Pneumatics PDF

Original instructions
787 2 en 2011-05-25
WATER CIRCUIT, DL3 SERIES AND DL4 SERIES

Maintenance
Table of Contents
1. GENERAL ...................................................................................................................................... 5
2. SAFETY ......................................................................................................................................... 6
3. OPERATION OF CIRCUIT ............................................................................................................. 7

3.1. Components ....................................................................................................................................................... 7
3.2. Normal flushing ................................................................................................................................................. 9
3.3. Double flushing ................................................................................................................................................. 9
3.4. Pressure settings ............................................................................................................................................. 9
3.5. Inspection of pressure switch operation ................................................................................................... 9
4. MUD SEPARATOR ........................................................................................................................ 10

4.1. Cleaning .............................................................................................................................................................. 10
5. WATER BOOSTER PUMP ............................................................................................................ 11

5.1. General ................................................................................................................................................................ 11
5.2. Components ....................................................................................................................................................... 11
5.3. Connections ....................................................................................................................................................... 11
5.4. Operation and maintenance .......................................................................................................................... 11
6. PRESSURE REDUCING VALVE ................................................................................................... 12

6.1. Components ....................................................................................................................................................... 12
6.2. Function of valve .............................................................................................................................................. 12
6.3. Maintenance ....................................................................................................................................................... 13
6.4. Adjusting of pressure ...................................................................................................................................... 14
7. OIL COOLER ................................................................................................................................. 15

7.1. General ................................................................................................................................................................ 15
7.2. Function .............................................................................................................................................................. 15
7.3. Maintenance ....................................................................................................................................................... 16
8. COOLER'S DISSIPATION FIGURES ............................................................................................ 17
9. ELECTRICALLY CONTROLLED VALVE ..................................................................................... 18

9.1. Components ....................................................................................................................................................... 18
9.2. Function .............................................................................................................................................................. 18
9.3. Disassembly and assembly ........................................................................................................................... 19
9.4. Changing the seals to water valve ............................................................................................................... 21
10. WATER FLUSHING FLOW CONTROL SWITCH S9 AND AIR FLUSHING FLOW CONTROL
SWITCH S10 (EXTRA EQUIPMENT) ............................................................................................ 23
10.1. Series 1000 ......................................................................................................................................................... 23
10.1.1. Before adjustment ......................................................................................................................................... 23
10.1.2. Adjusting .......................................................................................................................................................... 24
10.2. Series 5010 ......................................................................................................................................................... 25
10.2.1. Electrical connection ..................................................................................................................................... 25
10.2.2. Operating and display elements .................................................................................................................. 26
Copyright © Sandvik Mining and Construction 3 (36)

ID: 787 2 en 2011-05-25
10.2.3. Setting up for water media ........................................................................................................................... 28
10.2.4. Maintenance ................................................................................................................................................... 30
10.2.5. Scale drawing ................................................................................................................................................. 31
10.2.6. Technical data ................................................................................................................................................ 31
11. MAINTENANCE OF WATER CIRCUIT ......................................................................................... 32

11.1. Anti-freeze blowing (option) .......................................................................................................................... 32
11.1.1. Components ................................................................................................................................................... 32
11.1.2. Draining and anti-freeze blowing of the water circuit ............................................................................... 33
11.2. Draining ............................................................................................................................................................... 34
11.3. Frost protection ................................................................................................................................................ 34
12. TROUBLESHOOTING OF WATER CIRCUIT ............................................................................... 35
4 (36) Copyright © Sandvik Mining and Construction

ID: 787 2 en 2011-05-25
Maintenance
1. GENERAL
Water is used in a DL- drill rig for two main purposes: for drill hole flushing and for various cooling
functions. Water is fed inside the drill rod to the bottom of the hole to be drilled, the broken rock
material comes out with the out flowing water from the hole being drilled, cooling the drilling
equipments. Before leading the water to the drill rod it is led through oil cooler for drill oil cooling
purposes.

ID: 787 2 en 2011-05-25
Maintenance
2. SAFETY
The electrical connection must be carried out by an authorized

electrician in accordance with local regulations.
Never drill without adequate flushing.
Do not reuse the water returned from the flushing circulation.
Keep the pressure limits and the pressure switches in working

order and in the right settings.

ID: 787 2 en 2011-05-25
Maintenance
3. OPERATION OF CIRCUIT
3.1. Components
14
2
8
3
4
OIL OUT
9
OIL IN
12 10
13
6
FROM COMPRESSOR
7
11
1 Drain valve and mud separator

2 Water booster pump
3 Pressure reducing valve
4 Pressure switch
5 Pressure gauge
6 Oil cooler
7 Flushing valve
8 Shut-off valve
9 Thermostat valve
10 Collecting piece
11 Flushing manifold
12 Water flow switch
13 Pressure relief valve (15 bar)
14 Pressure relief valve (15 bar) (option)

ID: 787 2 en 2011-05-25
Maintenance
SL/A
CABIN FRONT Y506
WINDOW WASHER F
OPTION
TYRE FILLING DEVICE 5
OPTION
S422
S421 BOOT WASHER

OPTION B9
OPTION
4
AIR MIST FLUSHING
KVL OPTION From drilling circuit/
7
carr ier/drilling block M10
Y9
To drilling circuit/
carr ier/collec tor
12
Solo with canopy

S10
Pipe /
Y10
Y127
9 S9
FLUSHING VALVE
11
6
DRAIN
HIGH PRESSURE WASHER

BLOWING THE HOLE
OPTION
OPTION 10
L2
L3 L6
L5 L8
GREASE PUMP L4 L7
OPTION 2 L1
M Water pump
15 Bar
IN
IP 5
15 OPTION 13
COMPRESSED AIR
3 WASHING HOS E
OUT
Pressure
reducing valve
OPTION OPTION
1-- 7 bar
OVER FLOW IN
ANTIFREEZE
38X3
PIPE
WATER RECEIVER
FILLING
FOR SCRUBBER
OUT
OPTION
WASHING HOS E WITH REEL
Y7 WATER
SCRUBBER
PRESSURE
RELIEF
VALVE 1 8
IN
To control valve of reels
port T
15 Bar OUT
COMPRESSED AIR OUTLET OPTION
FAN COOLING
14
WITH CT10, CT16
M AND CT28
COMPRESSORS M OPTION
IN From control valve of reels
port P2
OPTION
COMPRESSOR
WATER HOSE
OIL EMPTYING COMPRESSOR REEL
1 Drain valve and mud separator

2 Water booster pump
3 Pressure reducing valve
4 Pressure switch (S422)
5 Pressure gauge
6 Oil cooler
7 Flushing valve (Y9)
8 Shut-off valve
9 Thermostat valve
10 Collecting piece
11 Flushing manifold
12 Water flow switch (S9)
13 Pressure relief valve (15 bar)
14 Pressure relief valve (15 bar) (option)
15 Venting valve

ID: 787 2 en 2011-05-25
Maintenance
3.2. Normal flushing
Water supply to the rig is opened by opening the shut-off valve (8). Before opening the shut-off valve
(8), make sure that the mud separator screen (at the shut-off valve) is cleaned.
Check that the operating switch of the water booster pump (2) is in position I. The pump is started
automatically almost simultaneously with the powerpack.
Water pressure is adjusted with the pressure reducing valve (3) if necessary. Flushing water pressure
is increased with the water booster pump (2) that carries water to the water line. The flushing water
pressure to the rock drill is indicated by water pressure gauge (5). Pressure switch (4) and water
pressure gauge (5) are connected to the water line. From the water booster pump flushing water is
led to the oil cooler (6). Flushing pressure may not exceed 15 bar.
From the oil cooler water flows to electric-controlled flushing valves (7). The flushing valves switch
flushing on when control switch S74 is switched on the control panel.
The flushing system is provided with a flow control switch (12) that activates the flushing flow
disturbance function if flushing flow drops below the set value of the switch. If the flushing water
pressure on flow drops below the set values, the anti-jamming automatics engages. Flushing
pressure may not exceed 15 bar.
The water circuit is provided with a thermostatic valve (9). It monitors the temperature of return oil
after the oil cooler (6). If the temperature rises above the set value, the valve opens up and lets water
flow through the cooler to the ground.
3.3. Double flushing
The system includes two electric flushing valves, one connected to the water circuit and the other to
the pneumatic circuit. Water flushing operates during drilling as decribed with the circuit presented
above, but when the hole is completed, pressurized air can be used for blowing the hole clean.
3.4. Pressure settings
The pressure switch (4) is set to operate at 2.8 bar with a 4 second delay. If flushing pressure drops
below this value, the switch automatically stops the water pump and drilling.
3.5. Inspection of pressure switch operation
Close the water circuit shut-off valve (8). If water pressure is below 2.8 bar and the pressure switch
(4) operates, the indicator light H601 (low water pressure) in the QN panel lights up. Acknowledge
the disturbance by pressing the button S505. The pressure switch is working properly, if the indicator
light does not go off. Open the water circuit shut-off valve (8). If water pressure is over 2.8 bar and
the indicator light H601 goes off, the pressure switch is working properly.
H601
S505

