compressor.pdf

365 1 en 2009-04-08

Air End and Pneumatic CircuitDX and DX_R

Table of Contents

1. GENERAL .............................................................................................................................. 3

2. SAFETY ................................................................................................................................. 4

3. COMPONENTS OF THE COMPRESSOR AND PNEUMATIC CIRCUITS ........................... 53.1. Pneumatic circuit diagram and components .................................................................................... 53.2. Location of pneumatic circuit components DX500, 680, 700, 780, 800 ..................................... 83.3. Location of components - DX_R .......................................................................................................... 9

4. AIR END ................................................................................................................................. 104.1. Technical data ........................................................................................................................................... 104.2. Air end main components ...................................................................................................................... 104.3. Compressing principle ........................................................................................................................... 11

5. OPERATING PRINCIPLE OF THE COMPRESSOR CIRCUIT ............................................. 135.1. General ........................................................................................................................................................ 135.2. Description of components ................................................................................................................... 145.3. Air circulation ............................................................................................................................................ 165.4. Oil circulation ............................................................................................................................................ 175.5. Compressor regulating system ............................................................................................................ 18

5.5.1. Before starting, ignition key position 0 ......................................................................................... 185.5.2. Ignition key to position 1 ................................................................................................................. 195.5.3. Starting, load relief 30 s; ignition key position 2 ......................................................................... 205.5.4. 30 seconds after starting ................................................................................................................ 215.5.5. Delivery ............................................................................................................................................. 225.5.6. Throttling ........................................................................................................................................... 235.5.7. Idling .................................................................................................................................................. 245.5.8. Stopping ............................................................................................................................................ 25

6. CONTROL INSTRUMENTS OF THE COMPRESSOR CIRCUIT .......................................... 266.1. Pneumatic circuit control instruments and warning lights .......................................................... 26

6.1.1. Compressor thermal switch ........................................................................................................... 266.1.2. Air filter service indicator ................................................................................................................ 27

6.2. Oil circuit control instruments .............................................................................................................. 286.2.1. Thermostat ....................................................................................................................................... 286.2.2. Oil filter service indicator ................................................................................................................ 28

7. ADJUSTING PRESSURE AND VALVE BLOCK CONNECTIONS ....................................... 29

8. TROUBLESHOOTING ........................................................................................................... 318.1. The compressor overheats .................................................................................................................... 318.2. Oil in the compressed air ....................................................................................................................... 318.3. Insufficient air output .............................................................................................................................. 328.4. Pressure too high ..................................................................................................................................... 32

Copyright Sandvik Mining and Construction 1 (34)ID: 365 1 en 2009-04-08

2 (34) Copyright Sandvik Mining and ConstructionID: 365 1 en 2009-04-08

GENERAL ID: 16479

This document describes the components, operating principle and troubleshooting of the DX andDX_R compressor and pneumatic circuits.Control instruments and warning lights are described in the operators manual, in the chapter entitledControl instruments.

1.



SAFETY ID: 16480

Always follow the safety instructions and be careful with yourwork.

Only people who have been given specific service training areallowed to undertake service, adjustment and repair proce-dures. Read the instructions before undertaking any servicing,adjusting or repairing.

Hazardous moving and rotating parts. Carry out service and re-pair work only when the rig is not running. Make sure that therig cannot be accidentally started or moved when you are car-rying out the service.

High-pressure air spray hazard. Risk of severe injury. Releasepressure before opening any plugs or joints.

2.



COMPONENTS OF THE COMPRESSOR AND PNEUMATIC CIRCUITS ID: 16484

Pneumatic circuit diagram and components ID: 16485

DX and DX_R rigs are equipped with a compressor producing compressed air for- flushing the drill hole;- lubricating the shank;- cleaning dust collector filters;- dust collector air cylinder;- rod thread greasing device (option)

3.

3.1.



56

3

7

8

9

10

11

12

13

14

15

16

17

33

27

28

26

35

38

3234

39

36

25

1819

31

30

37

24

202122 23

29

ID: 16563

1. Air pre-cleaner*2. Ejector*3. Compressor air filter



4. Air filter service indicator*5. Air end, screw compressor6. Intake valve7. Oil/air receiver8. Oil separator elements9. Minimum pressure valve10. Safety relief valve11. Thermostat12. Oil cooler13. Oil filter14. Strainer (in the oil regeneration line)15. Orifice (in the oil regeneration line)16. Non-return valve (in the oil regeneration line)17. Temperature gauge, compressor18. Pressure regulator19. Blow-down valve20. Non-return valve21. Non-return valve22. Solenoid valve23. Solenoid valve24. Pressure accumulator25. Pressure gauge26. Flushing valve27. Half flushing valve28. Flushing regulating valve29. Pressure gauge30. Drill rod greasing valve31. Suction cut-off valve32. Dust collector solenoid valve33. Dust collector34. Air output connection and valve35. Shank lubrication pneumatic valve36. Water separator37. Shank lubrication unit38. Flushing control39. Rock drill40. Non-return valve of the oil filling pump*41. 3-way valve of the oil filling pump*42. Oil filling pump** = not shown on the chart, see location of components and functional diagram



Location of pneumatic circuit components DX500, 680, 700, 780, 800 ID:16486

39 30

29

3

2

11

12

14

7

5

6

33

34

25

31

37

42

32

38

27

4

2817

26

4140

3635

24232218 212019

1

8 9 10

15 16

13

ID: 16567

3.2.



