until loose.
Valve No. 6
Screw out the thumb wheel on the acoustic fan/water pump relief valve
(No. 6, mounted on triple vane pump) until it is loose.
Priority flow control valve (No. 7)
Screw this adjustment all the way in then back out 2 full turns
(for the acoustic fan and water pump circuit).
It is mounted inside the mast pivot frame.
Valve No. 14
Screw in the adjuster on case flush flow control valve (14), and then
back it out just over half a turn. It is located on right hand rear of the rig.
Valve No. 85
Screw out the pilot pressure reducing valve (85), and adjust until loose.
It is located right hand rear of the rig.
Valve No. 27
Screw the main holdback relief pilot valve (27) all the way in.
Valve No. 76
The rotation torque pressure reducing valve (76) is to be wound out

until it is loose. It is located inside cabinet enclosure.
Compressor Regulator Valves
Remove the reducing pressure regulator valve

on the compressor manifold and preset it to 85 psi.
Remove the reducing pressure regulator valve on the compressor

and preset it to 65 psi.
Testing the Low Air Pressure Circuit (rod spanners. etc. )
Remove air lines from the Fisher Valve at the ‘T’ connection.
• Connect external (workshop) 100 psi air supply to ‘T’, which is now
connected to the flexible lines. (Do not connect to the Fisher Valve.)
• Test the functions of the air-operated rod spanners via foot controls located
on the Control Panel driller’s deck.
• Disconnect the external air supply and reconnect the air lines to the Fisher
Valve.
• Check the cooler fan (situated in the top of the engine enclosure) is free
to turn, clear of all guards, etc.
• Check the cooler fan (situated in compressor ‘V’ pack enclosure) is free
• Check the cooler fan (situated on right hand side of Funk gearbox) is free
Control Panel Pre-Start Check List
56
57
41 58
59
34 51 52 53 54
36
48 46 50
30
55
• Check all general control levers are in the Neutral position

• Mast lock control (K-55) is in the Unlock position
• Rotation torque forward control knob (K-30) is wound out completely
• Rotation reverse torque control knob (K-50) is wound out completely
• Feed pressure up control knob (K-54) is wound out completely
• Feed pressure down control knob (K-52) is wound out completely
• Clamp pressure control knob (K-51) is wound out completely
• Water pump on/off control (K-34) is in the Off position
• Dust suppression control valve (K-46) is in the Off position
• Feed holdback control knob (K-53 ) is wound in completely
• Hammer oiler control knob (K-48) is wound in completely
• Compressor start / run control (K-56) is in the Start position
• Compressor pressure setting control (K-57) is set to 175 psi.
• Blow down control (K-58) is set to the Off position
• Blow down air swivel control (K-59) is set to Open position
• Engine throttle control (K-41) is set to Minimum
• Air dump valve (K-36 ) is in the Closed position.
Have a person near the Emergency Stop, ready to shut down the
engine if any problems should occur.
• Set the safety shutdown parameters on the Murphy gauges situated on

the Control Panel according to the following table:
Discharge temperature 130°C
Interstage temperature 130°C
Hydraulic oil temperature 80°C
• Crank the engine without override activated for a period of 30 seconds
(DO NOT START).
• Check for oil and water leaks, and rectify if present.
• Have a person near the Emergency Stop, ready to shut down the engine
if any problems should occur.
• Start rig and check idle speed is 1400 rpm
(DO NOT OPERATE BELOW THIS IDLE SPEED).
• Proceed to check all Emergency Stops, battery isolators, and Murphy shut
down gauges for correct operation.
• Reset the Murphy shutdown gauges to the above values after testing
their operation.
• Restart the rig and, if all is OK to run, idle the rig at 1400 rpm for 5 minutes
while looking for fluid leaks
• Check the ‘V’ pack fan to make sure air is sucking through the
radiators.
• Shut down the rig.
• Recheck the following fluids levels:
Engine oil
Coolant
Hydraulic oil
Compressor oil
• Restart the rig and check the engine range is between 1400 rpm (idle
speed) and 1800 rpm (maximum speed).
• Check for leaks and then shut down the rig.
Settings
Cooler Fan Pump
Fit a high pressure ball valve into the compressor temperature switch
(17) line from pump.
Insert the ball valve between hoses  and .
Close the ball valve and temporarily set the cooler fan pump PO7 (3)
to 1500 psi. Read the pressure on the cooler fan gauge
on the Control Panel (63).
NOTE: This is a temporary adjustment only to allow setting of auxilliary