ID: 787 2 en 2011-05-25
Maintenance
4. MUD SEPARATOR
The mud separator does not work properly if water which has
been once in the flushing circulation is reused.
Restricted water flow causes flushing and cooling problems. The most common reason for the drop
of pressure is blocked mud separator. This is why the separator shall be cleaned at least once a
week. If the conditions change, clean the separator more often at first, and determine the correct
cleaning interval on the basis of experience.
4.1. Cleaning
When cleaning, observe the following:

1. Check that the shut-off valve (1) of the supply line is open.
2. Open the drain valve (3) of the mud separator (2) enough to allow the dirt in the strainer to come
out.
3. Close the drain valve of the mud separator.
4. If dirt does not come out then change or clean the strainer.
1 Shut-off valve (option)

2 Mud separator 1
3 Drain valve
4 Strainer

ID: 787 2 en 2011-05-25
Maintenance
5. WATER BOOSTER PUMP
5.1. General
The water booster pump is used when the pressure of the water supply network is not sufficient to
ensure proper flushing.
5.2. Components
1 Motor
2 Pump 1
3 Primer- / vent plug
4 Primer valve- / drain plug
3
5.3. Connections
The arrows on the base of the pump indicate the direction of flow of the water. If protective caps are
installed to the pump’s hose connectors for transport or storage, remove them before connecting the
hoses. Always check that the hoses are clean on the inside.
5.4. Operation and maintenance
Before starting the pump,see instruction 419“Water booster pump; Operation and maintenance”.

ID: 787 2 en 2011-05-25
Maintenance
6. PRESSURE REDUCING VALVE
6.1. Components
1 Body
2 Bottom cover
3 Spring casing 19 17
4 Piston
14
5 Valve sleeve 18
6 Valve sleeve 13
7 Valve disc 3
8 Valve stem 4
9 High pressure seal 16
C 11
10 High pressure seal ring
9
11 Distance piece
20
12 Washer 10
13 Locking ring 5
22
14 Adjusting screw A
8
15 Bottom cover gasket
OUT
16 Piston seal IN
B
17 Adjusting spring 7
18 Valve spring 6
12
19 Ball 15 1
20 Set screw
21 Cap gasket 21 2
22 Body gasket
6.2. Function of valve
The water is drawn with a hose onto the shut-off valve’s stem. When the valve is opened, the water
flows through the mud separator and to the water pump, after that there is a pressure reducing valve.
The pressure to be regulated acts on the valve‘s inlet side, both on the valve sleeves‘s (5) top surface
(A) and bottom surface (B). These surface areas are in balance so that the pressure acting on them
does not alone cause movement of the piston (4) in either direction. Spring (2) causes the piston to
move downwards. Now the valve sleeve opens and lets the pressure into the outlet-side channel.
The same pressure, however, is acting through an internal port also on the undersurface (C) of the
valve sleeve (5), causing a force pushing the piston (4) upwards. The flow always continues as long
as the force pushing the piston upwards, a force arising from pressure, overcomes the spring force,
whereupon the disc valve closes. When the pressure on the outlet side decreases, the spring force
again becomes determining.
Then the piston lowers, the disc valve opens, opening the flow passage, the pressure effect on the
underside of the big piston becomes determining, etc. Raising of the outlet pressure is thus effected,
as can be concluded from what has been told above, by tightening the spring.
Correspondingly, for lowering the outlet pressure the spring must be slackened.

ID: 787 2 en 2011-05-25
Maintenance
6.3. Maintenance
If the pressure acting on the pressure restrictors outlet side varies greatly, or it changes considerably
in either direction, the most likely reason is in the valve’s leaking seal, which therefore must be
changed.
Disassembly of the valve is started by loosen locking ring (13) and screwing anti-clockwise the
adjusting screw (14). Disassembly adjusting screw (14). Be carefully because of spring force. Do not
lose the spring casing‘s ball (19). After this, disassembly the ball (19), upper spring plate (17) and the
valve spring (18). Disassembly set screws (20), spring casing (3), piston (4), piston seal (16) and
distance piece (11). Disassembly is continued on the lower side of the valve by detaching the bottom
cover (2) which is screwed on to the valve body. When the cup has been detached, disassemble
valve stem (8), washer (12), disc holder (6), valve disc (7), valve sleeve (5), high pressure seal (9),
and high pressure seal ring (10).
Change the seal (9), seal ring (10) and valve disc (7) around the valve sleeve (5). Doing the same to
the piston seal (16). Assemble the valve in reverse order, using gasket 12, 21, 22 or suitable sealing
compound for the sealing of the bottom cup and the spring casing.
NOTE! If you are disassembling the valve in position, be particularly careful not to lose the
spring chamber’s ball.
NOTE! See to it that the valve is adjusted before use.

ID: 787 2 en 2011-05-25
Maintenance
6.4. Adjusting of pressure
FLUSHING PRESSURE = INLET PRESSURE + PUMP PRESSURE. The pressure before the pumps
is adjusted with the pressure-reducing valve (3). The flushing pressure value can be read from the
pressure gauge (5). The value must never exceed 15 bar. To ensure adequate flushing, the minimum
inlet pressure to the drilling rig must be 5 bar. An optional 15-bar relief valve (14) can be installed
before the flushing circuit, in case high-pressure peaks occur in the working site’s water supply
system.
14
2
8
3
4
OIL OUT
9
OIL IN
12 10
13
6
FROM COMPRESSOR
7
11
HLX 5 HL 700 HL 800 HL 1000 HL 1500

Flow 150 l/min (15 150 l/min (15 150 l/min (15 200 l/min (15 200 l/min (15
bar) bar) bar) bar) bar)

ID: 787 2 en 2011-05-25
Maintenance
7. OIL COOLER
7.1. General
The OW21, OW30, OW45 and OW60 hydraulic oil coolers are used with Sandvik’s hydraulic
powerpacks. The oil coolers differs from each others only in size and efficiency.
The working principle of the cooler is ”from oil to water”. The cooling water flows inside the cooler
in ”three stages” so that it changes direction twice at the cooler’s end flange. Because of this
arrangement, the cooler does not drain completely through the bottom plug but pressured air blown
through the flow-circuit is needed for assistance.
7.2. Function
The flow path of the water that takes care of the oil cooling opens normally automatically when the
drilling hydraulics’ percussion circuit is actuated. In certain cases cooling may be needed also during
drilling pauses, but the valve that answers for the automatic flushing is, however, then closed. The
situation can be helped by the aid of the by-pass valve (5) connected to the oil cooler. By opening
this valve, a nonstop water flow (= cooling flow) is produced.
The volume flow is then not so great as when using the normal flow course, this serves the purpose
of additional cooling. However, it must be noted that if the available water flow is limited, by-pass
running can cause deficiency in the flushing flow. This manifests itself in a great pressure difference
at the flushing valve, depending on whether the drilling is going on or not.
4 3
1 5
1 Water in
2 Water out
3 Oil in
4 Oil out
5 By-pass valve
If, for example, the water hoses are fitted the other way a loss in cooling efficiency will result.