Location of components - DX_R ID: 16487

39 30

29

3

2

11

12

14

7

5

6

33

34

25

31

37

42

32

38

27

4

26

4140

3635

24232218 212019

1

8 9 10

15 16

13

28

17

ID: 16568

3.3.



AIR END ID: 16488

Technical data ID: 16489

DX500, DX680, DX500R,DX680R

DX700, DX780, DX800,DX700R, DX780R, DX800R

Type Enduro 12 Enduro 25Max. ambient temperature 40...45 C 40...45 COutlet air thermal switch 115 C 115 COutput 5.8 m 3/min 8.1 m 3/minMax. operating pressure 10 bar 10 barBearings Roller bearings Roller bearingsMale rotor dia 120 mm 155 mmGear ratio 1:2.4 1:1.564

Air end main components ID: 16490

The main components of the air end include:

5 43221

ID: 16625

1. Housing2. Rotors3. Outlet cover4. Bearing housing cover5. Gear

4.

4.1.

4.2.



Compressing principle ID: 16491

Together with the housing, the two meshing rotors form the compression chamber. The rotating rotorstake air into the housing through the intake port as the grooves of the rotors pass the intake port.As the rotors turn, the meshing point closes the passage to the intake port and the air is trapped inthe chamber.As rotation continues, the volume of the chamber between the two rotors becomes smaller and thepressure increases.When the desired and most economical operational pressure is reached, the compressed air flowsthrough the outlet port into the receiver.

ID: 16626

4.3.



24 21

22

23

18

25

1920

1 3 3.1 3.226.1 6.2

6

5

12.112

12.2

16 15 14 9

10

78

8.1

4140

42

11

13

13.1 13.2

17

4

ID: 16627The components are shown under normal operating conditions when compressed air is being pro-duced.



OPERATING PRINCIPLE OF THE COMPRESSOR CIRCUIT ID: 16492

General ID: 16493

The air end (5) produces the compressed air used by the drilling rig. From the air end the air is ledinto the oil/air receiver (7), where the oil is separated from the air.The pressure regulator (18) adjusts the intake valve (6) that regulates the intake port according tothe air consumption. The temperature gauge (17) indicates the output air temperature.

5.

5.1.



Description of components ID: 16494

1. Air pre-cleaner The intake air is forced into a whirling motion inside the air filter housing and the centrifugal

force separates the coarsest impurities from the air.2. Ejector

The diesel engine exhaust pipe is used as a venturi tube to generate suction in the pipeconnected to the air filter. The impurities separated in the air pre-cleaner are drawn throughthe pipe and blown out with the exhaust gases.

3. Compressor air filter From the pre-cleaner the air flows through the filter unit (3) where it first passes through the

air filter (3.1) and then through the safety filter (3.2).4. Air filter service indicator

The filter element must always be changed when the service indicator shows red. It locks intothis position. The indicator must be checked daily by pressing the button on the top and thered warning colour must show. (For filter servicing refer to the carrier manual and maintenanceschedules.)

5. Air end, screw compressor The filtered intake air is compressed by the rotating rotors. Oil is used to cool the air. It also

seals the clearances between the rotors and the housing, and lubricates the unit6. Intake valve

Suction acting on the valve disc opens the intake valve when the compressor is started. Theintake valve also acts as an air end underload valve by restricting the intake flow whenever thecompressor output exceeds the air consumption. The disc valve acts as a non-return valvewhen the rotors are stopped. This prevents the oil in the rotor chamber from entering the intakeduct through the compressor.

7. Oil/air receiver The receiver functions as an air and oil receiver as well as an oil separator.

8. Oil separator The oil separator separates the oil mixed with the compressed air.

9. Minimum pressure valve The minimum pressure valve keeps the pressure in the receiver at least at 3 bar while the

compressor is running. This pressure ensures oil circulation in the compressor.10. Safety relief valve

Restricts the maximum pressure in the receiver to 11.7 bar.11. Thermostat

The thermostat directs the oil below 45 C past the oil cooler. The thermostat starts to closewhen the oil temperature exceeds 45 C, allowing some of the oil to flow through the cooler.When the oil temperature exceeds 48 C, the thermostat closes and all of the oil flows throughthe oil cooler.

12. Oil cooler The system includes cooling cores for the hydraulics, and for the compressor oil circuit. The

cooling efficiency can be regulated by allowing some or all of the oil to the fan motor (12.2) toflow through the orifice (12.1) to the tank.

5.2.



13. Oil filter The oil filter is a full-flow in-line unit with a mechanical service indicator and a built-in by-pass

valve. The by-pass valve (13.1) opens when the pressure difference over the unit exceeds 3.5bar. The red knob of the service indicator (13.2) pops up when the pressure difference exceeds2.5 bar. The indicator has a built-in bimetallic device to prevent it operating until the oiltemperature exceeds 27 C.

14. Strainer Prevents impurities from entering the air end.

15. Orifice Restricts the oil flow in the oil regeneration line.

16. Non-return valve Prevents the oil/air mixture from entering the air end oil/air receiver when stopping. The screw

unit remains pressurized until the pressure in the oil/air receiver is released.17. Temperature gauge

Indicates the temperature of the compressor output air. The sensor (17.1) is located under theair end.

18. Pressure regulator The pressure regulator controls the intake valve in accordance with the air consumption,

maintaining the desired pressure. By adjusting the spring of the valve, the compressor outputpressure can be regulated between 4 and 10 bar.

