Appendix Q

LS-100 Maintenance

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Maintenance is a critical but often overlooked aspect of water development projects. Often it is not considered until there is a crisis because machines have broken down at a critical time or wells stop producing water during dry seasons. Special attention must be given to properly maintain critical drill machine components including:

• LS-100 Engine and Transmission Oil Levels
• Swivel/Quill Assembly
• LS-100 Chain, Bearings and Mast Lubrication
• Mud Pump

1. Check oil level in the engine crank case before beginning a new hole, and each day thereafter during the drilling operation add oil if necessary. Note: change oil after first five hours of operation, thereafter every 25 hours of operation. Use oil as recommended in the engine maintenance manual.
2. The oil level in the transmission case does not need to be checked between oil changes unless there is an obvious leak.
3. For all other maintenance of the engine and transmission refer to the operators manual which is included with the equipment.
4. The frame itself requires little or no maintenance.
5. Inspect, clean, replace (if necessary) and re-grease the swivel seals after each borehole.

If properly maintained, one set of seals should last for 1000 feet of drilling. If not properly maintained, sand can come in contact with seals, mix with the grease and act as a grinding wheel, causing grooves to form around the quill within 1 hour. Once this occurs, leaking can not be stopped. This problem is the number one cause of LS100 drill rig breakdown!! To ensure that this does not happen, follow the proceedure listed below prior to drilling EVERY DAY:

1. Loosen the set screws on the upper and lower compression nuts.
2. Loosen the upper and lower compression nuts of the water entry swivel, remove the 3/8-inch bolt from the shaft, and pull out the quill.
3. Look for any grooves or notches worn into the quill at the position of the seals. If these signs of wear are noticed, replace the quill with one that is new or reconditioned. Worn quills should be immediately reconditioned by welding over the wear points and then smoothing the quill down using a lathe.
4. Apply grease liberally to the inside surfaces of the seals. Do not apply grease to the outside of the seals or to the seal seats on the swivel housing.
5. Reinstall the quill, insert the 95 mm (3/8 in) bolt and tighten the bolt lock nut. A lock nut must be used to keep the bolt from vibrating off during rig operation.
6. Tighten the upper compression nut until it is snug. Engage the rotary and, circulating clean water, continue to tighten the compression nut until the quill starts to bind. Then loosen slightly and lightly tighten the compression nut set screw an Allan wrench.
7. Repeat tightening procedure for the lower compression nut.
8. Using a grease gun, pump grease into both top and bottom compression nuts through the grease fittings. Keep adding grease until it is no longer easy to inject grease. Do not force grease into the fitting or continue to inject grease until it becomes visible at the top or bottom of the fittings.
9. If any leaks are observed from the upper or lower compression nuts during rig operation, loosen the set screws and tighten the compression nuts immediately. If leaking stops, re-tighten the set screw and continue drilling. If the leaking does not stop, stop drilling and re-prepare the swivel and quill assembly by repeating all the above points immediately.

LS-100 Chain, Bearings and Mast Lubrication

Mud Pump

1. Check oil level in the engine crank case before beginning a new hole, and each day thereafter during the drilling operation; add oil if necessary. Note: change oil after first five hours of operation, thereafter every 25 hours of operation. Use oil as recommended in the engine maintenance manual.
2. After each borehole, remove the drain plug from the pump housing and clean out sand, gravel or other debris that may have accumulated by flushing the pump with clean water.
3. For all other maintenance of the engine refer to the engine operators manual which is included with the equipment.
4. Replace the seals in the mud pump when a leak is detected at the pump shaft.
5. Inspect the impeller and replace it if it is badly worn. Drilling is very hard on the mud pump and it will be necessary to replace it after 10-20 wells have been drilled.