ID: 787 2 en 2011-05-25
Maintenance
7.3. Maintenance
If the temperature of oil increases or the pressure with the flushing valves falls, that may be a sign of
cleaning need of the oil cooler. On the lowering of the pressure there can be also other reasons, so
the cause in question must be clarified.
If it has been ascertained that cooler is blocked, and if the cooler is dismountable model, the cleaning
work must be begun by letting out both the water and the oil from the cooler unit.
Open the fastening bolts of the ends of the cooler. Remove the ends and pull the cooler’s tubing out.
The tubing’s water circuit-side surfaces (tubes’ inner surfaces) can best be cleaned by pushing a 3
mm steel rod into the tube, in direction which is against the water’s flow direction when the cooler is
used.
When the cleaning has been done, all impurities must be carefully removed from both surfaces of the
tubing. This can be done for example by washing the unit first carefully and then blowing with
compressed air any loose materials and the water off the tube surfaces.
New seals should be used when assembling the cooler.
Be careful not to overtighten the bolts. The tightening torque (37

Nm) of the cooler end fastening bolts should be adhered to so
that the ends do not bend and get damaged from excessive
tightness.
If the cooler’s hoses are loose, care should be taken of their

correct order when reconnecting them. The inflowing oil must
be led the upper way, for the reason alone that then the running
direction of the oil is natural in consideration of the cooling. For
the same reason the water must be led into the cooler the
bottom way.
Take care to observe the given pressure limits. For example the
oil cooler is in danger of getting damaged if the water circuit’s
pressure exceeds the specified limit. If a further damaged cooler
admits water in the hydraulic oil, the damages can be very
serious.

ID: 787 2 en 2011-05-25
Maintenance
8. COOLER'S DISSIPATION FIGURES
Cooler’s nominal dissipation:
OW21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21kW
OW30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30kW
OW45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45kW
OW60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60kW
kW Dissipated when oil outlet temperature exceeds the water inlet temperature by 25 °C.
120
kW
105
90
OW60
75
60
OW45
45 OW30
30
OW21
15
25 50 75 100 125 150 175 200 225 250 275 300

oil flow l / min
The heat dissipation figures are based on a water flow rate which is 50% of the oil flow. For other
water flow rates, multiply the dissipation figure by the following correction factor.
25% 50% 100%

0,8 1 1,2
When the oil outlet temperature exceeds the water inlet temperature by other than 25 °C, multiply
the dissipation figure by the following correction factor.
15 °C 20 °C 25 °C 30 °C 35 °C
0,6 0,8 1 1,2 1,4

ID: 787 2 en 2011-05-25
Maintenance
9. ELECTRICALLY CONTROLLED VALVE
9.1. Components
FLUSHING MANIFOLD
1 Pressure gauge 1
2 Water flow switch S9 2
3 Water 10
4 Compressed air
5 Pressure gauge 9
3
6 Air valve (Y10)
7 Air flow switch S10 4 8
8 To the flushing
9 Pressure switch 7
10 Water valve (Y9)
5 6
9.2. Function
When water flushing is switched on with joystick S74 (middle position), solenoid becomes activated
and pulls piston open. Because the cooling water for the oil cooler is also directed through this valve,
cooling also works only when the valve is open.

ID: 787 2 en 2011-05-25
Maintenance
9.3. Disassembly and assembly
14 2
17
10
4
13
5
11
7
12
16 3 9 8
1
15
Disconnect hoses and wires from the flushing valve.

Remove the flushing valve from the rig.
1. Open the screws (14, 4 pcs.) of the water valve (2), and remove the water valve (2) from the
flushing valve block (5).
2. Open the screws (15, 4 pcs.) of the air valve (1), and remove the air valve (1), O-ring (6), and seal
(7) from the block (5).
3. Remove the non-return valve (3) nut (8).
Remove the non-return valve (3) from the block (5).
4. If necessary, disconnect the connectors and remove the plugs (4 , 10, 11, 12, and 13).
5. Clean the block thoroughly.
6. Replace damaged parts, O-rings (6 and 9), the seal (7), and the seal rings of connectors and
plugs (if removed or leaking).

ID: 787 2 en 2011-05-25
Maintenance
7. Reconnect the connectors and reinstall the plugs.

8. Reinstall the non-return valve (3).
9. Install the O-ring (9) on the nut (8).
10. Install and tighten the nut (8) in place.
11. Attach the seal (7) to the block.
Make sure that the position is correct: collar towards the block.
12. Install the O-ring (6) on the block.
13. Install the O-ring (16) on the block.
14. Attach the air valve (1).
15. Install the O-rings (17) on the block.
16. Attach the water valve (2).
Make sure the position is correct; there are guide pegs below the valve that go into the holes on
the block.
Install the serviced flushing valve to the rig. Connect the hoses and connectors.
Test the operation of the valve.

ID: 787 2 en 2011-05-25
Maintenance
9.4. Changing the seals to water valve
2 27 22 23 24 15 8 25 26 5 13
7 4
21 19
6 18
8 12 8 20
14
16
9 10
1
3
10 11 28
18 15
3 12 2 8 21 22 23 8 13 5
14 9 8 7 4 19
6,16
26
27 27 24 25
11 11 1
20
21
8
22 15
25
23
24
1. Take spool (2) and make full assembly. Install parts (21, 22, 23 and 27).
2. Take housing and install seals (8 and 24). Use installation grease to the both seals.
3. Install seals (8 and 15) to bushing (25) according to drawing. Use installation grease.
4. Install the spool assembly (2) from the spring ends direction to the housing (1).

ID: 787 2 en 2011-05-25
Maintenance
5. Install the bushing assembly (25) to housing (1) and lock it with circlip (26). Use grease on seals.
6. Take spring plate (5) and spring (7) and install them according to picture.
7. Take spring cover (4) and o--ring (13) and install them to the housing. See right installation position
from drawing (drain hole pointing down). Tighten screws (19) to 25 Nm.
8. Take pilot cover (3). Install orifice (14) and seal (8), use installation grease to the seal (8). Install
spool pusher (9). Use installation grease to seals of proportional valve (6). To install the
proportional valve (6), give a gentle push to the valve (6) and tighten screws (16) to 4 Nm.
9. Install o--rings (10 and 12) to the pilot cover (3). Install seal (8) to pilot covers seal cavity (3). Install
the pilot cover (3) to the housing (1) and tighten the screws (18) to 25 Nm.
10. Finally install o--rings (10 and 11). Position valve correctlywith pin (28) and tighten screws (20).

ID: 787 2 en 2011-05-25
Maintenance
10. WATER FLUSHING FLOW CONTROL SWITCH S9 AND AIR FLUSHING

FLOW CONTROL SWITCH S10 (EXTRA EQUIPMENT)
10.1. Series 1000
Flushing flow is monitored by an electronic flow control sensor.
1 BN
2 L+
4 BK
3 1 A
3 BU
4 L--
Normally open (NO) TAS CONTROL SYSTEM
3 BU
2 L+
4 BK
3 1 A
1 BN
4 L--
Normally closed (NC) RELAY CONTROL SYSTEM

Core colours of sockets:
1 = BN (brown), 3 = BU (blue), 4 = BK (black)
10.1.1. Before adjustment
Note! Do the adjustment when the drilling equipment is in the hole and the maximum drilling hole
length is drilled.
Connect the power on to the control system.
The sensor can be adjusted when power has been switched on for flushing by the flushing control
lever.
Wait 10 seconds with water and 20 seconds for air to allow the flow to become constant.

ID: 787 2 en 2011-05-25
Maintenance
10.1.2. Adjusting
• Press the Learn/Set button and keep it pressed

until the outmost green LEDs on the right and
on the left will flash.
• After 3 s the LED bar (green) fills from left to
right.
• Release the button as soon as the first LED light
comes steady (the LED bar (green) continues
filling from left to right).
• The indication goes off briefly.
• The unit stores the current flow rate.
• The unit is ready for normal operation.
Adjusting scales the units maximum flow, 100%.

If flow lowers to 70% of the maximum flow, sensor
activates and gives “flow failure” information.

ID: 787 2 en 2011-05-25
Maintenance
10.2. Series 5010
10.2.1. Electrical connection
The unit must be connected by a qualified electrician.