19. Blow-down valve The blow-down valve automatically releases the pressure from the oil/air receiver when the

compressor is stopped. The pressure is released through a valve.20. Non-return valve

Prevents oil from entering the pneumatic circuit after the compressor has stopped.21. Non-return valve

Prevents the pressure accumulator from losing its pressure.22. Solenoid valve

Allows the pressure from the pressure accumulator to the intake valve when the rig is started.The valve remains activated for 30 seconds when the rig is started.

23. Solenoid valve Releases the pressure from the intake valve when the system is switched on. When the rig is

started, the valve closes for 30 seconds, preventing the pressure accumulator from losing itspressure through the valve. The valve is open while drilling occurs.

24. Pressure accumulator Functions as a pressure accumulator by closing the intake valve when the rig is started.

25. Pressure gauge Displays the system pressure.

26. Flushing valve Allows pressure for flushing the hole

27. Half flushing valve Allows pressure for flushing the hole.

28. Flushing regulating valve Restricts the amount of air for half flushing.

29. Pressure gauge Displays the flushing air pressure.



30. Drill rod greasing valve Allows pressure for rod thread greasing

31. Cut-off cylinder and flap Dust collector suction can be shut off easily and quickly by closing the valve: the pressure stops

affecting the cut-off cylinder and the exhaust port flap is closed by the spring.32. Dust collector solenoid valves

Allow pressure onto the dust collector filters.33. Dust collector34. Air output connection and valve

Compressed air output for external use35. Solenoid valve for the shank lubrication air line

Allows pressure for the rock drill when the shank lubrication pump is on.36. Water separator

Separates the water from the compressed air.37. Shank lubrication pump unit

Pumps oil to the rock drill.38. Pressure difference switch and venturi for the flushing automatics

The pressure difference switch measures pressure difference over the venturi.39. Rock drill40. Non-return valve of the oil filling pump

Prevents the oil from flowing from the tank to the pump41. 3-way valve

Directs the oil from the oil filling pump (42) to the compressor receiver or to the drilling hydraulictank.

42. Oil filling pump The pump is used to add oil into the compressor and the drilling hydraulic circuits. The required

circuit is selected with the valve (42). The non--return valve (40) prevents the air circuit pressurefrom breaking the seals in the pump.

Air circulation ID: 16495

The ejector (2) in the diesel engine exhaust pipe generates suction that is used to draw out thecoarsest impurities from the pre-filter housing (1) and blow them out with the exhaust gases.The pre-cleaned air flows through the air filter (3) into the air end (5). The intake and non-return valve(6) on top of the air end opens when the air end is started. The intake valve (6) is controlled by thepressure from the pressure regulator (18).After compression, the oil/air mixture is led into the oil/air receiver (7), where the oil is separated fromthe air. As soon as the air pressure in the receiver exceeds the opening pressure of the minimumpressure valve (9), the clean, oil-free air is led off for hole flushing and other pneumatic devices.

5.3.



Oil circulation ID: 16496

While the compressor is running, the minimum pressure valve (9) keeps the pressure in the oil/airreceiver at least at 3 bar. This pressure forces the oil from the receiver into the oil circuit. The oilcirculation is based on the pressure difference between the receiver and the intake side of the com-pressor.The oil flows to the thermostat (11) through the connection at the bottom of the air/oil receiver.Oil temperature below 45 CThe cold oil flows directly through the thermostat valve (11) and the oil filter (13) to the compressor(5).Oil temperature 4548 CThe wax core in the thermostat valve (11) expands, partially closing the thermostat valve, and someof the oil flows through the oil cooler (12).Oil temperature over 48 CThe thermostat valve is fully closed and all of the oil flows through the oil cooler (12).From the oil cooler the oil flows to the oil filter (13). The filter has a built-in by-pass valve (13.1) thatallows the oil to flow past the filter if the filter is clogged or if the oil is too thick while it is cold. Theopening pressure of the by-pass valve is 3.5 bar. The filter unit also includes a mechanical indicator(13.2) with a red button that pops up if the filter element is clogged (pressure difference over 2.5 bar).From the filter the oil is led into the lubricating channels at the intake side of the screw compressor(5). At the beginning of the single phase compression, oil is injected onto the rotors to cool down theair and to seal the clearances between the rotors and the housing. Oil is also led through otherchannels to lubricate the bearings and the shaft gasket.After compression, the compressed oil/air mixture is led from the screw compressor into the spiralduct of the oil/air receiver (7), where most of the oil is separated from the air and falls to the bottomof the receiver. The rest of the oil mixed with the air is separated when the air flows through the oilseparator elements (8). The oil from the bottom of the separator chamber is forced through the pipeto the intake side of the compressor unit using the pressure difference. The pipe includes the strainer(14) and orifice (15) (on top of the oil/air receiver) which must be cleaned regularly.

5.4.



Compressor regulating system ID: 16498

Before starting, ignition key position 0 ID: 16499

The system is not pressurised. The air end (5) is not running and the intake valve (6) is closed,preventing oil from entering the intake duct from the compressor. The minimum pressure valve (9) atthe top of the oil/air receiver (7) is also closed. The solenoid valves (22) and (23) are closed and notactivated.

22

23

9

7

6

5

ID: 16710

5.5.

5.5.1.



Ignition key to position 1 ID: 16500

When the rigs power is switched on with the ignition key, the solenoid valve (23) is activated. Thevalve opens and releases the pressure from the intake valve (6).

23

6

ID: 16713

5.5.2.