banks and raising mast. Final PO7 pump cut-off pressure will be set later.
Pilot Pressure Valve (85)
Insert a gauge into the line and set pilot pressure to 500 psi on the valve.
Open the temporary ball valve in the compressor temperature switch line.
Adjust the pressure relief valve to 500 psi as read on pilot pressure gauge
situated in engine temp switch (16) and compressor temp switch (17) load
sense line (to maintain minimum 500 psi pilot pressure).
The relief valve is situated in the tank return manifold.
Confirm pilot pressure is 500 psi.

Remove the temporary ball valve from the compressor switch circuit.
Control Panel Auxiliary Valve Banks

Load sense relief valves on auxiliary valve banks 60, 61 & 62 must be
wound all the way in before attempting to set.
Reading on the clamp pressure gauge on the Control Panel adjust the load
sense main relief in the following order:
Valve 60 3600 psi bottom
Valve 61 3550psi middle
Valve 62 3500psi top
Setting secondary load sense relief valves on auxiliary valve banks

situated inside Control Panel enclosure:
Valve (62)
Main air valve section ‘A’ port is set to 1000 psi
Main air valve section ‘B’ port is set to 1000 psi
Wind in clamp pressure control valve (93)
Break out clamp section ‘A’ port is set to 3000 psi

Break out clamp section ‘B’ port is set to 3000 psi
Valve (61)
Mast tilt section ‘A’ (mast up) port is set to 3000psi
Mast tilt section ‘B’ (mast down) to be set after mast raise
Valve (60)
Mast dump section ‘A’ port is set to 3000 psi
Mast dump section ‘B’ port is set to 3000 psi
Extend and retract all jack legs to bleed out air and to check the direction of
operation.
Adjust jack legs counterbalance valves. Wind fully out and then wind in a
quarter of a turn.
Cabin Yaw and Cyclone Slew

Before operating, screw spool stops all the way in and then out a quarter
of a turn.
Carefully check the speed. Adjust both operations in both directions until a slow
manageable speed is obtained for both cabinet yaw and cyclone slew.
Check the direction of cabinet in and out.
Check the hoses in the tray run correctly and are not too tight.
Rod Trough Counterbalance/Flow Control Valve

Mast in Down position
Valve 53 is situated inside the mast above the rod trough motor. Completely
open the flow control valve and adjust cartridge C2 all the way out.
Move the rod trough lever to the Up position on the Control Panel and adjust
cartridge C2 until the rod trough tray just starts to move in the Up direction.
Lock the locknut on the cartridge.
Adjust flow control valve (51) until a slow steady speed is obtained.
Check the operation in both direction, slow to raise trough, fast to return.
Mast dump over centre valves

Screw the cylinder end overcentre cartridge all the way in,
then turn out 1¼ turns.
Screw the rod end overcentre cartridge all the way in,
then turn out 3½ turns.
Mast Raise and Dump Cylinders

NOTE: Ensure cylinders have been pre-filled with hydraulic oil and have
been fully extended and retracted before attempting to raise the mast.
The head must be at the bottom of the mast before the mast is raised.
The mast must be checked for any loose objects that may fall when
raising the mast.
PLEASE READ AND ENSURE YOU UNDERSTAND THE FOLLOWING