The national and international regulations for the installation of electrical equipment must be adhered
to.
• Disconnect power.
• Connect the unit as follows:
BN BN
L+ L+
2 BK BK
3 1 A BU B BU
L-- L--
4 WH WH
P P
Normally open (NO) TAS CONTROL SYSTEM

A: SI5010 (positive switching ); B: SI5010 (negative switching)
Core colours of ifm sockets:
P: programming wire (for remote adjustment) -> 7.5)
1 = BN (brown), 2 = WH (white), 3 = BU (blue), 4 = BK (black)
Note! Use 4-wire connection cables without a link between pins 2 and 4. With 3-wire sockets with a
link between pin 2 and pin 4 switching of the output stage triggers the remote adjustment.
NOTE! See section 10.2.3. (configure the switching output) for normally closed (NC) operation
for RELAY CONTROLLED SYSTEM.

ID: 787 2 en 2011-05-25
Maintenance
10.2.2. Operating and display elements
Flow
Low High
1
0 1 2 3 4 5 6 7 8 9
Setpoint
2 3
1: Operation display
• The green LEDs indicate the current flow (the LEDs 0 to 9 represent the range between no flow
and maximum flow).
• A lighting LED indicates the position of the switch point (orange = output closed, red = output open).
2, 3: Setting buttons for adjustment and configuration
Operation
After every power on all LEDs light and go out again step by step (during this time the output is closed
if configured as normally open). The unit is then ready for operation.
In case of power failure or interruption all settings remain.
Operating indicators
Green LED bar: Current flow within the represen-

tation range.
Indication of the switch point (SP): 0 1 2 3 4 5 6 7 8 9
• LED orange: output closed.
• LED red: output open.
LED 9 flashes: current flow above the represen-
tation range.
0 1 2 3 4 5 6 7 8 9
LED 0 flashes: current flow far below the repre-

sentation range.
0 1 2 3 4 5 6 7 8 9
Interference indicators

ID: 787 2 en 2011-05-25
Maintenance
Short circuit at the switching output:

The operating indicator and red LEDs light alter-
0 1 2 3 4 5 6 7 8 9
nately.
If the short circuit has been rectified, the unit im-
mediately passes into the normal operating state.
The current operating state is displayed. 0 1 2 3 4 5 6 7 8 9
Operating voltage too low (< 19 V) or failed. En- Display OFF (no LED lights ) :
sure a correct voltage supply.
Basic functionality of set-up
• Switch on the supply voltage.

- All LEDs light and go out again step by step. During this time the output is open (Normally closed
operation) (if configured as normally open). The unit is in the operating mode.
• Let the normal flow circulate in the installation.
• Check the display and determine further actions.
1 The factory setting is suitable for the ap- Low

Flow
High
plication.
• No further settings are required.
0 1 2 3 4 5 6 7 8 9
2 Your normal flow is below the represen- Flow

Low High
tation range of the display. 2 setting op-
tions:
• Change the switch point. 0 1 2 3 4 5 6 7 8 9
• Carry out high flow adjustment.

3 Your normal flow exceeds the represen- Flow
Low High
tation range of the display (LED 9 flash-
es).
• Carry out high flow adjustment. 0 1 2 3 4 5 6 7 8 9
You can restore the factory setting any time.

ID: 787 2 en 2011-05-25
Maintenance
10.2.3. Setting up for water media
High flow adjustment for water flow sensor S9 and air flow sensor S10
The unit determines the existing flow as normal flow and adapts the display representation (all LEDs
except the switch point LED light green).
• Let the normal flow circulate in the installation. Note that different kind of drill steel (tubes/rods and
drill bits) effects the flow. As well as the maximum drilling hole length.
• Press the push button and keep it pressed.
- LED 9 lights, after approx. 5 s it flashes.
• Release the push button.
The unit is now adapted to your flow conditions. It passes into the operating mode, the display should
now show example 1.
1 The factory setting is suitable for the ap- Flow

Low High
plication.
• No further settings are required.
0 1 2 3 4 5 6 7 8 9
Note: The switching point (LED 7) is now set to 70% of the normal flow.
Switch point can be adjusted in case of switch point differs from 70%. See section “Change the switch
point”.
Note: The adjustment affects the switch point: It is increased proportionally (maximum up to LED 7).
Low flow adjustment for air flow sensor S10
Note: When using other media than water, it is highly recommended that you should additionally adapt
the unit to the minimum flow (flow as 0 %).
Note: The following adjustment must only be carried out after the high flow adjustment.
• Let the minimum flow circulate in the installation or ensure flow standstill.
• Press the push button and keep it pressed.
• Release the push button. The unit adopts the new value and passes into the operating mode.

ID: 787 2 en 2011-05-25
Maintenance
Change the switch point (optional)
For the factory setting the switch point is at LED 7. A change makes sense if:
1. The display shows example 2.
2 Your normal flow is below the represen- Flow

High
Low
tation range of the display. 2 setting op-
tions:
• Change the switch point. 0 1 2 3 4 5 6 7 8 9
• Carry out high flow adjustment.

2. The flow fluctuates much or pulsates.
3. If a faster response time of the unit is requested (low switch point = fast response with rising flow,
high switch point = fast response with falling flow).
• Briefly press the pushbutton or
- The switch point LED flashes.
• Press the pushbutton or as often as required. Each press of the pushbutton shifts
the LED by one position in the indicated direction.
Note: If no pushbutton is pressed for 2 s, the unit returns to the operating mode with the newly set
value.
Note: The typical response time of the unit is 1...10 s. It can be influenced by the setting of the switch
point:
• Low switch point = quick reaction with rising flow
• High switch point = quick reaction with falling flow
Configure the switching output
The unit is delivered as normally open. In case of need you can change the output to normally closed:
• Press the unit’s pushbutton for at least 15 s.
- After 10 s the current setting is displayed: LEDs 5...9 light orange (= output normally open).
- After approx. 15 s LEDs 0...4 flash orange.
• Release the pushbutton. The output is changed to normally closed operation.
For a new changeover repeat the operation.
Restore the factory setting (reset)
If the unit is not working properly or connecting the settings failed, the unit can be reset to factory
settings. After this continue connecting the settings, see section 10.2.3.
• Press the unit’s pushbutton for at least 15 s.
- After approx. 15 s LEDs 0...9 flash orange.
• Release the pushbutton. All settings are reset to the factory setting:
- Operating area: 5 ...100 cm/s for water
- Switch point: LED 7
- Output function: NO
- Unlocked.

ID: 787 2 en 2011-05-25
Maintenance
Lock / unlock the unit
The unit can be locked electronically to prevent unintentional settings.

• Press both setting pushbuttons simultaneously for at least 10 s in the operating mode.
- The indication goes out, the unit locks or unlocks.
On delivery: unlocked.
Error during adjustment
If no adjustment is possible, all LEDs flash red. The unit then passes into the operating mode with
unchanged values.
Possible cause / aid:
Error during installation. Check whether all requirements have been met.
The difference between maximum flow and min- Increase the flow difference and carry out the ad-
imum flow is too small. justment once again.
The sequence high flow / low flow adjustment Carry out the two adjustment operations again in
was not adhered to. the right sequence.
10.2.4. Maintenance
Recommended maintenance:
• Check the sensor tip for build-up from time to time.
• Clean it using a soft cloth. Stubborn build-up (e.g. lime) can be removed using a common vinegar
cleaning agent.

ID: 787 2 en 2011-05-25
Maintenance
10.2.5. Scale drawing
1 2
50 63
27
M12x1
113
14
65
22
60
45
7,7
1 LED bar display

2 set button
10.2.6. Technical data
Application area Liquids and gases

Operating voltage [V] 19 ... 36 DC
Current rating [mA] 250
Short-circuit protection, pulsed; reverse polarity / < 2.5
overload protection Voltage drop [V] < 60
Current consumption [mA] 10, optically indicated
Power-on delay time [s]

ID: 787 2 en 2011-05-25
Maintenance
11. MAINTENANCE OF WATER CIRCUIT
11.1. Anti-freeze blowing (option)
11.1.1. Components
6 7 4
1 Mud separator 2 Water pump