Starting, load relief 30 s; ignition key position 2 ID: 16501

When the diesel engine is started, the solenoid valve (22) opens and the solenoid valve (23) remainsclosed for 30 seconds after starting. The pressure of the pressure accumulator (24) keeps the intakevalve (6) closed so the compressor does not load the diesel engine.

23

6

2224

ID: 16714

5.5.3.



30 seconds after starting ID: 16502

The solenoid valve (22) closes after 30 seconds after starting the engine. At the same time the sol-enoid valve (23) is activated and the valve remains open. Compressor creates suction which opensthe spring-loaded intake valve (6), allowing air to enter the air end. At the same time, the compressorsucks oil from the oil/air receiver (7). The rotating rotors compress the oil and air into a mixture whichis led into the receiver. In the receiver the oil is separated from the air with oil separators. Since thepressure in the receiver is below the opening pressure of the minimum pressure valve (9) duringstarting, the valve remains closed.

23

6

22

57

9

ID: 16717

5.5.4.



Delivery ID: 16503

The disc valve is fully open and the pressure in the oil/air receiver (7) starts rising. When the pressurereaches 3 bar, the receivers minimum pressure valve (9) opens. The pressure regulator (18) is usedto adjust the desired output pressure. Normally, the pressure is adjusted with the valve (18) so thatthe intake valve starts closing at 8 bar, and is fully closed at 9 bar. The intake valve operates steplesslybetween 8 and 9 bar. The oil separated in the separators is led into the air end by the regenerationline. The line includes the orifice, non-return valve, and strainer.

18

6

7

9

ID: 16719

5.5.5.



Throttling ID: 16504

When the system pressure reaches the pressure setting of the regulator (18), the regulator opens,allowing the air to enter into intake valve (6). The pressure pushes the piston of the valve and partiallycloses the air intake port, thus restricting air flow to the compressor. At the same time, the air flowsto the compressor through the non-return valve (20). In this way the compressor receives extra airwhen the intake valve (6) is closing; this prevents noise caused by the reduced intake air flow intothe compressor.The intake valve (6) operates steplessly over a 1-bar range (for example it starts to close at 7 barand is completely closed at 8 bar). The pressure setting for the system is normally 7 bar but it isadjustable between 4 and 10 bar.

18

6

20

ID: 16723

5.5.6.



Idling ID: 16505

In this situation the compressor output exceeds the air consumption. The only difference with throttlingis that the intake valve (6) is now completely closed. Only oil and the air from the non-return valve(20) circulate in the compressor circuit.

6

20

ID: 16733

5.5.7.



Stopping ID: 16506

When the compressor stops rotating, it also stops sucking air. With no suction present, the intakevalve (6) is closed by the spring. Because of the pressure in oil/air receiver (7), the compressor (5)becomes pressurised through the delivery line. The line from the compressor to the blow-down valve(19) is pressurised and the valve opens. Both lines of the blow-down valve are pressurised but be-cause of different diameters of the valve spools, the pressure from the compressor can push the otherspool open, releasing the pressure from the oil/air receiver (7).The non-return valves in the oil regeneration line (18) and the regulator exhaust line (20) prevent theair/oil mixture from entering the system.When the pressure in the receiver drops below the minimum pressure valve (9) setting, the valvecloses.

6

2019

5

9

7

16

ID: 16737

5.5.8.



CONTROL INSTRUMENTS OF THE COMPRESSOR CIRCUIT ID: 16507

Pneumatic circuit control instruments and warning lights ID: 16508

Compressor thermal switch ID: 16509

The compressor temperature gauge (in the op-erating panel) indicates the compressor temper-ature. The thermal switch stops the diesel engineand lights a warning light if the compressor tem-perature exceeds 115 C.

ID: 16784

6.

6.1.

6.1.1.



Air filter service indicator ID: 16510

The filter element must always be cleaned whenthe service indicator (4) shows red while the com-pressor is running. The filter element must be re-placed every 600 hours of operation, or every sixmonths. The safety filter must be replaced whenevery third air filter is removed, or every 1,200hours.The operation of the indicator can be checkedwith the button on the service indicator. The redwarning colour must show when the button ispressed.

4

4

6.1.2.



Oil circuit control instruments ID: 16511

Thermostat ID: 16512

The thermostat (11) controls the amount of oil flowing through the oil cooler according to the tem-perature.

11

ID: 16807

Oil temperaturebelow 45 C thermostat fully openover 48 C thermostat fully closed

Oil filter service indicator ID: 16513

The compressor oil filter has a mechanical serv-ice indicator (13.2). The filter element (13) mustbe replaced if the red indicator knob stays upwhile the compressor is running and the oil hasreached normal operating temperature (above48 C).For operating principle and operating range, referto the chapter entitled Description of compo-nents/Oil filter.

13

13.2

6.2.

6.2.1.

6.2.2.



ADJUSTING PRESSURE AND VALVE BLOCK CONNECTIONS ID: 16514

1. The pressure is adjusted while the compressor is running.2. Flushing must be off.3. Adjust the pressure to 8 bar with the valve (18). Read the pressure from the gauge (25) (if you

want to adjust the pressure lower, open the ball valve slightly before adjusting).

1

45

6

22

25

23

18

21

20

19

ID: 1682418. Pressure regulator19. Blow-down valve20. Non-return valve21. Non-return valve22. Solenoid valve23. Solenoid valve25. Pressure gauge

7.



