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AIR FLUSHING CIRCUIT

MAINTENANCE MANUAL

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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PRELIMINARY REMARKS

1/1

SAFETY

1/2

ABOUT THIS BOOKLET

EXPLANATION PLAN

AIR SUPPLY

3/1

MACHINE AIR COMPRESSOR

3/2

AIR CLEANER

AIR FLUSHING CIRCUIT

AIR RECEIVER

LUBRICATED AIR CIRCUIT

5/1

WATER SEPARATOR

5/2

PRESSURE SWITCH

5/3

PRESSURE REDUCER

5/4

AIR OILER

5/5

OIL INDICATOR

4
4/1

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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1 PRELIMINARY REMARKS
1/1 SAFETY
The informations contained in this manual must be studied and thoroughly assimilated before
undertaking any maintenance work on the equipment

Remember: SAFETY FIRST!

Always observe the warnings accompanied by the following symbols.
WARNING Operation, maintenance and adjustments are only allowed to persons with
specific training in operation and maintenance of the equipment. Read the operating
and maintenance instructions before using or servicing the equipment.
WARNING: Before starting any maintenance operation ensure that the machine is in a
safe location with good safety, ventilation and lighting conditions. Ensure that lifting
equipments and pedestals are compatible with elements weight. Follow all the safety
instructions and ware safety protections as gloves, goggle, helmet, safety boots, ear
protectors.
WARNING: Before any operation stabilize and fix steadily all the elements on suitable
pedestals. Stop the power packs, switch the general power breaker. Place a tag or a
board to warn other members of the personnel that maintenance work on the machine
WARNING is in progress.
WARNING: Pressurized oil jets could cause severe injuries. Before any operation on
hydraulic circuit, STOP the power packs and release remaining pressure in
components by operating hydraulic control levers several times. Always release the
static
pressure in cylinders before disassemble them.
WARNING
NEVER WORK ON AN OPERATING CIRCUIT.
WARNING: While tests are in progress, do not allow any other member of the
personnel to stand in the area surrounding the machine. Stay at the control station to
be able to stop the movement and switch off the power pack.
WARNING

WARNING: Maintenance, adjustment and repairs are restricted to qualified personnel

with special training for the particular equipment. Always read the instructions carefully
before starting any maintenance work.
WARNING

CAUTION: Always use suitable tools and work in a clean place when dismantling and
assembling hydraulic components. After removing cylinders the hydraulic inlet/outlet
ports must be plugged to prevent dirt and air intrusion during operation.
WARNING: The operator must always wear required personal protection, such as safety
helmet, protective overall, safety boots, hearing protectors, safety goggles etc.

WARNING

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

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WARNING: Danger of hot surface.

Hot surface can cause serious injuries.
Components rod, shank or hydraulic component can be hot and before
starting 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: central
articulation, front chassis and rear chassis.
WARNING

SAFETY

Always follow the

marked safety instructions, and
observe caution while working.
The following safety instructions are general rules.
Keep tools and drilling
equipment clean.

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

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 just
drilled.
Use proper tools.

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

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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1/2 ABOUT THIS BOOKLET

The present manual is destined for the use of personnel in charge of carrying out, servicing and
maintenance 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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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2 EXPLANATION PLAN
TO BOOM 2 (*2)

AIR OILER

LUBRICATED AIR
TO ROCK DRILL

OIL INDICATOR

TO BOOM 1

WATER / AIR
WATER

TO FLUSHING HEAD
T - FITTING

PRESSURE
REDUCER

(*3)

PRESSURE
SWITCH

AIR RECEIVER
(*2)

WATER
SEPARATOR

MACHINE AIR
COMPRESSOR

AIR FLUSHING
VALVE

CONTROL PANEL

A
ir
ci flu
rc sh
u i in
t g

Lu
ai br
r c ic
irc a t e
ui d
t

(*1)

AIR CLEANER

ir
s

up
pl
y

(*3)

MINES AIR
(*1) Depends on rock drill

The elements localisation depends on machine range.

See the operator manual to know their localisation.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

(*2) Depends on application

(*3) Optional equipment

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3 AIR SUPPLY
3/1 MACHINE AIR COMPRESSOR
Different types of compressor can be mounted on the drilling machines.

FOR ALL COMPRESSOR MAINTENANCE OPERATIONS, SEE

COMPRESSOR MAINTENANCE MANUAL ENCLOSED IN THIS SECTION.

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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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3/2 AIR CLEANER

If the machine is equiped with mines air connection (optional equipment), the air flushing can be
assured wether by machine compressor or by mines air.
The mines air contains too much dust to supply the flushing circuit, a filter device like the IP5 air
cleaner is so needed.

1
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 mines 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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

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5/4 AIR OILER

FOR ALL AIR OILER MAINTENANCE OPERATIONS, SEE AIR OILER

MAINTENANCE MANUAL ENCLOSED IN THIS SECTION.

6
5

1 : Lubrication pump
2 : Oil flow adjustement screw

3
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.

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.

19, av. De Lattre de Tassigny
B.P. 46 - 69881 LYON cedex, FRANCE
Tel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80