3 Pressure reducing valve 4 T valve
5 Non-return valve 6 Filling cap
7 Filling adapter 8 Shut-off valve
9 Drain valve

ID: 787 2 en 2011-05-25
Maintenance
11.1.2. Draining and anti-freeze blowing of the water circuit
1. Disconnect the rig’s water hose from water

supply line and open the rig’s main valve (8).
2. Turn the three-way valve (4) into the position
where air can enter the flushing circuit (handle 4
turned towards pressurized air inlet) and start the
compressor. Water is now expelled from the
pump’s inlet line.
3. Close the rig’s main valve (8) and open the

drain cocks (9) of the oil cooler. Water is now
drained from the cooler. 9
4. Close the oil cooler drain cocks (9). Turn the

air flushing on by pulling the joystick (S74) on the
drilling panel. Continue draining until plain air
comes out at the rock drill.
S74
5. Stop the compressor and turn the three-way
4
valve (4) into the position where the filling line is
connected to the flushing line (handle towards
filling nipple).
6. Open the filling cap (6) and pour anti-freeze

(100%) into the flushing line. Close the filling cap
(6).
6

ID: 787 2 en 2011-05-25
Maintenance
7. Open the main valve (8). Turn the three-way

valve (4) into the position where pressurized air 4
is connected to the flushing line, and start the
compressor.
8. Repeat points 6-8 until a mixture of anti-freeze

and air comes out at the rock drill or the end of
the drill steel.
Remember to fill the water pump before starting to drill.
It is important to ensure that the three-way valve is NOT left in

the position where pressurized air can enter the water circuit.
Make sure that nobody is in front of rock drill or drill rod during
blowing.
11.2. Draining
In cold conditions always remember to drain the water circuit

for the time of a longer shut-down.
11.3. Frost protection
If it becomes necessary to drain the water circuit on account of

a freezing risk, compressed air blowing must be used so that
the whole circuit (including the oil cooler) is got drained.

ID: 787 2 en 2011-05-25
Maintenance
12. TROUBLESHOOTING OF WATER CIRCUIT
Problem Possible cause

Pump not starting No current. Water pump switch (at electric cabi-
net) in position ”0”.
Motor protector switch triggered.
Motor protector switch contact points or electro-
magnet faulty.
Control voltage circuit faulty.
Motor protector switch triggered (triggered right Motor protector switch contact points faulty.
after starting) Loose or faulty cable connection.
Motor winding faulty.
Pump mechanically blocked.
Set value too low.
Motor protector switch triggered erratically Set value too low.
Fluctuation in voltage.
Mains voltage too low.
Motor protector switch not triggered but pump still No current.
not running Water pump switch (at electric cabinet) in posi-
tion ”0”.
Pump output varying Water supply capacity too small for pump output.
Water inlet pressure too low with respect to tem-
perature, flow disturbances, and flow volume.
Supply line partly blocked.
Mud separator partly blocked.

ID: 787 2 en 2011-05-25
Maintenance

ID: 787 2 en 2011-05-25
www.sandvik.com
AIR CIRCUIT
AIR CIRCUIT
B61170--3 en 0507/LH 1 (15)

AIR CIRCUIT
2 (15) B61170--3 en 0507/LH

AIR CIRCUIT
CONTENTS
1. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. COMMON VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. USE OF COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. AIR CLEANER IP 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7. WATER MIST FLUSHING (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8. BLOWING THE HOLE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
B61170--3 en 0507/LH 3 (15)

AIR CIRCUIT
4 (15) B61170--3 en 0507/LH

AIR CIRCUIT
1. SAFETY
Service and adjustment procedures are only allowed to persons who

have been given specific service training.
WARNING
Suspected leaks should be searched visually or by listening. Do not

touch pressurized hoses with bare hands. They may have unnoticeable
pin-- holes to let out a thin air flow which might penetrate through the skin
WARNING and cause personal injuries.
Check the condition of the pneumatic hoses and make sure they run
properly on the supporting guides. Remember that a hose breakage may
cause personal injuries.
WARNING
In cold weather any water in the air cleaner must be carefully drained. If
the water is allowed to freeze it can damage the cleaner.
CAUTION
Maintenance and repair work should only be done when the rig is out of
operation. Make sure that it cannot be accidentally started (open the
main power switch, for instance) during the repair work. Unauthorized
CAUTION
persons are not allowed near the rig during the repair work.
B61170--3 en 0507/LH 5 (15)

AIR CIRCUIT
2. GENERAL
Pressurized air on the DL drilling rig is mainly used for two main purpose:
1. Primarily for rock drill shank lubrication.

2. To blow the hole clean after drilling and for water mist flushing with a certain
amount of water added into the air flow.
Pressurized air is taken from the compressor mounted on the rig or from the air line of the
drilling site.
Shank lubrication is very important for the operation of the rock drill. Insufficient lubrication
causes damages to the rotation mechanism and the shank of the rock drill. This is why
the drilling is automatically prevented if the shank lubrication is insufficient; a pressure
switch detects low air pressure and prevents drilling.
Neglecting proper shank lubrication will result in serious damages on

the equipment.
CAUTION
3. COMMON VALUES
The air consumption for shank lubrication with 4--6 bar is approx. 0,3 m3/min.
6 (15) B61170--3 en 0507/LH

AIR CIRCUIT
3
only with SLU S9
14
S10
5
10
7 8
11 12
13
16
1. Compressor
2. Pressure switch
3. Water separator
5. Drainage valve
7. Flushing valve
8. Air flow switch
10. Pressure gauge
11. Ball valve
12. Air cleaner IP5
13. Water drainage valve
14. Shut--off valve (only with SLU)
16. Restrictor
B61170--3 en 0507/LH 7 (15)

AIR CIRCUIT
4. CIRCUIT OPERATION
The pressurized air system is provided with a pressure switch (2) that
monitors the pressure in the system. If the pressure drops below the set
value (2,8) bar for longer than 10 seconds the drilling is prevented.
CAUTION
PRESSURIZED AIR FROM COMPRESSOR

The filtered, pressurized air flows through the discharge valve into the circuit.
The pressurized air for shank lubrication flows through the water separator (3). The
separator has a drainage valve (5) to let the water out. The valve can be left slightly open
to blow continuously the water out.
From the water separator (3) the pressurized air flows to the central lubricator, KVL or
SLU. The purpose of the shank lubricator is to provide sufficient lubrication for the rock
drill shank. The lubricating oil is mixed with the air that carries it to the rock drill. For
removal of the water the shank lubricator is provided with the drainage valve.
A part of the air that comes from the compressor is led through one way restrictor (16) and
an electrically-controlled flushing valve (7) for blowing the drilled hole clean.
The flushing valve (7) is controlled with a control lever in the control panel. The adjustable
one way restrictor (16) will provide the sufficient air flow for the central lubricator even if
the flushing valve (7) is open.
The pressure gauge (10) indicates the air pressure in the circuit.
ADJUSTMENT OF THE ONE WAY RESTRICTOR (16)

Start the compressor and wait till the pressure reaches the normal operation level. Open
the flushing valve (7) to let the air flow into the rock drill shank lubrication line. Check the
pressure reading of the shank lubricator gauge.
Adjust the lubricator pressure up to minimum of 4 bar by the one way restrictor. If the
pressure goes under this minimum level the pressure switch (2) will stop the drilling. If this
happens the one wayrestrictor (7) must be turned clockwise to increase the pressure.
Secure the valve by lock nut after the adjustment.
PRESSURIZED AIR FROM THE MINE OWN AIR NETWORK

Pressurized air can be taken into the circuit also from the air network of the mine. To let
the pressurized air from the network flow into the rig’s circuit the ball valve (11) must be
opened, whereby the air is led through a separate air cleaner (12) before entering the
circuit. The IP5 air cleaner (12) cleans the air coming from the network, and removes water
from the air. The IP5 is provided with a water drain valve (13).
The air from the mine air line can be taken through the electric--controlled flushing valve
(7) to blow the drilled hole clean or to flush the hole if the water--mist flushing (option) is
used.
Otherwise the circuit operates as described in chapter ”Pressurized air from compressor”.
8 (15) B61170--3 en 0507/LH

AIR CIRCUIT
5. USE OF COMPRESSOR
The operating switch has three positions (S502, located in the SW panel of the
cabin/safety canopy).
S502
POSITION 0
Compressor not running. As the first compressor starts (any compressor) pressure
monitoring is activated. Used when the required air is taken from the mine network so that
no compressor is needed.
POSITION 1
Normal position, compressor running. As the first powerpack starts, compressor will start
1 second after that, and pressure monitoring is activated. With powerpack already
running, the turning of the switch to position 1 will start the compressor. The compressor
is switched off when the powerpacks are stopped.
POSITION S (non--locking)
If no powerpacks are running, turning the switch to the non--locking S position will start
the compressor alone (manual control for production of compressed air).
NOTE! Air pressure control is NOT activated when the compressor is running
alone.
Turn the switch to position 0 for stopping the compressor. When the compressor is in
manual control, the starting of powerpacks is not possible. For starting powerpacks you
must first switch off the manual control of the compressor. In case of power failure, or if
the emergency stop button is depressed, the compressor will not start again automatically
but needs to be restarted.
B61170--3 en 0507/LH 9 (15)