PROCEDURES BEFORE PROCEEDING TO THE NEXT STEP.
WORKING NEAR OVERHEAD POWER LINES

A Job Safety Analysis must be carried out prior to working in
the vicinity of power lines.
Workers must be trained in the hazards associated with
working near live wires and the nominal safety distances
must be adhered to.
LOOK UP AND LIVE — POWER LINES

Raising the Mast

NOTE: When starting the rig with the mast lock disconnected, the mast
lock cylinder will drop slightly before raising back up. This happens
because pilot pressure takes a few seconds to stabilize.
15 16 17 18
IMPORTANT Jacking the Base

Always lift the front or rear
Lower all four jacking legs onto stable ground using the levers [L15, 16, 17,
jacks as a pair to avoid
and 18] to raise drill rig base to the required height.
severe twisting of the rig base
structure. Ideally, the truck wheels should just be touching the ground.
Typically raise the fronts Set the drill rig base level.
300mm then raise the rear jacks
300mm or all together.
Initial Mast Raise
NOTE: Whilst raising the mast check that:
• there is no fouling with any hoses and no fouling between
counterbalance manifolds and the frame.
• hoses are not caught up on anything.
• the mast dump frame is not twisted by the mast raise cylinders when
they are at full extension.
• Raise mast up to 15°.

• Lower the mast back down to see if you have full control.
• Raise mast up to 30 ° and lower back down.
• Raise mast up to 45°, then fully extend and retract the mast dump whilst
raising the mast, and check for correct function.
• Lower the mast and adjust mast down relief valve to 1500 psi
(using valve 49, located under hydraulic tank).
• Raise the mast to 90°.
• Mast tilt section ‘B’ (mast down) should be set whilst the mast is in a vertical
position and should be set to 1500 psi.
This setting may be required to be increased slightly in some instances
if the mast cannot be lowered from vertical.
Cooler Fan Setttings

Start the rig with the (temporary) high pressure ball valve already fitted to
compressor thermal valve lines in the Open position.
Once rig is started, close the (temporary) high pressure ball valve.
Check the fan direction is correct, and air is being drawn through the
radiators.
Set pump P07 cut-off pressure to 2800 psi or a cooler fan speed on the Vee
Pack of 1400 rpm (whichever comes first).
NOTE: The fan speed needs to set before commissioning the pumps
and the compressor.
Contact Neil from ‘Allied Heat Transfer’ to commission the Vee Pack and
confirm exact air flows. Temperatures and fan speeds should be recorded
and set. (Allow 1 full working day to test the Vee Pack.)
Standby Settings
P16 Pump
Fit a gauge into the outlet ports on the 3 x P16 pumps

and set their standby pressures to 440 psi.
Rotation Circuit
Remove the two hoses going to one of the Rotation motors and plug and cap
at the motor connection.
Connect a hose from other rotation motor to a flow meter that is capable of
reading a minimum 450 lpm @ 5000 psi.
Also fit a 5000 psi gauge to the test port on the rotation pump outlet.
Ensure all secondary reliefs on valve 21 (CVG30) are wound in to maximum
and also wind in the main relief.
Do not adjust internal pilot pressure relief setting on CVG 30 as this is

preset by the supplier.
Wind the rotation torque control valve (valve 75) fully in.
Wind the reverse rotation torque control valve (valve 74) fully in.
Start the engine at 1400 rpm and engage Forward Rotation on the Control
Panel.
Slowly close load valve fully on the flowmeter and then increase the
pump cut-off pressure to 3900 psi by adjusting the compensator screw
on the rotation pump.
Whilst the pump is loaded through the flowmeter and is at cut-off pressure,
slowly back out the main relief on the valve bank (21) until oil is just heard to
be going across the relief.
Lock the main relief and re-adjust the pump cut-off setting to 3600 psi.
Ê

Ê Secondary Relief Valves

Ë Main Relief Valve
Ì Internal Pilot Relief
Open the load valve on the flowmeter.

