Compressor PDF

Original instructions
365 2 en 2011-10-03
Air End and Pneumatic Circuit

DX, DX_R and DQ500
Table of Contents
1. GENERAL ...................................................................................................................................... 5
2. SAFETY ......................................................................................................................................... 6
3. COMPONENTS OF THE COMPRESSOR AND PNEUMATIC CIRCUITS ................................... 7

3.1. Pneumatic circuit diagram and components ............................................................................................ 7
3.2. Location of pneumatic circuit components DX500, 680, 700, 780, 800 ............................................. 10
3.3. Location of components - DX_R .................................................................................................................. 11
4. AIR END ......................................................................................................................................... 12

4.1. Technical data ................................................................................................................................................... 12
4.2. Air end main components .............................................................................................................................. 12
4.3. Compressing principle .................................................................................................................................... 13
5. OPERATING PRINCIPLE OF THE COMPRESSOR CIRCUIT ..................................................... 14

5.1. General ................................................................................................................................................................ 14
5.2. Description of components ........................................................................................................................... 15
5.3. Air circulation .................................................................................................................................................... 17
5.4. Oil circulation .................................................................................................................................................... 18
5.5. Compressor regulating system .................................................................................................................... 19
5.5.1. Before starting, ignition key position 0 ....................................................................................................... 19
5.5.2. Ignition key to position 1 ............................................................................................................................... 20
5.5.3. Starting, load relief 30 s; ignition key position 2 ....................................................................................... 21
5.5.4. 30 seconds after starting .............................................................................................................................. 22
5.5.5. Delivery ............................................................................................................................................................ 23
5.5.6. Throttling ......................................................................................................................................................... 24
5.5.7. Idling ................................................................................................................................................................ 25
5.5.8. Stopping .......................................................................................................................................................... 26
6. CONTROL INSTRUMENTS OF THE PNEUMATIC CIRCUIT ....................................................... 27

6.1. Pneumatic circuit control instruments and warning lights ................................................................... 27
6.1.1. Compressor thermal switch .......................................................................................................................... 27
6.1.2. Air filter service indicator .............................................................................................................................. 28
6.2. Oil circuit control instruments ...................................................................................................................... 29
6.2.1. Thermostat ...................................................................................................................................................... 29
6.2.2. Oil filter service indicator .............................................................................................................................. 29
7. ADJUSTING PRESSURE AND VALVE BLOCK CONNECTIONS ............................................... 30
8. TROUBLESHOOTING ................................................................................................................... 33
8.1. The compressor overheats ............................................................................................................................ 33
8.2. Oil in the compressed air ............................................................................................................................... 33
8.3. Insufficient air output ...................................................................................................................................... 34
8.4. Pressure too high ............................................................................................................................................. 34
9. MAINTENANCE ............................................................................................................................. 35
Copyright © Sandvik Mining and Construction 3 (36)

ID: 365 2 en 2011-10-03
4 (36) Copyright © Sandvik Mining and Construction
ID: 365 2 en 2011-10-03
DX, DX_R and DQ500
1. GENERAL
This document describes the components, operating principle and troubleshooting of the compressor
and pneumatic circuits.
Control instruments and warning lights are described in the operator’s manual, in the chapter entitled
“Control instruments”.

ID: 365 2 en 2011-10-03
DX, DX_R and DQ500
2. SAFETY
Always follow the safety instructions and be careful with your

work.
Only people who have been given specific service training are
allowed to undertake service, adjustment and repair
procedures. Read the instructions before undertaking any
servicing, adjusting or repairing.
Hazardous moving and rotating parts. Carry out service and

repair work only when the rig is not running. Make sure that the
rig cannot be accidentally started or moved when you are
carrying out the service.
WARNING! HIGH PRESSURE INJECTION HAZARD!

Compressed air jets could cause severe injury.
Release pressure before opening the filling caps or the
compressed air connectors.