AIR CIRCUIT
The QN panel has the following indicator lights for the compressor: green “compressor
running” indicator light H618, red “compressor overload” indicator light H605, and red
“compressor overheat” indicator light H604. Activation of the overload and temperature
controls of the compressor will stop the powerpacks, the water pump, and the compressor.
H618 H605 H604
10 (15) B61170--3 en 0507/LH

AIR CIRCUIT
6. AIR CLEANER IP 5
The shank lubrication is one of the most important

functions affecting the operating condition of the rock
drill. Therefore, the air used in the shank lubrication
system must be sufficiently clean. When the rig’s own
compressor is used the pressurized air is filtered. If,
however, the air comes from an air network at the drilling
site, a separate air cleaner (IP 5) must be used. It is
installed in the line before the central lubricator. The IP
5 not only cleans the air from impurities but also
separates water from the air.
The IP 5 operates with the cyclone principle. All of the air
that flows through the cleaner is cleaned. The impurities
and the water separated by the cleaner remain in the
bottom of the cleaner. The manually operated valve at
the bottom is opened to drain the cleaner.
TAP
Open the drain valve of the cleaner at least once during each shift.
CAUTION
B61170--3 en 0507/LH 11 (15)

AIR CIRCUIT
7. WATER MIST FLUSHING (Optional)
In water mist flushing, water is sprayed into the flushing air. The amount of water depends
on the hole diameter, the drilling direction, and the rock type. When using water flushing,
be sure, that the volume of the water is enough. When using air mist flushing, be sure, that
the volume of the air is enough.
The flow of flushing air is monitored by a flow control switch (S10). If the flushing air flow
drops under the set value, the drilling direction is reversed and drilling is interrupted.
To flushing valve F
A Water mist valve
C
B Flow control valve
C Flow meter
Y210
Water
The air mist flushing is activated when the control lever S74 is pulled backwards. In this
case air can flow through the air valve (S9), flow meter and non return valve to the rock
drill.
The flushing valves (water valve (A), air valve), switch flushing on when control lever S74
is pulled “on“ position on the control panel. The flushing system is provided with a flow
meter (S10) that activates the flushing flow disturbance function if flushing flow drops
below the set value of the switch. If the flushing water pressure drops below the set values,
the anti--jamming automatics engages
12 (15) B61170--3 en 0507/LH

AIR CIRCUIT
Procedures to be carried out before starting the drilling:

-- Pull the flushing control lever (S74) backward the operator and adjust the flushing
water amount for the rock conditions (flow control valve (B))
Solo
Solo 7V (Cabin)
Water mist valve (A)
Flow control valve (B)
Flow meter (C)
GUI
Flushing control
lever S74
B61170--3 en 0507/LH 13 (15)

AIR CIRCUIT
Air flushing flow control switch S10

Flushing flow is monitored by an electronic flow control sensor.
PNP NC
. BLUE
24V
S10 BROWN
0V
SIG
BLACK
Before adjustment
Connect the power on to the control system.
The sensor can be adjusted when power has been switched on for flushing by the flushing
control lever.
Wait 10 seconds with water and 20 seconds for air to allow the flow to become constant.
Adjusting
D Press the Learn/Set button and keep it pressed until the outmost green LEDs on
the right and on the left will flash.
D After 3 s the LED bar (green) fills from left to right.
D Release the button as soon as the first LED light comes steady (the LED bar
(green) continues filling from left to right).
D The indication goes off briefly.
D The unit stores the current flow rate.
D The unit is ready for normal operation.
14 (15) B61170--3 en 0507/LH

AIR CIRCUIT
8. BLOWING THE HOLE (OPTIONAL)
For blowing the hole clean, the DL device uses an air receiver (9). The purging speed of
the receicer can be regulated using a restrictor (17). Using a pressure relief valve (18),
the maximum receiver pressure has been restricted to 8 bar.
9 18
60L
17
B61170--3 en 0507/LH 15 (15)

331 2 en 2009-11-18
SLU 1/2/3
Operation and Maintenance
Table of Contents
1. GENERAL ...................................................................................................................................... 3
2. MAIN COMPONENTS .................................................................................................................... 4
3. OPERATING PRINCIPLE .............................................................................................................. 5

3.1. General ................................................................................................................................................................ 5
3.2. Operation of the pump .................................................................................................................................... 6
3.3. Control unit ........................................................................................................................................................ 6
3.4. Technical data ................................................................................................................................................... 7
3.4.1. Oil container .................................................................................................................................................... 7
3.4.2. Pump unit ........................................................................................................................................................ 7
3.4.3. Shank lubricator control unit SLCU ............................................................................................................. 7
3.4.4. Tightening torques ......................................................................................................................................... 7
4. ADJUSTMENTS ............................................................................................................................. 8
4.1. Output settings ................................................................................................................................................. 9
4.2. Bleeding .............................................................................................................................................................. 10
4.3. Boost switch ...................................................................................................................................................... 11
5. MAINTENANCE ............................................................................................................................. 12
5.1. Checking the oil level ...................................................................................................................................... 12
5.2. Draining the condensed water ...................................................................................................................... 12
5.3. Cleaning the tank .............................................................................................................................................. 13
5.4. Changing the breather .................................................................................................................................... 13
5.5. Checking the function of the monitoring system .................................................................................... 14
5.6. Replacing the faulty shank lubrication hose ............................................................................................ 14
5.7. Changing the seals .......................................................................................................................................... 15
6. TROUBLESHOOTING ................................................................................................................... 16

ID: 331 2 en 2009-11-18
ID: 331 2 en 2009-11-18
SLU 1/2/3
1. GENERAL ID: 14275
The shank lubricator SLU 1/2/3 is one of the most important units on Sandvik drilling equipment. Its
purpose is to provide sufficient lubrication for Sandvik rock drills under varying drilling conditions and
situations. Sufficient and accurate lubrication is made possible by regulating the working frequency
of the shank lubricator pump(s).

ID: 331 2 en 2009-11-18
SLU 1/2/3
2. MAIN COMPONENTS ID: 14277
13 7 13
10
9 9 4
4 12
2 3
3 2
6
11
ID: 17200
1 Monitoring switch CT 1 2 Hydr. bleed screw CT 4

3 Directional valve CT 5.1 4 Bleed screw CT 7
5 Oil container 6 Pump unit (1 main block, max. 2 auxiliary
blocks)
7 Level guard 8 SLCU regulating unit
9 Boost switch 10 Breather / filler cap
11 Drain valve 12 Fine adjustment switches
13 Oil dipstick

ID: 331 2 en 2009-11-18
SLU 1/2/3
3. OPERATING PRINCIPLE ID: 14278
1
7
8
3
5
11
12
6
9
10
ID: 17206
1 Breather / filler cap 2 Oil container

3 Boost-switch 4 Pump unit
5 Pump operating pressure 6 Pressure line
7 Level switch 8 SLCU - control unit
9 Tank 10 Hydr. oil tank line
11 Air 12 Rock drill
3.1. General ID: 14279
The pump unit delivers oil to the rock drill along an inserted pipe. Pressurized air is used for distributing
the oil to the lubricating points. In a recovering system, pressurized air is used for collecting the
lubricating oil into a separate receiver. The system is equipped with an oil level switch.