122

25

23

182120 19

24

2

3

4

5

1

1

2 3 4 5

ID: 168251. From the air receiver2. To the pressure accumulator3. To the intake valve4. To the compressor5. Out-blow from the air receiver



TROUBLESHOOTING ID: 16531

The compressor overheats ID: 16532

POSSIBLE REASON CHECK / OPERATIONOil level too low. Check the oil level before starting and fill up if

necessary. Avoid overfilling (about 1/3 of theheight of the sight glass is sufficient).

Faulty thermostat (11). (Oil circulation throughthe cooler core is partially or completelyobstructed.)

Check the operation and condition of thethermostat (11).

Dirty oil cooler core (12). Clean the core.Clogged oil filter (13). (Poor oil circulation poorcooling efficiency.)

Replace the oil filter (13).

Low output pressure. (Poor oil circulation withlow receiver air pressure.)

Increase the pressure by adjusting the pressureregulator (18). Low pressure may also be causedby excessive air consumption.

Oil viscosity too high (oil too thick). (Poor oilcirculation poor cooling efficiency.)

Check the oil grade, refer to the oilrecommendations.

Air in the oil cooler core.(Poor circulation) Bleed the oil cooler core and change the oil typeif foaming occurs.

Incorrectly adjusted/leaking/faulty pressurerelief valve (84) of the pump (80) for the oilcooler. (The fan rotates slowly poor coolingefficiency.)

First check that the one-way restrictor valve at thefan motor is not open; all oil should go through thefan motor (12.2). Refer to the instructions forDrilling hydraulics. Check/adjust the pressurerelief valve.

Oil in the compressed air ID: 16533

POSSIBLE REASON CHECK / OPERATIONClogged oil return line. (Too much oil in theseparator chamber of the oil/air receiver oilmixes with the output air.)

Clean the orifice (15) ( 1.0 mm) on top of the oil/air receiver, and the strainer (14) and the non-return valve (16) located in the same line.

Faulty oil separator element (8) or O-ring (8.1). Check the oil separator elements (8) and the O-rings (10.1) (for example, a hole in the element).

Oil level too high in the tank. Check the oil level and drain if necessary.Foaming oil. Check the oil grade, refer to the oil

recommendation. Check the oil level.

8.

8.1.

8.2.



Insufficient air output ID: 16534

POSSIBLE REASON CHECK / OPERATIONIncorrectly adjusted or faulty pressureregulator (18).

Adjust the regulator for higher pressure. Checkthe operation and condition of the regulator.

Leaking blow-down valve (19). Clean the blow-down valve.Clogged breather hole of the intakevalveconnecting nipple. (The pressure underthe intake valve piston not released.)

Clean the breather hole of the intake valveconnecting nipple (intake line).

Leaking pneumatic circuit.(For example, abroken hose allows the air to escape.)

Repair the leaks.

Faulty dust collector solenoid valve(s). Turn the switch to the forced flushing position.The solenoid valve is not activated and it closes.Loosen the connector to the dust collector whilethe flushing is on. If air comes out through theconnection, the solenoid valve is faulty.

Pressure too high ID: 16535

Leaking intake valve (6) piston seal, or faultyintake valve. (The intake valve does not closeproperly.)

If air escapes through the breather hole above thepiston while the compressor is running and theintake valve is closed, the piston seals must bereplaced.

Incorrectly adjusted or faulty pressureregulator (18).

Adjust the pressure regulator for lower pressure.Check the operation and condition of theregulator.

8.3.

8.4.



w w w . s a n d v i k . c o m

Original instructions377 2 en 2011-04-12

Shank Lubrication System (SLU)Operation and Maintenance

Table of Contents

GENERAL ......................................................................................................................................1. 5

SAFETY PRECAUTIONS ..............................................................................................................2. 6

MAIN COMPONENTS ....................................................................................................................3. 7

TECHNICAL DATA ........................................................................................................................4. 8

DESCRIPTION OF OPERATION ...................................................................................................5. 9Shank lubrication system monitoring .........................................................................................................5.1. 9Operating principle of the shank lubrication system .............................................................................5.2. 9Operation diagram of the shank lubrication oil pump ...........................................................................5.3. 10Monitoring unit ..................................................................................................................................................5.4. 11Heating circulation function ..........................................................................................................................5.5. 12Boost switch ......................................................................................................................................................5.6. 14Air line pressure switch S305 .......................................................................................................................5.7. 14Cabin indicator lights ......................................................................................................................................5.8. 14

ADJUSTING THE SHANK LUBRICATION DEVICE .....................................................................6. 15

MAINTENANCE INSTRUCTIONS .................................................................................................7. 17Checking the operation of the monitoring unit ........................................................................................7.1. 17Bleeding the shank lubrication oil line .......................................................................................................7.2. 18Bleeding the shank lubrication oil pump ...................................................................................................7.3. 19Replacing seals .................................................................................................................................................7.4. 20Replacing a faulty shank lubrication hose ................................................................................................7.5. 21Draining the condensed water from the oil tank ......................................................................................7.6. 22Cleaning the oil receiver .................................................................................................................................7.7. 22Replacing the oil tank breather .....................................................................................................................7.8. 23

TROUBLESHOOTING ...................................................................................................................8. 24


GENERAL

The purpose of shank lubrication is to lubricate the rock drills rotation mechanism and shank.Lubrication is carried out using a mixture of shank lubrication oil and compressed air. Proper shanklubrication is essential. Inadequate lubrication rapidly causes serious damage to the rock drill.Following these instructions will significantly increase the safety, reliability and operating life of therig. Sandvik Service is always willing to provide advice and help with any problems related to the rig.