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3. COMPONENTS OF THE COMPRESSOR AND PNEUMATIC CIRCUITS
3.1. Pneumatic circuit diagram and components
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)

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25
21 18
20 19
23
22
24
9
15
10
3 16 14 8
6 12
7
17 11
13
38
29
30 28
39
31
26 27
32
34
33 36 35 37
1. Air pre-cleaner*
2. Ejector*
3. Compressor air filter

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DX, DX_R and DQ500
4. Air filter service indicator*

5. Air end, screw compressor
6. Intake valve
7. Oil/air receiver
8. Oil separator elements
9. Minimum pressure valve
10. Safety relief valve
11. Thermostat
12. Oil cooler
13. Oil filter
14. 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, compressor
18. Pressure regulator
19. Blow-down valve
20. Non-return valve
22. Solenoid valve
23. Solenoid valve
24. Pressure accumulator
25. Pressure gauge
26. Flushing valve
27. Half flushing valve
28. Flushing regulating valve
29. Pressure gauge
30. Drill rod greasing valve
31. Suction cut-off valve
32. Dust collector solenoid valve
33. Dust collector
34. Air output connection and valve
35. Shank lubrication pneumatic valve
36. Water separator
37. Shank lubrication unit
38. Flushing control
39. Rock drill
40. 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

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3.2. Location of pneumatic circuit components DX500, 680, 700, 780, 800
39 30
17 28 29
26 27
7 8 9 10
38
14 15 16
32
40 41 42 12
35 36 37
11 13
31
18 19 20 21
22 23 24 25
34 2
33 1 3
6 4

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3.3. Location of components - DX_R
39 30
29
26 27
28
7 8 9 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
33 1 3
6 4

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4. AIR END
4.1. Technical data
DX500, DX680, DX500R, DX700, DX780, DX800,

DX680R DX700R, DX780R, DX800R
Type Enduro 12 Enduro 25
Max. ambient temperature 40...45° C 40...45° C
Outlet air thermal switch 115° C 115° C
Output 5.8 m 3/min 8.1 m 3/min
Max. operating pressure 10 bar 10 bar
Bearings Roller bearings Roller bearings
Male rotor dia 120 mm 155 mm
Gear ratio 1:2.4 1:1.564
4.2. Air end main components
The main components of the air end include:
5 1 2 2 3 4
1. Housing
2. Rotors
3. Outlet cover
4. Bearing housing cover
5. Gear

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DX, DX_R and DQ500
4.3. Compressing principle
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.
The components are shown under normal operating conditions when compressed air is being
produced.

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5. OPERATING PRINCIPLE OF THE COMPRESSOR CIRCUIT
5.1. General
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.

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5.2. Description of components
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.

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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 3.5
bar. The red knob of the service indicator (13.2) pops up when the pressure difference exceeds
2.5 bar. The indicator has a built-in bimetallic device to prevent it operating until the oil
temperature exceeds 27 °C.
14. Strainer
• Prevents impurities from entering the air end.
15. Orifice
• Restricts the oil flow in the oil regeneration line.
• 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 the
air end.
• 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 output
pressure 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.
• Prevents oil from entering the pneumatic circuit after the compressor has stopped.
• 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 its
pressure 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.

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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 collector
34. Air output connection and valve
• Compressed air output for external use
35. 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 drill
40. Non-return valve of the oil filling pump
• Prevents the oil from flowing from the tank to the pump
41. 3-way valve
• Directs the oil from the oil filling pump (42) to the compressor receiver or to the drilling hydraulic
tank.
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 pressure
from breaking the seals in the pump.
5.3. Air circulation
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.

ID: 365 2 en 2011-10-03
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5.4. Oil circulation
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 45–48 °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.