ID: 331 2 en 2009-11-18
SLU 1/2/3
3.2. Operation of the pump ID: 14280
The lubricating pump is a hydraulically operated piston pump with electric control. The metered
amount of oil is determined by electrically altering the pump’s working frequency.
The lubricating pump is made up of blocks. The pump consists of one main block with 1-2 auxiliary
blocks connected to it (depending the number of the booms). The main block and each auxiliary block
have their own lubrication monitoring switch. Electric control is for the main block only. Monitoring is
activated always when operating voltage is switched on.
3.3. Control unit ID: 14281
The closing ball in the non-return valve of the lubricating pump outlet port operates as a monitoring
switch against its seat. Oil flow through the non-return valve lifts the ball off the seat surface, whereby
the circuit is cut. The ball in the non-return valve of the control valve connects electrically to the frame
of the pump (and the drilling rig) Voltage is connected to the ball via a spring that is insulated from
the pump frame.
If the ball remains open over four working cycles, the alarm is
switched on. The indicator light goes on, the joystick(s) are
centered and the drilling function is disabled. Correspondingly,
if the ball does not open over four working cycles, alarm is
switched on. Alarm is removed when normal pumping is
resumed.
Pump block flowchart
CT1 = monitoring switch

CT2 = intake side non-return valve
CT3 = working piston
CT4 = hydr. bleed screw
CT5.1 = directional valve
CT5.2 = non-return valve
CT6.2 = bleed screw
CT7 = bleed screw
ID: 17210

ID: 331 2 en 2009-11-18
SLU 1/2/3
3.4. Technical data ID: 14282
3.4.1. Oil container ID: 14283
ITEM SLU 22 SLU 14

Total oil capacity (liters) 22 14
Effective oil capacity without oil heater (liters) 18 12
Effective oil capacity with oil heater (liters) 16 -
Breather (µm) 10 10
Oil screen (mm) 1 1
Level guard yes yes
3.4.2. Pump unit ID: 14284
Displacement standard 0.85 cm³ (7.5 mm stroke) (max. 1.25

cm³, 11 mm stroke)
Output range 80–1200 g/h (with standard stroke)
Max. hydr. pressure (pilot control) 210 bar
Min. hydr. pressure (pilot control) 25 bar
Max. lubricating pressure 25 bar
3.4.3. Shank lubricator control unit SLCU ID: 14285
- EMC approved
- 3 alarm outputs
- Boost function
- Operating voltage 24VDC
3.4.4. Tightening torques ID: 14286
Monitoring switch 7 Nm
Pump unit mounting screws 20 Nm

ID: 331 2 en 2009-11-18
SLU 1/2/3
4. ADJUSTMENTS ID: 14287
The working frequency of the lubricator pump can

be adjusted between 2 and 30 strokes per minute
using the two rotary switches on the SLCU unit.
The 16 positions of the switches are marked
using numbers 0...9 and letters A...F. One of the
switches selects Range, and it is preset and
sealed at the factory. The other switch is for Fine
adjustment. The metered values with different
switch settings are shown in the table and graph
in chapter 'Output settings'.
ID: 17235

ID: 331 2 en 2009-11-18
SLU 1/2/3
4.1. Output settings ID: 14288
Range Fine [ g / h ] Rock drill type

0 80–150 HE 122, HEX1, HLX1, HSX1
1 100–200 HL 300
2 150-300 HLX5, HFX5 -series
3 200-400 HL 510
4 300-600 HL 560, HL 600
5 400-850 HL 700, HL 1000, HL 710, HL 800, HL 1010
6-F 600-1200 HL 1500, HL 1560
A circuitboard delivered as a spare part is set to maximum

values. Adjust correct output according to the information on
this page.
Depending on the drilling conditions (hole depth, type of rock,

etc.) the required amount of lubrication may vary in the given
range and more. For small hole sizes (for the drifter in question)
and in upwards drilling and bolting, we recommend to choose
low Fine settings. For larger hole sizes and high temperature
surface applications, we recommend to choose higher Fine
setting.
Chart reading example:

Range = 5. Fine adjusting = 9.
Lubrication oil amount is approx. 590 g/h
ID: 17287
Figure: Lubricant metering curves

ID: 331 2 en 2009-11-18
SLU 1/2/3
4.2. Bleeding ID: 14289
Bleeding of SLU TANK is based on gravity, and it

is carried out by opening the bleeding screw (4) 9 8
(CT7) 1–2 turns and then waiting until the oil no
longer contains any bubbles. During the bleeding
the diesel engine/power pack must be stopped. 4 12
When bleeding the PUMP, connect an extra hose
(04-JIC) from port L to a suitable reservoir and 2
start the diesel engine/power pack. Open the
bleeding screw (4) (CT7) 1/2 turn and the 3
bleeding screw (2) (CT4) 1 turn. Leave them open
6
for about 1 minute. Close the bleeding screw (4)
(CT7). Wait until the oil no longer contains any
bubbles. Close the bleeding screw (2) (CT4) and 1
remove the extra hose from line L and connect
the original hose to port L. Start the power pack 11
and compressor. Switch on the Booster switch
ID: 17290
(position 1) approx. for 10 minutes to make sure
that there is shank lube oil in the hose all the way
to the drifter and to make sure that the rod side of
the SLU pump is bled. After boosting remember
to switch off the booster switch (position 0).
Remember to bleed all pump blocks in same time!
Hydraulic bleeding screw (CT4) is used only for bleeding the

pump.
Pump block flowchart
CT1 = monitoring switch

CT2 = intake side non-return valve
CT3 = working piston
CT4 = hydr. bleed screw
CT5.1 = directional valve
CT6.2 = bleed screw
CT7 = bleed screw
ID: 17210

ID: 331 2 en 2009-11-18
SLU 1/2/3
4.3. Boost switch ID: 14290
The boost switch is used in cases as follows:

• to fill the shank lubrication hose
• when higher shank lubrication is temporarily needed
When the boost switch is activated, the indicator light of the control valve of the pump(s) starts to
flash. The oil output of the pump(s) is now 1200 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!

ID: 331 2 en 2009-11-18
SLU 1/2/3
5. MAINTENANCE ID: 14291
5.1. Checking the oil level ID: 26137
1. Check the oil level from the dipstick (1). Fill the
tank as necessary.
1
ID: 47825
5.2. Draining the condensed water ID: 26122
1. Drain the condensation water from the oil tank

to the receptacle using the drain valve (1).
ID: 26130

ID: 331 2 en 2009-11-18
SLU 1/2/3
5.3. Cleaning the tank ID: 26124
1. Empty the oil tank into the receptacle using the

drain valve (1).
2. Clean the receiver from the inside.
ID: 26130
5.4. Changing the breather ID: 26127
1. Replace the breather (1).

Replace the breather at the intervals specified
in the maintenance instructions or earlier as 1
required e.g. in the event that breather has
become wet.
ID: 26129

ID: 331 2 en 2009-11-18
SLU 1/2/3
5.5. Checking the function of the monitoring system ID: 26125
• Disconnect directional valve connector, alarm is switched on (wait 4 pulses), or

• Disconnect flow monitoring cable, alarm is switched on (wait 4 pulses), or
• Short-circuit flow monitoring cable to pump body, alarm is switched on (wait 4 pulses)
5.6. Replacing the faulty shank lubrication hose ID: 26126
When replacing the 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: 331 2 en 2009-11-18
SLU 1/2/3
5.7. Changing the seals ID: 14292
1 SLU-pump unit
2 Piston plug
3
3 Piston
4 Piston seals 2 1
4
ID: 17196
Before assembling the SLU-piston into the cylinder! – After

installing the seals on the piston the seals at the both ends of it
NOTE! need to be calibrated using this tool below, and preferably a
lubricant should be applied (oil or grease) to prevent any
damage on the seals when performing that.
1 SLU-piston
2 Piston seal
1
3 Calibration tool
ID: 17197

ID: 331 2 en 2009-11-18
SLU 1/2/3
6. TROUBLESHOOTING ID: 14300
Problem: No oil output, indicator on in cabin
POSSIBLE REASON: REMEDY:

Oil level too low Add oil and remove air from pump through
bleeding screw (4)
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 hydr. 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 (13) 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 plug non-return valve Clean control plug / container
Breather blocked (underpressure) Clean breather
Return hose to collector tank blocked Clear obstruction
Problem: Too much oil

Hydraulics bleed screw open Close bleed screw (2)
Timer frequency incorrectly adjusted Check adjustment
Piston seals damaged Check piston and replace seals
BOOST switch activated Check and turn off
Problem: Internal hydraulic oil leakage of pump

Hydraulics bleed screw open Close bleed screw (2)
Piston seals damaged Check piston and replace seals

