Professional Documents
Culture Documents
Table of Contents
1. GENERAL .............................................................................................................................. 3
2. SAFETY ................................................................................................................................. 4
3. COMPONENTS OF THE COMPRESSOR AND PNEUMATIC CIRCUITS ........................... 5
3.1. Pneumatic circuit diagram and components .................................................................................... 5
3.2. Location of pneumatic circuit components DX500, 680, 700, 780, 800 ..................................... 8
3.3. Location of components - DX_R .......................................................................................................... 9
1 (34)
2 (34)
This document describes the components, operating principle and troubleshooting of the DX and
DX_R compressor and pneumatic circuits.
Control instruments and warning lights are described in the operators manual, in the chapter entitled
Control instruments.
3 (34)
4 (34)
3.1.
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)
5 (34)
25
21
22
18
20 19
23
24
15
3
16
14
12
9
10
8
7
5
11
17
13
38
29
30
28
39
31
32
33
27
26
34
36
35
ID: 16563
1. Air pre-cleaner*
2. Ejector*
3. Compressor air filter
6 (34)
37
7 (34)
Location of pneumatic circuit components DX500, 680, 700, 780, 800 ID:
16486
39
30
17 28 29
26 27
38
14 15 16
32
12
40 41 42
35 36 37
11 13
31
18 19 20 21
22 23 24 25
34
33
2
1
5
ID: 16567
8 (34)
10
39
30
29
26 27
28
10
38
14 15 16
17
32
12
40 41 42
35 36 37
11 13
31
18 19 20 21
22 23 24 25
2
34
1
33
ID: 16568
9 (34)
4.1.
Type
Enduro 12
Enduro 25
40...45 C
40...45 C
115 C
115 C
Output
5.8 m 3/min
8.1 m 3/min
10 bar
10 bar
Bearings
Roller bearings
Roller bearings
120 mm
155 mm
Gear ratio
1:2.4
1:1.564
4.2.
ID: 16625
1.
2.
3.
4.
5.
10 (34)
Housing
Rotors
Outlet cover
Bearing housing cover
Gear
Together with the housing, the two meshing rotors form the compression chamber. The rotating rotors
take 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 in
the chamber.
As rotation continues, the volume of the chamber between the two rotors becomes smaller and the
pressure increases.
When the desired and most economical operational pressure is reached, the compressed air flows
through the outlet port into the receiver.
ID: 16626
11 (34)
21
24
22
2
6.1
3.1
3.2
6.2
23
6
18
4
5
20
17
12
12.1
16
15
14
19
9
10
12.2
25
7
8
8.1
13.1 13.2
40
41
11
13
42
ID: 16627
The components are shown under normal operating conditions when compressed air is being produced.
12 (34)
5.1.
The air end (5) produces the compressed air used by the drilling rig. From the air end the air is led
into 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 to
the air consumption. The temperature gauge (17) indicates the output air temperature.
13 (34)
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 pipe
connected to the air filter. The impurities separated in the air pre-cleaner are drawn through
the 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 into
this position. The indicator must be checked daily by pressing the button on the top and the
red warning colour must show. (For filter servicing refer to the carrier manual and maintenance
schedules.)
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 unit
6. Intake valve
Suction acting on the valve disc opens the intake valve when the compressor is started. The
intake valve also acts as an air end underload valve by restricting the intake flow whenever the
compressor output exceeds the air consumption. The disc valve acts as a non-return valve
when the rotors are stopped. This prevents the oil in the rotor chamber from entering the intake
duct 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 close
when 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 through
the 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) to
flow through the orifice (12.1) to the tank.
14 (34)
15 (34)
5.3.
The ejector (2) in the diesel engine exhaust pipe generates suction that is used to draw out the
coarsest 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 the
pressure from the pressure regulator (18).
After compression, the oil/air mixture is led into the oil/air receiver (7), where the oil is separated from
the air. As soon as the air pressure in the receiver exceeds the opening pressure of the minimum
pressure valve (9), the clean, oil-free air is led off for hole flushing and other pneumatic devices.