ID: 365 2 en 2011-10-03
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5.5. Compressor regulating system
5.5.1. Before starting, ignition key position 0
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
5 7

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DX, DX_R and DQ500
5.5.2. Ignition key to position 1
When the rig’s 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: 365 2 en 2011-10-03
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5.5.3. Starting, load relief 30 s; ignition key position 2
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

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DX, DX_R and DQ500
5.5.4. 30 seconds after starting
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

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5.5.5. Delivery
The disc valve is fully open and the pressure in the oil/air receiver (7) starts rising. When the pressure
reaches 3 bar, the receiver’s 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

ID: 365 2 en 2011-10-03
DX, DX_R and DQ500
5.5.6. Throttling
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: 365 2 en 2011-10-03
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5.5.7. Idling
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: 365 2 en 2011-10-03
DX, DX_R and DQ500
5.5.8. Stopping
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 (16) 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.
8 bar pressure remains in the pressure accumulator (24) when diesel engine is stopped.
24
19 20
5
16
The line from the oil/air container remains pressurized when the
minimum pressure valve has closed, unless air is used for some
function, e.g. to blow clean the dust collector filters.

ID: 365 2 en 2011-10-03
DX, DX_R and DQ500
6. CONTROL INSTRUMENTS OF THE PNEUMATIC CIRCUIT
6.1. Pneumatic circuit control instruments and warning lights
6.1.1. Compressor thermal switch
The compressor temperature gauge (in the op-

erating panel) indicates the compressor temper-
ature. The thermal switch stops the diesel engine
and lights a warning light if the compressor tem-
perature exceeds 115 °C.

ID: 365 2 en 2011-10-03
DX, DX_R and DQ500
6.1.2. Air filter service indicator
The filter element must always be cleaned when

4
the service indicator (4) shows red while the com-
pressor is running. The filter element must be re-
placed every 500 hours of operation, or every six
months. The safety filter must be replaced when
every third air filter is removed, or every 1,000
hours.
The operation of the indicator can be checked
with the button on the service indicator. The red
warning color must show when the button is
pressed.
4

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6.2. Oil circuit control instruments
6.2.1. Thermostat
The thermostat (11) controls the amount of oil flowing through the oil cooler according to the
temperature.
11
Oil temperature
below 45 °C thermostat fully open
over 48 °C thermostat fully closed
6.2.2. Oil filter service indicator
The compressor oil filter has a mechanical serv-

ice 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 13.2
reached normal operating temperature (above 48
°C). 13
For operating principle and operating range, refer
to the chapter entitled ”Description of compo-
nents/Oil filter”.

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DX, DX_R and DQ500
7. ADJUSTING PRESSURE AND VALVE BLOCK CONNECTIONS
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).
22
21
23
4
18
20
5
19
6
25
1

19. Blow-down valve
22. Solenoid valve
23. Solenoid valve
25. Pressure gauge

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3
25
4 21 18
20 19
23
24 22
5
2 3 4 5
1
1. From the air receiver

2. To the pressure accumulator
3. To the intake valve
4. To the compressor
5. Out-blow from the air receiver

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26
2
24
26
Slightly open the hose fitting (26) of the accumulator (24) and allow the pressure to be released before
opening the compressed air connectors.

ID: 365 2 en 2011-10-03
DX, DX_R and DQ500
8. TROUBLESHOOTING
8.1. The compressor overheats
POSSIBLE REASON CHECK / OPERATION

Oil level too low. Check the oil level before starting and fill up if
necessary. Avoid overfilling (about 1/3 of the
height of the sight glass is sufficient).
Faulty thermostat (11). (Oil circulation through Check the operation and condition of the thermo-
the cooler core is partially or completely obstruc- stat (11).
ted.)
Dirty oil cooler core (12). Clean the core.
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 recommen-
circulation – poor cooling efficiency.) dations.
Air in the oil cooler core.(Poor circulation) Bleed the oil cooler core and change the oil type
if foaming occurs.
Incorrectly adjusted/leaking/faulty pressure First check that the one-way restrictor valve at the
relief valve (84) of the pump (80) for the oil fan motor is not open; all oil should go through the
cooler. (The fan rotates slowly – poor cooling ef- fan motor (12.2). Refer to the instructions for Drill-
ficiency.) ing hydraulics. Check/adjust the pressure relief
valve.
8.2. Oil in the compressed air

Clogged oil return line. (Too much oil in the Clean the orifice (15) (ø 1.0 mm) on top of the oil/
separator chamber of the oil/air receiver – oil mix- air receiver, and the strainer (14) and the non-
es with the output air.) 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 recommen-
dation. Check the oil level.