1.



SAFETY PRECAUTIONS

Take all safety factors into consideration and perform your workwith care. Follow all drilling site safety regulations.

Operating, service and adjustment procedures must be carriedout only by personnel with specialized operation and servicetraining. Read and ensure that you understand the operating,maintenance, and safety instructions before using or servicingthe rig.

Danger of venting compressed air. Compressed air jets cancause serious injury. Allow the pressure to be released beforeopening the filling cap or the compressed air connector.

2.



MAIN COMPONENTS

1 8

29

3

5

10

4

11

12

137

6

1 Level switch 2 Breather / filler cap3 SLCU control unit 4 Forced operation button (Boost)5 Pump control valve CT5.1 6 Pump unit7 Drain valve 8 Oil dipstick9 Oil tank 10 Fine adjustment switches

11 Bleeding screw CT7 12 Hydraulics bleeding screw CT413 Control switch CT1

3.



TECHNICAL DATA

Oil tankTotal amount of oil (l) Depends on the equipment typeBreather (m) 10Oil strain (mm) 1Level switch Yes

Pump unitStroke volume 2,0 cmOutput range 188 - 2800 g/hMax. operating pressure 210 barMin. operating pressure 25 barMax. lubrication oil pressure 25 bar

Tightening torques NmControl switch 7ump unit fastening screws 20

4.



DESCRIPTION OF OPERATION

Shank lubrication system monitoring

The shank lubrication system monitors air pressure, oil flow and oil level in the oil tank. If the airpressure drops, oil flow decreases too much (or stops completely) or the tank runs out of oil, theshank lubrication system goes into alarm state. In the alarm state, drilling is stopped, the joystick isautomatically centered and the red indicator light turns on.

Operating principle of the shank lubrication system

1 5

2

3

4

78

10

6

9P

1 Breather / filler cap 2 Oil tank3 Pump unit 4 Hydraulic oil pressure line5 Level switch 6 Shank lubrication oil line7 Hydraulic oil tank line 8 Compressed air line9 Pressure switch 10 Rock drill

5.

5.1.

5.2.



Operation diagram of the shank lubrication oil pump

CT1 control switch CT2 suction side non-return valveCT3 operating piston CT4 hydraulics bleeding screwCT5.1 directional valve CT6.1 non-return valveCT7 bleeding screw CT8 heating circuit

The lubrication pump is a hydraulic, elctrically controlled piston pump. The lubricant dosage isdetermined electrically by changing the operating frequency of the pump.The main block has its own lubrication control switch CT1. The control is always operational whenthe operating voltage is switched on.The directional valve (CT5.1) guides the hydraulic oil pressure to the piston side and the piston rodside alternately. When valve (CT5.1) receives the control voltage, it prevents the pressure fromentering at the piston side, whereupon the pressure on the piston rod side forces the oil on the pistonside into the tank line. At the same time, the lubrication oil is sucked from the tank through port S intothe operating piston chamber. When the control voltage is cut off from the valve (CT5.1), the higherpressure is directed to the piston side, and the oil on the piston rod side re-enters circulation. Thelubrication oil is pumped to the rock drill through port L.

5.3.



Monitoring unit

The shut-off ball of the lubrication pump output port non-return valve operates as a control switch(CT1) against the valve seat. The oil flow through the non-return valve removes the ball from the seatsurface and shuts off the circuit. The control switch non-return valve ball is electrically connected tothe pump (and rock drill) frame. The voltage is directed to the ball via a spring isolated from the pumpframe.

If the ball remains against the seat or remains open for fouroperational cycles, an alarm is switched on and drillingfunctions stop.

5.4.



Heating circulation function

The performance of the pump decreases in coldconditions. This is due to the increased viscosityof both the shank lubrication oil and the hydraulicoil that drives the pump. The increase in viscositycauses problems in, for example, the ON/OFFvalve (CT5), which controls the pump and thepump intake valve (CT2).The heating circulation function is based on cir-culating the hydraulic oil driving the pump throughthe pump. The oil circulates through an 0.6-mmorifice (CT8) and then directly into the tank. Thevolume flowing through the orifice is approx. 12.5 l/min. The heating circulation function can beenabled and disabled.

5.5.



Heating circulation components

1

5

4

3

2

1 Locking nut2 Heating circulation orifice, 0.6 mm3 Plug screw4 Seal5 Cap

Enabling/disabling the heating circulation function

Enabling the heating circulation Disabling the heating circulation1. Unscrew the cap (5)2. Loosen the locking nut (1) but do not remove

the nut3. Turn the plug screw (3) 2.5 turns counter-

clockwise4. Tighten the locking nut (1)5. Reinstall the cap (5)

1. Unscrew the cap (5)2. Loosen the locking nut (1) but do not remove

the nut3. Turn the plug screw (3) 2.5 turns clockwise4. Tighten the locking nut (1)5. Reinstall the cap (5)



Boost switch

The boost switch is used in the following cases: to fill the shank lubrication hose when higher shank lubrication is temporarily neededWhen the boost switch is activated, the indicator light of the pump control valve starts to flash. Theoil output of the pump is now 2800 g/h and the pumps stroke frequency is 30 strokes / minute. Theboost function is active as long as the boost switch is on.

Remember to turn off the boost switch after the serviceoperations!

Air line pressure switch S305

The air line pressure switch monitors the air pressure to the rock drill when the SLU pump is activated.If the air flow is disturbed (the pressure drops below the value set to the pressure switch) the redindicator light turns on, the green indicator light turns off and the joystick is automatically centered.