Increase the engine speed to 1800 rpm and, with Forward Rotation actuated,
check the flow rate on the flowmeter. It should be a minimum of 400 lpm.
Slowly close the load valve on the flowmeter to ensure this flow is obtained
up to 3300 psi.
Open the load valve and repeat the flow and pressure test with the Rotation
lever in the Reverse Rotation position.
Remove the flow meter and refit the hoses.
Valve 21 (CVG30) Main Relief Set at 3900 psi

Rotation Pump Pressure Cut-off set at 3600 psi
Maximum Rotation Flow Rate at 1800rpm
(No Load) Forward Lpm
(3300 psi) Forward Lpm
(No Load) Reverse Lpm
Maximum Rotation Flow Rate att 1800rpm
(3300psi) Reverse Lpm
Feed Circuit
Be sure to fast feed head up and down the mast at least 6 times to expel all
air from feed cylinders before continuing.
Make sure the head is left at bottom of the mast and the fine feed pressure
valve is wound out completely before shutting the rig down.
Shut down the rig
Fit a 5000 psi gauge to the feed pump outlet test port.
Flow Meter position for Feed Circuit Testing.

The Mast should be in the Up Position.
2 x Tees in the A and B Ports may be required for testing in both
directions.
Connect a Flowmeter to A and B in the Feed Circuit
Ensure the secondary reliefs on CVG50 valve ( 23 ) are wound in to maximum

and also wind in the main relief.
CVG 50 Main Relief Valve
CVG 50 Secondary Relief Valves x 2 on Centre Section of Valve

Setting the Lower Feed Pump
Ê Lower P16 Feed Pump

Ë Upper P16 Feed Pump
Remove the load sense line from the Upper P16 Fast Feed Pump, then plug
and cap the connection.
Start the engine and at 1400 rpm engage the Fast Feed Up lever on the
Control Panel.
Slowly wind in the load valve on the flow meter (approx. 1000 psi) to allow
the drill head to travel to the top of the mast.
Slowly close the load valve fully on the flowmeter and then increase the
pressure cut-off on the feed pump to 4550 psi by adjusting the compensator
screw on the pump.
Then slowly back out the CVG50 valve main relief until you can hear oil just
start to flow across the relief. Lock this up.
Re-adjust the Lower P16 pump pressure cut-off setting to 4250 psi.
NOTE: A minimum of 500 psi must be maintained at the flowmeter during

testing so that the check valve (15) on the other feed pump does not
open.
Open the load valve on the flowmeter.

Increase engine speed to 1800 rpm and, with the Feed lever still in the Up
position, check the flow rate on the flowmeter.
It should be a minimum of 400 lpm at 500 psi.
Slowly close the load valve on the flowmeter and ensure this flow rate is
maintained up to 4000 psi.
Open the load valve to maintain 1000 psi and allow the drill head to travel to
the bottom of the mast with the Feed lever in the Down position, and repeat
flow test in this direction.
Feed Valve Main Relief set at 4550 psi

Feed Pump Cut-off set at 4250 psi
Max Feed Flow Rate at 1800 rpm
(No Load – 500 psi must be maintained) Feed Up Lpm
(4000psi) Feed Up Lpm
(No Load – 500 psi must be maintained) Feed Down Lpm
(4000 psi) Feed Down Lpm
Refit the load sense line to the Upper P16 Feed Pump.
Setting the Upper Feed Pump

Remove the load sense line from the Lower P16 Fast Feed Pump, then
plug and cap the connection.
Start the engine and at 1400 rpm engage the Fast Feed Up lever on the
Control Panel, adjust the flow meter to 1000 psi, and allow the head to travel
to the top of the mast.
Slowly close the load valve fully on the flowmeter, and then increase the
pressure cut-off on the upper feed pump to 4250 psi by adjusting the
compensator screw on the pump.
Open the load valve on the flowmeter whilst maintaining 500 psi, and increase
the engine speed to 1800 rpm.
With the feed lever still in the Up position, check the flow rate on the
flowmeter.
It which should be a minimum of 400 lpm.
Slowly close the load valve on the flowmeter and ensure this flow rate is
maintained up to 4000 psi.
Feed Pump Cut-off set at 4250 psi