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8.3. Insufficient air output

Incorrectly adjusted or faulty pressure regulator Adjust the regulator for higher pressure. Check
(18). the operation and condition of the regulator.
Leaking blow-down valve (19). Clean the blow-down valve.
Clogged breather hole of the intake valvecon- Clean the breather hole of the intake valve con-
necting nipple. necting nipple (intake line).
(The pressure under the intake valve piston not
released.)
Leaking pneumatic circuit.(For example, a bro- Repair the leaks.
ken hose allows the air to escape.)
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 while
the flushing is on. If air comes out through the
connection, the solenoid valve is faulty.
8.4. Pressure too high

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 regu- Adjust the pressure regulator for lower pressure.
lator (18). Check the operation and condition of the regula-
tor.

ID: 365 2 en 2011-10-03
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9. MAINTENANCE
• The inside of the air receiver must be checked for corrosion and other possible wear at least every
four years.
• No welding is to be implemented on the air receiver for fasteners or other purposes.

ID: 365 2 en 2011-10-03
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Original instructions
377 2 en 2011-04-12
Shank Lubrication System (SLU)

Operation and Maintenance
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. Shank lubrication system monitoring ......................................................................................................... 9
5.2. Operating principle of the shank lubrication system ............................................................................. 9
5.3. Operation diagram of the shank lubrication oil pump ........................................................................... 10
5.4. Monitoring unit .................................................................................................................................................. 11
5.5. Heating circulation function .......................................................................................................................... 12
5.6. Boost switch ...................................................................................................................................................... 14
5.7. Air line pressure switch S305 ....................................................................................................................... 14
5.8. Cabin indicator lights ...................................................................................................................................... 14
6. ADJUSTING THE SHANK LUBRICATION DEVICE ..................................................................... 15
7. MAINTENANCE INSTRUCTIONS ................................................................................................. 17

7.1. Checking the operation of the monitoring unit ........................................................................................ 17
7.2. Bleeding the shank lubrication oil line ....................................................................................................... 18
7.3. Bleeding the shank lubrication oil pump ................................................................................................... 19
7.4. Replacing seals ................................................................................................................................................. 20
7.5. Replacing a faulty shank lubrication hose ................................................................................................ 21
7.6. Draining the condensed water from the oil tank ...................................................................................... 22
7.7. Cleaning the oil receiver ................................................................................................................................. 22
7.8. Replacing the oil tank breather ..................................................................................................................... 23
8. TROUBLESHOOTING ................................................................................................................... 24

ID: 377 2 en 2011-04-12
ID: 377 2 en 2011-04-12
1. GENERAL
The purpose of shank lubrication is to lubricate the rock drill’s 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.

ID: 377 2 en 2011-04-12
2. SAFETY PRECAUTIONS
Take all safety factors into consideration and perform your work
with care. Follow all drilling site safety regulations.
Operating, service and adjustment procedures must be carried

out only by personnel with specialized operation and service
training. Read and ensure that you understand the operating,
maintenance, and safety instructions before using or servicing
the rig.
Danger of venting compressed air. Compressed air jets can

cause serious injury. Allow the pressure to be released before
opening the filling cap or the compressed air connector.