Cabin indicator lights

H93 Shank lubrication is working.

H94Shank lubrication malfunctioning (drilling isstopped) or shank lubrication oil level islow.

H93

H94

5.6.

5.7.

5.8.



ADJUSTING THE SHANK LUBRICATION DEVICE

The pumping frequency of the lubrication pumpcan be set within the range of 2...30 strokes perminute using the two 16-position rotary switcheson the SLCU unit. The 16 positions of each switchare indicated with numbers 0...9 and letters A...F.The first switch is the range switch (RANGE)which is pre-set and sealed at the factory. Theother switch is the fine adjustment switch (FINE).Correct lubrication dosage for various rock drillsin various drilling conditions is achieved by thedifferent positions of these adjustment switches.The range switch settings are the same in set-tings 6-F.

Rock drilltype

Range of the RANGEswitch setting (g/h)

Settingof theRANGEswitch

Setting of theFINE switch

Amount of lu-brication tothe rock drill(g/h)

Lubricationcheck value (ml/5min)

HLX 5 300-600 0 4 230 21 3HLX 5T 200-400 1 5 310 28 3HL 510 200-400 1 5 310 28 3HL 600 300-600 2 1 400 38 4HL 710 400-850 2 5 470 44 5HL 650/710 400-850 2 5 470 44 5HL 710T 400-850 3 7 690 64 7HL/HF 810T 400-850 3 7 690 64 7HL 800T 400-850 3 7 690 64 7HL 800 400-850 3 7 690 64 7HL 1010 400-850 3 7 690 64 7HL 1560 600-1200 4 4 910 76 8

When a circuit board is supplied as a spare part, it is set at themaximum settings. Set the board to the correct settingsaccording to the values indicated in the lubrication table.

Depending on the drilling conditions (hole depth, rock type,etc.) the required amount of lubrication may vary both withinand beyond the specified range. For small hole sizes (for therock drill in question) and in upwards drilling and bolting, werecommend using low fine adjustment settings. For larger holesizes and high temperature surface applications, werecommend using higher fine adjustment settings.

Example for reading the table: Range setting = 3, Fine setting = 7 Lubrication oil volume is about690 g/h.

6.



LUBRICATION CONTROLLER 2.0cm^ 3

0

500

1000

1500

2000

2500

3000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16fine adjustment

]h/g[ noita cir bul

0123456



MAINTENANCE INSTRUCTIONS

Checking the operation of the monitoring unit

1. Check the operation of the monitoring unit as follows: Disconnect the directional valve (CT5) plug: the alarm must activate after four operational

cycles. Disconnect the flow monitoring cable from the monitoring unit (CT1): the alarm must activate

after four operational cycles. Short-circuit the flow monitoring cable to the pump body: the alarm must activate after four

operational cycles.

7.

7.1.



Bleeding the shank lubrication oil line

CT7CT4

L

1. Turn off the engine.2. Open the bleeding screw (CT7) 12 revolutions.3. Close the bleeding screw (CT7) when the oil bleeding out no longer contains air bubbles.

7.2.



Bleeding the shank lubrication oil pump

CT7CT4

L

1. Disconnect the hose from port L.2. Connect a separate hose to port L and place the other end of the hose in a receptacle.3. Start the diesel engine.4. Open the bleeding screw (CT7) half a turn and the bleeding screw (CT4) one turn.

Leave the screws open for about one minute.5. Close the bleeding screw (CT7).6. Close the bleeding screw (CT4) when the oil bleeding out no longer contains air bubbles.7. Turn off the engine.8. Disconnect the bleeding hose from port L and reconnect the original hose.9. Start the diesel engine.10. Start the forced shank lubrication by pressing the forced operation button (Boost).

Leave the forced operation on for about 10 minutes.11. Ensure that the rock drill receives shank lubrication oil.12. Stop the forced shank lubrication.

7.3.



Replacing seals

4

2 3 1

1 Pump unit2 Plug3 Piston4 Piston seals

7.4.



1. Remove the old seals from the piston grooves.

A B C D E F G H A

A

C

B D E

2. Clean the grooves.3. Install the guide sleeve C on to piston E as shown in the picture.4. Lubricate the o-ring D and slide it over the guide sleeve into the groove in the piston.5. Lubricate the piston seal B and slide it over the guide sleeve into the groove on top of the o-ring

D.Use the mounting sleeve A if needed.

6. Repeat the procedure with the o-ring F and the piston seal H using corresponding tools (G andA).

7. Press the seals lightly with oily fingers to better fit them into the grooves.8. Calibrate the seals from both ends of the piston (B, D, F and H) using mounting sleeve A.

Calibration is performed by sliding the mounting sleeve carefully over the piston and the pistonseal, and then carefully rotating the sleeve so that the seal is set to its groove evenly.

9. Install the piston back into the pump unit.

Replacing a faulty shank lubrication hose

When replacing a faulty shank lubrication hose with a new one, operate as follows:1. Change the faulty hose.2. Disconnect the end of the desired shank lubrication hose from the rock drill.3. Start the power pack (electric motor or diesel) and turn the air on.4. Turn the boost switch on.5. Keep the boost switched on, until oil comes out of the hose (drain it into the overflow receptacle).6. When system has bled, turn off the boost switch, and stop the powerpack.7. Re-connect the shank lubrication hose to the rock drill.

7.5.