(No Load – 500 psi must be maintained) Lpm
(4000PSI) Lpm
Adjust the flowmeter to 1000 psi and move the Fast Feed lever to the Down
position and confirm there is no flow from this pump (i.e. checking the operation
of valve 24).
Remove the flow meter from the feed circuit.
Rod Handler Circuit
Ê Fit a gauge into the test port of the rod bin valve (32) mounted on the
right hand rear deck.
Ë Wind in the load sense relief on the bin raise/lower valve (32).
Wind in the load sense relief on the rod handler 6-spool valve bank (91)
mounted in the mast.
Start the engine and idle.

Adjust the PO5 pump cut-off setting to 3200 psi .
Set the load sense relief valve on the 6-spool valve (91) until oil is just heard
to be going across the relief. (3200 psi )
Set the load/rod bin bank relief valve to 3050 psi.
Reset pump PO5 cut-off pressure to 2850 psi
NOTE: The Sandvik supplied rod handler has its counterbalance valves
and pressure reducing valves preset. The Boart Longyear manufactured
rod handler still requires OEM settings.
Check all functions of the rod handler as per the Operations Manual.
Check that all hoses are clear of fouling whilst checking the operation of the
rod handler.
Check for smooth mechanical operation and no interference with moving
components.
Check for rod-to-head alignment.
Shut down the rig
Acoustic Fan and Water Pump Circuit

Water Pump
Insert a 3500 psi test gauge into the outlet port of the vane pump (water
pump section).
Connect the water supply to the water/FMC pump assembly.
Fit a hose from the washdown port on the jack leg near the Control Panel to
the water supply.
Start the rig and idle at 1400 rpm.
Turn on the water pump control valve and wind fully out the water pump flow
control on main Control Panel.
Allow the water pump to operate in order to bleed hydraulic circuit for approx.
2 minutes.
Turn off the water pump control on the Control Panel.

Shut down the rig
Remove the hose from the inlet side of the hydraulic motor on the water pump
(not the check valve side), then plug and cap the connection.
Start the rig
Turn the water pump control valve to the On position.
Reading on the test gauge, set the pressure reducing valve (6) to
2200 psi.
Turn the water pump control valve to Off.

Shut down the rig
Reconnect water pump motor hose to its original location.
Fit a ball valve and 1500 psi test gauge to the water pump outlet.
(Ensure the valve is in the Open position)
Start the rig.
Turn the water pump control valve on the Control Panel to On, confirm the
operation of the pump is in the correct direction, and water flow is evident
from the pump outlet.
Wind in the water pump flow control valve on the main Control Panel and
ensure the water pump speed is infinitely variable from maximum to minimum
via this valve.
With the water pump flow control valve wound fully out, slowly close the
temporary ball valve fitted to the outlet side of the water pump until the relief
valve is unloading/relieving
Open the temporary ball valve.
Do not adjust the water pump relief valve as it

has been preset and tested by the supplier.
Open the rig washdown valve situated on the Control Panel and ensure a
flow is evident.
Close the rig washdown valve and make sure no water leaks are evident from
the washdown water circuit within the Control Panel, etc.
Stop the water pump, shut down the rig and remove all water pump test
equipment.
Acoustic Fan
Apply a reflective patch to the acoustic pack fan (mounted on top of the
engine enclosure).
Start the rig.
Whilst reading a handheld tachometer, adjust the priority flow control valve
(7) to obtain 1500 rpm on the acoustic pack fan motor (94).
Shut down the rig.