ID: 377 2 en 2011-04-12
3. MAIN COMPONENTS
1 8
2
9
10
11
12
6
7 13
1 Level switch 2 Breather / filler cap

3 SLCU control unit 4 Forced operation button (Boost)
5 Pump control valve CT5.1 6 Pump unit
7 Drain valve 8 Oil dipstick
9 Oil tank 10 Fine adjustment switches
11 Bleeding screw CT7 12 Hydraulics bleeding screw CT4
13 Control switch CT1

ID: 377 2 en 2011-04-12
4. TECHNICAL DATA
Oil tank
Total amount of oil (l) Depends on the equipment type
Breather (µm) 10
Oil strain (mm) 1
Level switch Yes
Pump unit
Stroke volume 2,0 cm³
Output range 188 - 2800 g/h
Max. operating pressure 210 bar
Min. operating pressure 25 bar
Max. lubrication oil pressure 25 bar
Tightening torques Nm
Control switch 7
ump unit fastening screws 20

ID: 377 2 en 2011-04-12
5. DESCRIPTION OF OPERATION
5.1. Shank lubrication system monitoring
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. Operating principle of the shank lubrication system
1 5
6
3
4
8
7
P
9 10
1 Breather / filler cap 2 Oil tank

3 Pump unit 4 Hydraulic oil pressure line
5 Level switch 6 Shank lubrication oil line
7 Hydraulic oil tank line 8 Compressed air line
9 Pressure switch 10 Rock drill

ID: 377 2 en 2011-04-12
5.3. Operation diagram of the shank lubrication oil pump
CT1 control switch CT2 suction side non-return valve

CT3 operating piston CT4 hydraulics bleeding screw
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.

ID: 377 2 en 2011-04-12
5.4. 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.

ID: 377 2 en 2011-04-12
5.5. Heating circulation function
The performance of the pump decreases in cold

conditions. This is due to the increased viscosity
of both the shank lubrication oil and the hydraulic
oil that drives the pump. The increase in viscosity
causes problems in, for example, the ON/OFF
valve (CT5), which controls the pump and the
pump intake valve (CT2).
The heating circulation function is based on cir-
culating the hydraulic oil driving the pump through
the pump. The oil circulates through an 0.6-mm
orifice (CT8) and then directly into the tank. The
volume flowing through the orifice is approx. 1–
2.5 l/min. The heating circulation function can be
enabled and disabled.

ID: 377 2 en 2011-04-12
Heating circulation components
3
1
1 Locking nut
2 Heating circulation orifice, 0.6 mm
3 Plug screw
4 Seal
5 Cap
Enabling/disabling the heating circulation function
Enabling the heating circulation Disabling the heating circulation

1. Unscrew the cap (5) 1. Unscrew the cap (5)
2. Loosen the locking nut (1) but do not remove 2. Loosen the locking nut (1) but do not remove
the nut the nut
3. Turn the plug screw (3) 2.5 turns counter- 3. Turn the plug screw (3) 2.5 turns clockwise
clockwise 4. Tighten the locking nut (1)
4. Tighten the locking nut (1) 5. Reinstall the cap (5)
5. Reinstall the cap (5)

ID: 377 2 en 2011-04-12
5.6. Boost switch
The boost switch is used in the following cases:

• to fill the shank lubrication hose
• when higher shank lubrication is temporarily needed
When the boost switch is activated, the indicator light of the pump control valve starts to flash. The
oil output of the pump is now 2800 g/h and the pumps’ stroke frequency is 30 strokes / minute. The
boost function is active as long as the boost switch is on.
Remember to turn off the boost switch after the service
operations!
5.7. 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 red
indicator light turns on, the green indicator light turns off and the joystick is automatically centered.
5.8. Cabin indicator lights
H93
H93 Shank lubrication is working.
Shank lubrication malfunctioning (drilling is