Draining the condensed water from the oil tank

1. Drain the condensed water from the oil tankinto a receptacle by using the drain valve.

Cleaning the oil receiver

1. Empty the oil tank into a receptacle.2. Wash the inside of the tank.3. Flush the tank.

7.6.

7.7.



Replacing the oil tank breather

1. Replace the breather at the intervals specifiedin the maintenance instructions or as required,e.g. in the event that the breather has becomewet.

7.8.



TROUBLESHOOTING

Problem: No oil output, green indicator light not on, drilling joystick is centered

POSSIBLE REASON: REMEDY:No operating voltage at the pump Check the rotation and percussion pressure

switches, electrical connections and wiring

Problem: No oil output, red indicator light on, green indicator light off, drilling joystick iscentered

POSSIBLE REASON: REMEDY:Oil level too low Add oil and remove air from pump through bleed-

ing screwPump intake blocked Check and clean containerDelivery pipe blocked Remove and clean or replace delivery pipeOil viscosity too high Select correct oil gradeNo pump operating pressure Problem in rigs hydraulic systemFaulty solenoid valve of pump Check / replace valveFaulty pump timer Check (measure) / replace timerSolenoid valve wiring fault Check / replace wiringShank lubrication pressure hose damaged Change or fix the hose

Problem: Too little oil

POSSIBLE REASON: REMEDY:Incorrectly set timer frequency Check settingAir in pump Check oil level and bleed pumpDirt in intake side non-return valve Clean ball of non-return valveDirt in control switch non-return valve Clean control switch / containerBreather blocked (underpressure) Clean breatherReturn hose to collector tank blocked Clear obstruction

Problem: Too much oil (red indicator light may turn on and drilling joystick may be centered)

POSSIBLE REASON: REMEDY:Hydraulics bleed screw open Close bleed screwTimer frequency incorrectly adjusted Check adjustmentPiston seals damaged Check piston and replace sealsBOOST switch activated Check and turn off

8.



Problem: Internal oil leakage of pump

POSSIBLE REASON: REMEDY:Hydraulics bleed screw open Close bleed screwPiston seals damaged Check piston and replace seals

Problem: Normal amount of oil, but alarm activated (red indicator light on, green indicatorlight off, drilling joystick is centered)

POSSIBLE REASON: REMEDY:Control switch wiring cut or shortcut to ground Check/replace wiringDirty oil, conducting electricity Change oil in shank lubricator tankWorn flow monitoring device (pitted ball surface) Check / replace flow switch assemblyAir line pressure switch wrongly adjusted or faulty Readjust the switch (correct value is ca. 1 bar on

the switch's scale), replace if needed

NOTE! If the air line pressure switch S305 or relay K150 are not activated when starting drilling,indicator lights (H93 ja H94) will not turn on and the drilling joystick is automatically centered.



w w w . s a n d v i k . c o m

V 64450-2 en 0106

COMPRESOR Y CIRCUITO DE AIREAIR END AND PNEUMATIC CIRCUIT: DX and DX_RTABLE OF CONTENTS1. GENERAL2. SAFETY3. COMPONENTS OF THE COMPRESSOR AND PNEUMATIC CIRCUITS3.1. Pneumatic circuit diagram and components3.2. Location of pneumatic circuit components DX500, DX680, DX700, DX780, DX8003.3. Location of components - DX_R

4. AIR END4.1. Technical data4.2. Air end main components4.3. Compressing principle

5. OPERATING PRINCIPLE OF THE COMPRESSOR CIRCUIT5.1. General5.2. Description of components5.3. Air circulation5.4. Oil circulation5.5. Compressor regulating system5.5.1. Before starting, ignition key position 05.5.2. Ignition key to position 15.5.3. Starting, load relief 30 s; ignition key position 25.5.4. 30 seconds after starting5.5.5. Delivery5.5.6. Throttling5.5.7. Idling5.5.8. Stopping

6. CONTROL INSTRUMENTS OF THE COMPRESSOR CIRCUIT6.1. Pneumatic circuit control instruments and warning lights6.1.1. Compressor thermal switch6.1.2. Air filter service indicator

6.2. Oil circuit control instruments6.2.1. Thermostat6.2.2. Oil filter service indicator

7. ADJUSTING PRESSURE AND VALVE BLOCK CONNECTIONS8. TROUBLESHOOTING8.1. The compressor overheats8.2. Oil in the compressed air8.3. Insufficient air output8.4. Pressure too high

SHANK LUBRICATION SYSTEM (SLU); OPERATION AND MAINTENANCETABLE OF CONTENTS1. GENERAL2. SAFETY PRECAUTIONS3. MAIN COMPONENTS4. TECHNICAL DATA5. DESCRIPTION OF OPERATION5.1. Shank lubrication system monitoring5.2. Operating principle of the shank lubrication system5.3. Operation diagram of the shank lubrication oil pump5.4. Monitoring unit5.5. Heating circulation function5.6. Boost switch5.7. Air line pressure switch S3055.8. Cabin indicator lights

6. ADJUSTING THE SHANK LUBRICATION DEVICE7. MAINTENANCE INSTRUCTIONS7.1. Checking the operation of the monitoring unit7.2. Bleeding the shank lubrication oil line7.3. Bleeding the shank lubrication oil pump7.4. Replacing seals7.5. Replacing a faulty shank lubrication hose7.6. Draining the condensed water from the oil tank7.7. Cleaning the oil receiver7.8. Replacing the oil tank breather

8. TROUBLESHOOTING

TAMROTOR ENDURO 25G: REPAIR INSTRUCTIONS

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