AIR FLUSHING CIRCUIT

Page 1

MAINTENANCE MANUAL

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

Page 2 A 23-06-2004 AR-RL-FLAIR FLUSHING CIRCUIT

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

1 PRELIMINARY REMARKS 3

1/1 SAFETY 3

1/2 ABOUT THIS BOOKLET 5

2 EXPLANATION PLAN 6

3 AIR SUPPLY 7

3/1 MACHINE AIR COMPRESSOR 7

3/2 AIR CLEANER 8

4 AIR FLUSHING CIRCUIT 8

4/1 AIR RECEIVER 8

5 LUBRICATED AIR CIRCUIT 9

5/1 WATER SEPARATOR 9

5/2 PRESSURE SWITCH 9

5/3 PRESSURE REDUCER 9

5/4 AIR OILER 9

5/5 OIL INDICATOR 10

Page 3A 23-06-2004 AR-RL-FL AIR FLUSHING CIRCUIT

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

1 PRELIMINARY REMARKS

1/1 SAFETY

The informations contained in this manual must be studied and thoroughly assimilated beforeundertaking any maintenance work on the equipment

WARNING Operation, maintenance and adjustments are only allowed to persons withspecific training in operation and maintenance of the equipment. Read the operatingand maintenance instructions before using or servicing the equipment.

WARNING: Before starting any maintenance operation ensure that the machine is in asafe location with good safety, ventilation and lighting conditions. Ensure that liftingequipments and pedestals are compatible with elements’ weight. Follow all the safetyinstructions and ware safety protections as gloves, goggle, helmet, safety boots, earprotectors.

WARNING: Before any operation stabilize and fix steadily all the elements on suitablepedestals. Stop the power packs, switch the general power breaker. Place a tag or aboard to warn other members of the personnel that maintenance work on the machineis in progress.

WARNING: Pressurized oil jets could cause severe injuries. Before any operation onhydraulic circuit, STOP the power packs and release remaining pressure incomponents by operating hydraulic control levers several times. Always release thestatic pressure in cylinders before disassemble them.NEVER WORK ON AN OPERATING CIRCUIT.

WARNING: While tests are in progress, do not allow any other member of thepersonnel to stand in the area surrounding the machine. Stay at the control station tobe able to stop the movement and switch off the power pack.

WARNING: Maintenance, adjustment and repairs are restricted to qualified personnelwith special training for the particular equipment. Always read the instructions carefullybefore starting any maintenance work.

CAUTION: Always use suitable tools and work in a clean place when dismantling andassembling hydraulic components. After removing cylinders the hydraulic inlet/outletports must be plugged to prevent dirt and air intrusion during operation.

WARNING: The operator must always wear required personal protection, such as safetyhelmet, protective overall, safety boots, hearing protectors, safety goggles etc.

WARNING: Danger of high pressure oil jets.High pressure oil jets can cause serious personal injuries.Release the pressure in the hydraulic circuits before opening caps or connections.(Accumulator, Cylinder and Hydraulic circuit)

Remember: SAFETY FIRST!Always observe the warnings accompanied by the following symbols.

WARNING

WARNING

WARNING

WARNING

WARNING

Page 4 A 23-06-2004 AR-RL-FLAIR FLUSHING CIRCUIT

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

WARNING: Danger of hot surface.Hot surface can cause serious injuries.Components rod, shank or hydraulic component can be hot and beforestarting a maintenance work, please let them cool off. The operator must have adequate wears as gloves.

WARNING: Crushing hazard : do not stay in dangerous area, for instance: centralarticulation, front chassis and rear chassis.

WARNING

SAFETY

Do not attempt any such repairs or adjustments that you do not fullyunderstand.

ABOUT THE SAFETY OF REPAIRS

Certain workstages require the use of the feed mechanism during the repair.Make sure then that:

- no danger is caused to anybody.- the machine can be immediately stopped when necessary.- the powerpack is stopped again before the repair-work is continued.

Before starting any repair-work move away from the area where you have justdrilled.

Use proper tools.

Always wear protective clothing, eye protection, earmuffs, safety footwear, andother safety equipment required by the work.

Always follow the marked safety instructions, andobserve caution while working.

The following safety instructions are general rules.

Keep tools and drillingequipment clean.

Page 5A 23-06-2004 AR-RL-FL AIR FLUSHING CIRCUIT

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

1/2 ABOUT THIS BOOKLET

The present manual is destined for the use of personnel in charge of carrying out, servicing andmaintenance operations on Jumbos.

It contains maintenance operations schedule and operating methods concerning the main elements of

the AIR FLUSHING CIRCUIT.

Note that servicing and maintenance operations must be carried out by personnel with the required

qualifications, technical knowledge, and proper training on the machine.

Page 6 A 23-06-2004 AR-RL-FLAIR FLUSHING CIRCUIT

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

2 EXPLANATION PLAN

AIR OILER

AIR RECEIVER

PRESSURE

PRESSURE

AIR FLUSHING

MACHINE AIR

OIL INDICATOR

WATER

AIR CLEANER

MINE’S AIR

LUBRICATED AIRTO ROCK DRILL

WATER / AIR

TO FLUSHING HEAD

REDUCER

SWITCH VALVE

SEPARATOR

COMPRESSOR

CONTROL PANEL

(*1)

(*2)

(*3)T - FITTING

(*3)

WATER

(*1) Depends on rock drill

(*2) Depends on application

(*3) Optional equipment

TO BOOM 1

TO BOOM 2 (*2)

Lubricat

ed

air ci

rcuit

Air flu

shin

g

circu

it

Air su

pply

The elements localisation depends on machine range.See the operator manual to know their localisation.