16 (34)
While the compressor is running, the minimum pressure valve (9) keeps the pressure in the oil/air
receiver at least at 3 bar. This pressure forces the oil from the receiver into the oil circuit. The oil
circulation is based on the pressure difference between the receiver and the intake side of the compressor.
The oil flows to the thermostat (11) through the connection at the bottom of the air/oil receiver.
Oil temperature below 45 C
The cold oil flows directly through the thermostat valve (11) and the oil filter (13) to the compressor
(5).
Oil temperature 4548 C
The wax core in the thermostat valve (11) expands, partially closing the thermostat valve, and some
of the oil flows through the oil cooler (12).
Oil temperature over 48 C
The 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) that
allows the oil to flow past the filter if the filter is clogged or if the oil is too thick while it is cold. The
opening 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 the
air and to seal the clearances between the rotors and the housing. Oil is also led through other
channels to lubricate the bearings and the shaft gasket.
After compression, the compressed oil/air mixture is led from the screw compressor into the spiral
duct of the oil/air receiver (7), where most of the oil is separated from the air and falls to the bottom
of the receiver. The rest of the oil mixed with the air is separated when the air flows through the oil
separator elements (8). The oil from the bottom of the separator chamber is forced through the pipe
to 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.
17 (34)
5.5.1.
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) at
the top of the oil/air receiver (7) is also closed. The solenoid valves (22) and (23) are closed and not
activated.
22
23
6
9
ID: 16710
18 (34)
When the rigs power is switched on with the ignition key, the solenoid valve (23) is activated. The
valve opens and releases the pressure from the intake valve (6).
23
ID: 16713
19 (34)
When the diesel engine is started, the solenoid valve (22) opens and the solenoid valve (23) remains
closed for 30 seconds after starting. The pressure of the pressure accumulator (24) keeps the intake
valve (6) closed so the compressor does not load the diesel engine.
24
22
23
ID: 16714
20 (34)
The solenoid valve (22) closes after 30 seconds after starting the engine. At the same time the solenoid valve (23) is activated and the valve remains open. Compressor creates suction which opens
the spring-loaded intake valve (6), allowing air to enter the air end. At the same time, the compressor
sucks oil from the oil/air receiver (7). The rotating rotors compress the oil and air into a mixture which
is led into the receiver. In the receiver the oil is separated from the air with oil separators. Since the
pressure in the receiver is below the opening pressure of the minimum pressure valve (9) during
starting, the valve remains closed.
22
23
5
7
ID: 16717
21 (34)
The disc valve is fully open and the pressure in the oil/air receiver (7) starts rising. When the pressure
reaches 3 bar, the receivers minimum pressure valve (9) opens. The pressure regulator (18) is used
to adjust the desired output pressure. Normally, the pressure is adjusted with the valve (18) so that
the intake valve starts closing at 8 bar, and is fully closed at 9 bar. The intake valve operates steplessly
between 8 and 9 bar. The oil separated in the separators is led into the air end by the regeneration
line. The line includes the orifice, non-return valve, and strainer.
18
7
ID: 16719
22 (34)
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 partially
closes the air intake port, thus restricting air flow to the compressor. At the same time, the air flows
to the compressor through the non-return valve (20). In this way the compressor receives extra air
when the intake valve (6) is closing; this prevents noise caused by the reduced intake air flow into
the compressor.
The intake valve (6) operates steplessly over a 1-bar range (for example it starts to close at 7 bar
and is completely closed at 8 bar). The pressure setting for the system is normally 7 bar but it is
adjustable between 4 and 10 bar.
20
18
ID: 16723
23 (34)
In this situation the compressor output exceeds the air consumption. The only difference with throttling
is 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.
20
ID: 16733
24 (34)
When the compressor stops rotating, it also stops sucking air. With no suction present, the intake
valve (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 because of different diameters of the valve spools, the pressure from the compressor can push the other
spool 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 the
air/oil mixture from entering the system.
When the pressure in the receiver drops below the minimum pressure valve (9) setting, the valve
closes.