H94 stopped) or shank lubrication oil level is
low.
H94

ID: 377 2 en 2011-04-12
6. ADJUSTING THE SHANK LUBRICATION DEVICE
The pumping frequency of the lubrication pump

can be set within the range of 2...30 strokes per
minute using the two 16-position rotary switches
on the SLCU unit. The 16 positions of each switch
are 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. The
other switch is the fine adjustment switch (FINE).
Correct lubrication dosage for various rock drills
in various drilling conditions is achieved by the
different positions of these adjustment switches.
The range switch settings are the same in set-
tings 6-F.
Rock drill Range of the RANGE Setting Setting of the Amount of lu- Lubrication
type switch setting (g/h) of the FINE switch brication to check value (ml/5
RANGE the rock drill min)
switch (g/h)
HLX 5 300-600 0 4 230 21 ±3
HLX 5T 200-400 1 5 310 28 ±3
HL 510 200-400 1 5 310 28 ±3
HL 600 300-600 2 1 400 38 ±4
HL 710 400-850 2 5 470 44 ±5
HL 650/710 400-850 2 5 470 44 ±5
HL 710T 400-850 3 7 690 64 ±7
HL/HF 810T 400-850 3 7 690 64 ±7
HL 800T 400-850 3 7 690 64 ±7
HL 800 400-850 3 7 690 64 ±7
HL 1010 400-850 3 7 690 64 ±7
HL 1560 600-1200 4 4 910 76 ±8
When a circuit board is supplied as a spare part, it is set at the

maximum settings. Set the board to the correct settings
according 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 within
and beyond the specified range. For small hole sizes (for the
rock drill in question) and in upwards drilling and bolting, we
recommend using low fine adjustment settings. For larger hole
sizes and high temperature surface applications, we
recommend using higher fine adjustment settings.
Example for reading the table: Range setting = 3, Fine setting = 7 → Lubrication oil volume is about
690 g/h.

ID: 377 2 en 2011-04-12
LUBRICATION CONTROLLER 2.0cm ^ 3
3000
2500
2000
0
1
l u b r i c a t i o n [ g /h ]
2
1500 3
4
5
6
1000
500
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
fine adjustment

ID: 377 2 en 2011-04-12
7. MAINTENANCE INSTRUCTIONS
7.1. 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.

ID: 377 2 en 2011-04-12
7.2. Bleeding the shank lubrication oil line
CT4 CT7
1. Turn off the engine.

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

ID: 377 2 en 2011-04-12
7.3. Bleeding the shank lubrication oil pump
CT4 CT7
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.

ID: 377 2 en 2011-04-12
7.4. Replacing seals
2 3 1
1 Pump unit
2 Plug
3 Piston
4 Piston seals

ID: 377 2 en 2011-04-12
1. Remove the old seals from the piston grooves.
A B C D E F G H A
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 and
A).
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 piston
seal, 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.
7.5. 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.

ID: 377 2 en 2011-04-12
7.6. Draining the condensed water from the oil tank
1. Drain the condensed water from the oil tank

into a receptacle by using the drain valve.
7.7. Cleaning the oil receiver
1. Empty the oil tank into a receptacle.

2. Wash the inside of the tank.
3. Flush the tank.

ID: 377 2 en 2011-04-12
7.8. Replacing the oil tank breather
1. Replace the breather at the intervals specified

in the maintenance instructions or as required,
e.g. in the event that the breather has become
wet.

ID: 377 2 en 2011-04-12
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 is
centered

Oil level too low Add oil and remove air from pump through bleed-
ing screw
Pump intake blocked Check and clean container
Delivery pipe blocked Remove and clean or replace delivery pipe
Oil viscosity too high Select correct oil grade
No pump operating pressure Problem in rig’s hydraulic system
Faulty solenoid valve of pump Check / replace valve
Faulty pump timer Check (measure) / replace timer
Solenoid valve wiring fault Check / replace wiring
Shank lubrication pressure hose damaged Change or fix the hose
Problem: Too little oil