Page 7A 23-06-2004 AR-RL-FL AIR FLUSHING CIRCUIT

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

3 AIR SUPPLY

3/1 MACHINE AIR COMPRESSOR

Different types of compressor can be mounted on the drilling machines.

1 : Clogging indicator

2 : Air filter

3 : Air circuit pressure gauge

4 : Compressor oil temperature

(Compressor type CT10 shown)

Maintenance operations at each shift :- Check that there is no pressure left in the circuit when motors are stopped.

- Verify that the clogging indicator is located in the green zone, if it is in red zone, all compressor

filter elements must be replace. After filters replacement, reset the clogging indicator.

- Check compressor oil level, add oil if needed. (Prior to add oil, make sure that there is no

pressure remainning in the circuit).

Maintenance operations every weeks :- Start the compressor, check the pressure. The pressure should not exceed 2 or 2.5 bar when

installing a gauge at the inlet port of the rock drill. According to the length of the air line the

pressure at the compressor or at the oiler may be higher. Adjust the compressor pressure to get

2 bar at the rock drill inlet port.

If a pressure reducer is installed on the machine, it is then possible to adjust the compressor

pressure to 7 bar.

Maintenance operations every months :- Replace filters elements.

- Replace cartridge element of oil separator.

Replace Compressor oil after 500 drilling hours.

FOR ALL COMPRESSOR MAINTENANCE OPERATIONS, SEE COMPRESSOR MAINTENANCE MANUAL ENCLOSED IN THIS SECTION.

1

43

2

Page 8 A 23-06-2004 AR-RL-FLAIR FLUSHING CIRCUIT

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

3/2 AIR CLEANER

If the machine is equiped with mine’s air connection (optional equipment), the air flushing can be

assured wether by machine compressor or by mine’s air.

The mine’s air contains too much dust to supply the flushing circuit, a filter device like the IP5 air

cleaner is so needed.

1 - Water separator

2 - Tank

3 - Drain valve

Maintenance operations at each shift :Bleed the air cleaner, full by condensed water.

4 AIR FLUSHING CIRCUIT

4/1 AIR RECEIVER

One, two or three air receivers can be

mounted, depending on machine

applications.

These air receivers are used to stock

suficiently air to assure the flushing with

wether compressor or mine’s air.

The air receivers are each equiped by one

safety valve (which keep the circuit in a

safety pressure under 8 bar), and a drain

valve.

Maintenance operations at each shift :- Stop the compressor and bleed the air receiver(s), full by condensed water.

- Check that safety valves are not damaged.

Replace air receivers after 10 years of use.

1

2

3

Page 9A 23-06-2004 AR-RL-FL AIR FLUSHING CIRCUIT

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

5 LUBRICATED AIR CIRCUIT

In standard drilling operation, it is necessary to provide a flow mixed air and oil at 2.5 bar to

lubricate the rock drill shank and the bronze driver to protect them from water and dust intrusion.

If the mixt pressure is to low, the pressure switch stops the drilling feed forward movement.

A lack in this lubrication will result in rapid damage or destruction of the rock drill.

It is so of prime importance to permanently assure a correct functioning of the pressurized

lubricated air circuit and its main components.

5/1 WATER SEPARATOR

The water separator (reclaimer) is necessary to prevent water presence in the rock drill and avoid

its destruction.

Maintenance operations at each shift :Bleed the water separator, full by water contained in oil.

5/2 PRESSURE SWITCH

This component is an informer, when the circuit pressure is less than 1 bar a warning light is

switched on and the drilling feed forward movement stop. It is exacly the same when the pressure

is higher than 2.5 bar.

5/3 PRESSURE REDUCER

The reducer is installed to protect the rock drill against over-pressure that could cause failures.

The air pressure to the rock drill must be adjusted and reduced to 2/2.5 bar.

Page 10 A 23-06-2004 AR-RL-FLAIR FLUSHING CIRCUIT

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

5/4 AIR OILER

1 : Lubrication pump

2 : Oil flow adjustement screw

3 : Sight glass

4 : Drain valve

5 : Oil flow adjusting device connection.

6 : Manifold

(Air oiler type KVL shown)

Maintenance operations at each shift :- Bleed the water separator : Slightly open the drain valve, let the condensed water get out the

oiler. Make sure that there is no remaining pressure in the circuit. The gauge should show 0bar.

- Check oil level : Remove the filling plug used as a dipstick. Add rock drill oil if the level is too low.

- Start the compressor, check that oil flows regularly by looking the sight glass.

Maintenance operations every weeks :- Drain the reservoir, replace the lubrication oil.

- Check the oil flow

- Remove the oil flow adjusting device, undo the adjusting device connection.

Start the compressor. Wait a couple of minutes until the reservoir is correctly pressurized.

Adjust the oil flow to get 30 drops of oil per minute and per boom. Retighten the oil flow adjusting

device to the manifold.

5/5 OIL INDICATOR

This component allows the operator to check the flow of the mixt use to the rock drill.

Keep the glass clean.

FOR ALL AIR OILER MAINTENANCE OPERATIONS, SEE AIR OILER MAINTENANCE MANUAL ENCLOSED IN THIS SECTION.

12

3

4

56