19
20
6
9
5
16
ID: 16737
25 (34)
6.1.
6.1.1.
The compressor temperature gauge (in the operating panel) indicates the compressor temperature. The thermal switch stops the diesel engine
and lights a warning light if the compressor temperature exceeds 115 C.
ID: 16784
26 (34)
27 (34)
6.2.1.
The thermostat (11) controls the amount of oil flowing through the oil cooler according to the temperature.
11
ID: 16807
Oil temperature
below 45 C
over 48 C
6.2.2.
The compressor oil filter has a mechanical service indicator (13.2). The filter element (13) must
be replaced if the red indicator knob stays up
while the compressor is running and the oil has
reached normal operating temperature (above
48 C).
For operating principle and operating range, refer
to the chapter entitled Description of components/Oil filter.
28 (34)
13.2
13
7.
22
21
23
18
20
5
19
25
1
ID: 16824
29 (34)
3
25
1
4
18
21
24
20
19
23
22
5
2
ID: 16825
30 (34)
8.1.
POSSIBLE REASON
CHECK / OPERATION
Faulty thermostat (11). (Oil circulation through Check the operation and condition of the
the cooler core is partially or completely
thermostat (11).
obstructed.)
Dirty oil cooler core (12).
Clogged oil filter (13). (Poor oil circulation poor Replace the oil filter (13).
cooling efficiency.)
Low output pressure. (Poor oil circulation with Increase the pressure by adjusting the pressure
low receiver air pressure.)
regulator (18). Low pressure may also be caused
by excessive air consumption.
Oil viscosity too high (oil too thick). (Poor oil Check the oil grade, refer to the oil
circulation poor cooling efficiency.)
recommendations.
Air in the oil cooler core.(Poor circulation)
Bleed the oil cooler core and change the oil type
if foaming occurs.
8.2.
POSSIBLE REASON
CHECK / OPERATION
Faulty oil separator element (8) or O-ring (8.1). Check the oil separator elements (8) and the Orings (10.1) (for example, a hole in the element).
Oil level too high in the tank.
Foaming oil.
31 (34)
POSSIBLE REASON
CHECK / OPERATION
8.4.
Leaking intake valve (6) piston seal, or faulty If air escapes through the breather hole above the
intake valve. (The intake valve does not close piston while the compressor is running and the
properly.)
intake valve is closed, the piston seals must be
replaced.
Incorrectly adjusted or faulty pressure
regulator (18).
32 (34)
33 (34)
www.sandvik.com
Original instructions
377 2 en 2011-04-12
Table of Contents
1. GENERAL ...................................................................................................................................... 5
2. SAFETY PRECAUTIONS .............................................................................................................. 6
3. MAIN COMPONENTS .................................................................................................................... 7
4. TECHNICAL DATA ........................................................................................................................ 8
5. DESCRIPTION OF OPERATION ................................................................................................... 9
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.
5.8.
7.2.
7.3.
7.4.
7.5.
7.6.
7.7.
7.8.
8. TROUBLESHOOTING ................................................................................................................... 24
3 (26)
4 (26)
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 shank
lubrication 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 the
rig. Sandvik Service is always willing to provide advice and help with any problems related to the rig.
5 (26)
SAFETY PRECAUTIONS
Take all safety factors into consideration and perform your work
with care. Follow all drilling site safety regulations.
6 (26)
MAIN COMPONENTS
1
3
10
4
11
5
12
13
Level switch
Pump unit
Drain valve
Oil dipstick
Oil tank
10
11
12
13
7 (26)
TECHNICAL DATA
Oil tank
Total amount of oil (l)
Breather (m)
10
Level switch
Yes
Pump unit
Stroke volume
2,0 cm
Output range
210 bar
25 bar
25 bar
Tightening torques
Nm
Control switch
20
8 (26)
DESCRIPTION OF OPERATION
5.1.