Fine Feed Circuit

Close completely the feed pressure control valve.
Close completely the feed up pressure control valve.
Open the holdback control valve.
Wind the secondary load sense relief on the fine feed control valve (26)
(situated in the control cabinet) all the way in.
Start the rig.
Move the Fine Feed lever on the Control Panel to the Down position and
allow the head to travel to the bottom of the mast.
Adjust the load sense relief on the fine feed control valve (26) (situated in the
control cabinet) to 3000 psi. (Read this value on the feed pressure gauge on
the Control Panel.)
Open the feed pressure control valve and confirm that pressure decreases
and increases as this valve is adjusted. (Read on feed pressure gauge.)
Move the Fine Feed lever on the Control Panel to the Up position and allow
the head to travel to the top of the mast.
Check the relief valve setting is 3000 psi in this direction.
SECTION 8
Electrical Schematics
This section contains electrical schematics of various
Boart Longyear components and items supplied by
OEMs.
8-3 Electrical Schematic – Detroit MTU Engine
935-700RC03019406K01 MTU.PDF
8-5 Electrical Schematic – Caterpillar Engine
935-700RC0802520K01 CAT.PDF
8-7 Electrical Schematics – RC Rod Handler
RC 1.PDF
RC 2.PDF
RC 3.PDF
RC 4.PDF

700rc Ops Manual

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700rc Ops Manual

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KWL700RC

Rig serial no.:

Engine model no.:

Rotation Pump serial no.:

Feed Pump serial no.:

Water Pump serial no.:

Section 2 Drill Introduction

Section 3 Drill Components

Section 4 Drilling Operations

Section 5 Hydraulic Explanation

Section 6 Drill Rig Maintenance

Section 7 Start Up Procedure

Section 8 Electrical System

Section 9 KWL700RC Parts List

Hazard Signal Words

DANGER indicates an imminently hazardous situation which, if not avoided,

WARNING indicates a potentially hazardous situation which, if not avoided,

CAUTION indicates a potentially hazardous situation which, if not avoided,

Boart Longyear Limited Warranty

Boart Longyear Pty Ltd

© Boart Longyear 2008

Ordering and Returning Parts

1 List the model and serial number of the drill.

You will be required to:

1 Wear appropriate Personal Protective Equipment (PPE).

Analyse Your Risk:

Safety is Your Responsibilty

• Power line contact can be fatal.

• Loose clothing can be fatal.

• Unsecured air hoses can be fatal.

• Falling components can be fatal.

• Beware — falling items can cause serious injury or death.

General Drill Arrangement

Vee Pack Cooler

Hydraulic Oil Tank

Left Hand Side

DRILLING DEPTH GUIDELINES

DEPTH 775 m 2,542.7 ft

RETRACT FORCE (max) 40 000 kg 88,183 lb

RETRACT SPEED (max) 930 mm/sec 36.6 in/sec

RAPID PULL DOWN FORCE 20 000 kg 44,100 lb

RAPID PULL DOWN SPEED 930 mm/sec 36.6 in/sec

OIL SUPPLY 765 lpm 202 gpm

ENGINE SPEED 1,600 to 1,850 rpm max

METRIC SYSTEM U.S. CUSTOMARY SYSTEM

ROTATION DRIVE HEAD

TORQUE AND RPM RATINGS

METRIC SYSTEM U.S. CUSTOMARY SYSTEM

METRIC SYSTEM U.S. CUSTOMARY SYSTEM

BASE FRAME ASSEMBLY

JACK LEG ASSEMBLIES

METRIC SYSTEM U.S. CUSTOMARY SYSTEM

CENTRAL GREASE STATION

METRIC SYSTEM U.S. CUSTOMARY SYSTEM

HYDRAULIC OIL COOLER

HYDRAULIC HOSES AND FITTINGS

METRIC SYSTEM U.S. CUSTOMARY SYSTEM

AUTO POWER BREAKOUT

DRILL ROD SPANNERS (2)

METRIC SYSTEM U.S. CUSTOMARY SYSTEM

VEE PACK COOLER

METRIC SYSTEM U.S. CUSTOMARY SYSTEM

ADDITIONAL SAFETY FEATURES

METRIC SYSTEM U.S. CUSTOMARY SYSTEM