Incorrectly set timer frequency Check setting
Air in pump Check oil level and bleed pump
Dirt in intake side non-return valve Clean ball of non-return valve
Dirt in control switch non-return valve Clean control switch / container
Breather blocked (underpressure) Clean breather
Return hose to collector tank blocked Clear obstruction
Problem: Too much oil (red indicator light may turn on and drilling joystick may be centered)

Hydraulics bleed screw open Close bleed screw
Timer frequency incorrectly adjusted Check adjustment
Piston seals damaged Check piston and replace seals
BOOST switch activated Check and turn off

ID: 377 2 en 2011-04-12
Problem: Internal oil leakage of pump

Hydraulics bleed screw open Close bleed screw
Piston seals damaged Check piston and replace seals
Problem: Normal amount of oil, but alarm activated (red indicator light on, green indicator
light off, drilling joystick is centered)

Control switch wiring cut or shortcut to ground Check/replace wiring
Dirty oil, conducting electricity Change oil in shank lubricator tank
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.

ID: 377 2 en 2011-04-12

ID: 377 2 en 2011-04-12
www.sandvik.com
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Air End and Pneumatic Circuit

3. COMPONENTS OF THE COMPRESSOR AND PNEUMATIC CIRCUITS ................................... 7

4. AIR END ......................................................................................................................................... 12

5. OPERATING PRINCIPLE OF THE COMPRESSOR CIRCUIT ..................................................... 14

6. CONTROL INSTRUMENTS OF THE PNEUMATIC CIRCUIT ....................................................... 27

7. ADJUSTING PRESSURE AND VALVE BLOCK CONNECTIONS ............................................... 30

Copyright © Sandvik Mining and Construction 3 (36)

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Always follow the safety instructions and be careful with your

Hazardous moving and rotating parts. Carry out service and

WARNING! HIGH PRESSURE INJECTION HAZARD!

6 (36) Copyright © Sandvik Mining and Construction

3. COMPONENTS OF THE COMPRESSOR AND PNEUMATIC CIRCUITS

3.1. Pneumatic circuit diagram and components

Rigs are equipped with a compressor producing compressed air for

Copyright © Sandvik Mining and Construction 7 (36)

8 (36) Copyright © Sandvik Mining and Construction

4. Air filter service indicator*

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10 (36) Copyright © Sandvik Mining and Construction

3.3. Location of components - DX_R

Copyright © Sandvik Mining and Construction 11 (36)

4.1. Technical data

DX500, DX680, DX500R, DX700, DX780, DX800,

4.2. Air end main components

The main components of the air end include:

12 (36) Copyright © Sandvik Mining and Construction

4.3. Compressing principle

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5. OPERATING PRINCIPLE OF THE COMPRESSOR CIRCUIT

14 (36) Copyright © Sandvik Mining and Construction

5.2. Description of components

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13. Oil filter

16 (36) Copyright © Sandvik Mining and Construction

30. Drill rod greasing valve

5.3. Air circulation

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5.4. Oil circulation

18 (36) Copyright © Sandvik Mining and Construction

5.5. Compressor regulating system

5.5.1. Before starting, ignition key position 0

Copyright © Sandvik Mining and Construction 19 (36)

5.5.2. Ignition key to position 1

20 (36) Copyright © Sandvik Mining and Construction

5.5.3. Starting, load relief 30 s; ignition key position 2

Copyright © Sandvik Mining and Construction 21 (36)

5.5.4. 30 seconds after starting

22 (36) Copyright © Sandvik Mining and Construction

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24 (36) Copyright © Sandvik Mining and Construction

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26 (36) Copyright © Sandvik Mining and Construction

6. CONTROL INSTRUMENTS OF THE PNEUMATIC CIRCUIT

6.1. Pneumatic circuit control instruments and warning lights

6.1.1. Compressor thermal switch

The compressor temperature gauge (in the op-

Copyright © Sandvik Mining and Construction 27 (36)

6.1.2. Air filter service indicator

The filter element must always be cleaned when

28 (36) Copyright © Sandvik Mining and Construction

6.2. Oil circuit control instruments