The shank lubrication system monitors air pressure, oil flow and oil level in the oil tank. If the air
pressure drops, oil flow decreases too much (or stops completely) or the tank runs out of oil, the
shank lubrication system goes into alarm state. In the alarm state, drilling is stopped, the joystick is
automatically centered and the red indicator light turns on.
5.2.
6
3
4
8
7
P
10
Oil tank
Pump unit
Level switch
Pressure switch
10
Rock drill
9 (26)
CT1
control switch
CT2
CT3
operating piston
CT4
CT5.1
directional valve
CT6.1
non-return valve
CT7
bleeding screw
CT8
heating circuit
The lubrication pump is a hydraulic, elctrically controlled piston pump. The lubricant dosage is
determined electrically by changing the operating frequency of the pump.
The main block has its own lubrication control switch CT1. The control is always operational when
the operating voltage is switched on.
The directional valve (CT5.1) guides the hydraulic oil pressure to the piston side and the piston rod
side alternately. When valve (CT5.1) receives the control voltage, it prevents the pressure from
entering at the piston side, whereupon the pressure on the piston rod side forces the oil on the piston
side into the tank line. At the same time, the lubrication oil is sucked from the tank through port S into
the operating piston chamber. When the control voltage is cut off from the valve (CT5.1), the higher
pressure is directed to the piston side, and the oil on the piston rod side re-enters circulation. The
lubrication oil is pumped to the rock drill through port L.
10 (26)
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 seat
surface and shuts off the circuit. The control switch non-return valve ball is electrically connected to
the pump (and rock drill) frame. The voltage is directed to the ball via a spring isolated from the pump
frame.
If the ball remains against the seat or remains open for four
operational cycles, an alarm is switched on and drilling
functions stop.
11 (26)
12 (26)
3
1
4
Locking nut
Plug screw
Seal
Cap
13 (26)
Boost switch
5.7.
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 red
indicator light turns on, the green indicator light turns off and the joystick is automatically centered.
5.8.
H93
14 (26)
HLX 5
300-600
230
21 3
HLX 5T
200-400
310
28 3
HL 510
200-400
310
28 3
HL 600
300-600
400
38 4
HL 710
400-850
470
44 5
HL 650/710
400-850
470
44 5
HL 710T
400-850
690
64 7
HL/HF 810T
400-850
690
64 7
HL 800T
400-850
690
64 7
HL 800
400-850
690
64 7
HL 1010
400-850
690
64 7
HL 1560
600-1200
910
76 8
15 (26)
2500
l u b r i c a t i o n [ g /h ]
2000
0
1
2
3
1500
4
5
6
1000
500
0
0
10
11
12
fine adjustment
16 (26)
13
14
15
16
MAINTENANCE INSTRUCTIONS
7.1.
17 (26)
CT7
18 (26)
CT7
1.
2.
3.
4.
19 (26)
Replacing seals
4
20 (26)
Pump unit
Plug
Piston
Piston seals
2.
3.
4.
5.
6.
7.
8.
9.
7.5.
When replacing a faulty shank lubrication hose with a new one, operate as follows:
1.
2.
3.
4.
5.
6.
7.
21 (26)
7.7.
22 (26)
23 (26)
TROUBLESHOOTING
Problem: No oil output, green indicator light not on, drilling joystick is centered
POSSIBLE REASON:
REMEDY:
Problem: No oil output, red indicator light on, green indicator light off, drilling joystick is
centered
POSSIBLE REASON:
REMEDY:
Add oil and remove air from pump through bleeding screw
REMEDY:
Check setting
Air in pump
Clean breather
Clear obstruction
Problem: Too much oil (red indicator light may turn on and drilling joystick may be centered)
POSSIBLE REASON:
REMEDY:
Check adjustment
24 (26)
REMEDY:
Problem: Normal amount of oil, but alarm activated (red indicator light on, green indicator
light off, drilling joystick is centered)
POSSIBLE REASON:
REMEDY:
Check/replace wiring
Worn flow monitoring device (pitted ball surface) Check / replace flow switch assembly
Air 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.
25 (26)
26 (26)
www.sandvik.com
V 64450-2 en 0106