ID: 331 2 en 2009-11-18
SLU 1/2/3
Problem: Normal amount of oil (but alarm activated)

Fault in monitoring plug wiring Check/replace wiring
Dirty oil, conducting electricity Change oil in shank lubricator container
Worn flow monitoring device (pitted ball surface) Check / replace flow switch assembly

ID: 331 2 en 2009-11-18
SLU 1/2/3

ID: 331 2 en 2009-11-18
www.sandvik.com
V 64107-1 en 0500
Screw compressor
CT 10-16
Operation and maintenance instructions
Spare parts
 2001 Gardner Denver Oy

Declaration by the manufacturer
(direktive 98/37/EY, Annex II B)
Manufacturer: Gardner Denver Oy
Address: Etu-Hankkionkatu 9
33700 Tampere
Finland
herewith declares that CT 10, CT 16
is intended to be incorporated into machinery

or to be assembled with other machinery to
constitute machinery covered by directive 98/37/EY
as amended;
does therefore not in every respect comply
with the provisions of this directive;
does comply with the provisions of the follo-
wing other EEC directives.
And furthermore declares that is not allowed
to put the machinery into service until the
machinery into which it is to be incorporated
or of which it is to be a component has been
found and declared to be in conformity with
the provisions of Directive 98/37/EY
and with national implementing legislation,
i.e. as a whole, including the machinery
referred to in this declaration
Tampere 02.02.2000
............................................... ..........................................
(place) (date)
...............................................
(signature)
Jorma Koivula, Design Manager

..........................................................
(signer, position in Company)
Gardner Denver Oy
P.O.Box 516
33101 Tampere
Finland
02.02.2000
List of contents
To the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation and preparations for use . . . . . . . . . . . . . . . . . 2
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
The safety signs used on the compressor . . . . . . . . . . . . . 3
Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operating principles
Compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air compressing process . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Oil circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Capacity control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Instrument panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Stocking, transporting and installing
Stocking the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lifting the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Moving the compressor with a forklift truck . . . . . . . . . . . 12
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installing location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electric connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connecting to pressurized air network . . . . . . . . . . . . . . 13
Operation
First start of compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Normal starting and stopping of compressor . . . . . . . . . . . 15
Adjust of modulating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance
Procedures before starting maintenance . . . . . . . . . . . . . . 18
Procedures after maintenance . . . . . . . . . . . . . . . . . . . . . . 18
Service chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Adding oil and oil change . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replacing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replacing oil separator element. . . . . . . . . . . . . . . . . . . . . 23
Removing drive wheel and its mounting sleeve . . . . . . . . 24
Removing the sheave of the air end. . . . . . . . . . . . . . . . . . 24
Installing drive wheel and its mounting sleeve . . . . . . . . . 25
Installing the sheave of the air end . . . . . . . . . . . . . . . . . . 26
Testing safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removing from service . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
To the user
09.02.1999
GARDNER DENVER wishes you welcome among the users of screw

compressors!
This manual instructs you in the correct operation, use, and service of your screw
compressor.
Read these instructions carefully before taking your screw compressor into use.
This ensures correct preparations and use from the very beginning.
Storing the books

All the instructions in this manual have been provided to guarantee long life and reliable
operation of your screw compressor.
Keep the manual always at hand near the compressor, and make sure that the compressor is
operated and serviced according to the instructions.
Terms of guarantee
Acquaint yourself with the terms of guarantee for the compressor. The guarantee becomes
void if the conditions are not observed.
Do not exceed the maximum pressure, rotation speed, and capacity ratings of the compressor.
The guarantee is not valid if other than original spare parts are used.
Always use the recommended oil types only.
Carefully fill in the guarantee slip accompanying the compressor, and return it as instructed
to the seller.
Log book
Any repairs of the screw compressor should be left for trained, qualified service personnel
authorized by Gardner Denver or its representative.
After any maintenance or repair, always fill in the service log provided with the compressor.
Inquiries
When making inquiries concerning your screw compressor, always quote the complete type
specification and the serial number as they are given on the type plate of the compressor.
Use original spare parts only.
Gardner Denver reserves itself the right to change the construction and manuals of the
compressors without prior notice.
1
Safety 09.02.1999
This chapter contains the general safety instructions concerning this compressor. Read also
the safety instructions for transport, commissioning, use, and maintenance presented
separately in each section of the manual. Always read the safety instructions before
starting to work. In this manual, the instructions concerning safety are marked with the
symbol:
In addition to these instructions, the local regulations in your country may impose additional
requirements that must be observed.
General safety instructions

Installation and preparations for use
The compressor’s noise level, measured in an open space, may rise higher if the installing
location is surrounded by walls that reflect sound. Observe this when choosing the best
location for the compressor.
Observe the local regulations on the use of hearing protectors.
Make sure that the intake air for the compressor is clean and cool. Prevent the exhausted air
from recirculating to the intake. Make sure that foreign objects cannot get into the compressor
with the intake air. Make sure that the intake air does not contain any explosive gases.
Do not exceed the compressor’s rated maximum pressure, capacity, or rotation speed
(Cf. Technical Specifications). Use pneumatic hoses that are rated to withstand the working
pressure. Pay special attention to the hose mountings. A whipping hose may cause
unpredictable damage. Remove the pressure in the hoses before disconnecting.
The pressure vessels in the pressurized air network must fulfill pressure vessel regulations.
The electrical connection shall be made by authorised, qualified persons.
There might be some oil in the water condensate. Notice the regulations concerning the oil
remove.
Operation
Do not blow pressurized air against the skin. Do not use the compressor with its doors open.
Use recommended oil types only. Do not mix different types of oil. Compressors with remote
starting should be provided with a warning sign that indicates the method of starting.
Do not use the compressor in explosive environment.
Maintenance
Maintenance work on the compressor should always be done with the compressor stopped
and disconnected from the mains. The shut-off valve to the pressurized air network should
also be closed. Make sure that the air/oil receiver is pressureless before you start maintenance.
Do not repair the container by welding. All alterations must conform to the regulations
concering pressure vessels.
Starting of compressors with remote control and in multicompressor use must be prevented
while maintenance work is in progress. Do not neglect the regular check-ups and maintenance
of the compressor. With the exception of the repairs described in this manual, all repair work
should be carried out by company authorized by Gardner Denver.
2
The safety signs used on the compressor 03.03.1999
Read the operator’s Hearing protection

instruction must be worn
Risk of hot surface Risk of electric

shock
Compr. is remotely Risk of rotating

controlled and may parts
start without
warning
Blow down
3
Technical spesification
02.02.2000
CT 10 8bar
Capacity and power consumption
Normal working pressure bar 7
3
Capacity at normal working pressure m /min 1,0
Shaft power at normal working pressure kW 7,5
Maximum working pressure bar 8
Minimum working pressure bar 3
Idling shaft power consumption kW
Male rotor speed rpm 4850
Transmission Belt
Cooling (without after cooler)
Allowed ambient temperature °C -20...+40
Compressed air temperature above cooling me- °C
dium temperature
Air-cooled compressor
Cooling air flow m3/s 0,5
Dimensions of air outlet mm
Max. cooling air pressure drop Pa
Cooling air temperature rise °C
Motor and electrical values
Main motor: F-class, IP54 kW 7,5
Speed of rotation 50Hz rpm 2855
General technical data
Oil quantity l 5,0
Oil content mg/m3 3
Air delivery pipe R1out
Noise level (Cagi Pneurop PN8NTC2.2, ±3dB) dB(A) 80
Compressor weight kg 165
4
Technical spesification
02.02.2000
CT 16 8bar
Capacity and power consumption
Normal working pressure bar 7
3
Capacity at normal working pressure m /min 1,6
Shaft power at normal working pressure kW 11
Maximum working pressure bar 8
Minimum working pressure bar 3
Idling shaft power consumption kW
Male rotor speed rpm 6600
Transmission Belt
Cooling (without after cooler)
Allowed ambient temperature °C -20...+40
Compressed air temperature above cooling me- °C
dium temperature
Air-cooled compressor
Cooling air flow m3/s 1,0
Dimensions of air outlet mm
Max. cooling air pressure drop Pa
Cooling air temperature rise °C
Motor and electrical values
Main motor: F-class, IP54 kW 11
General technical data
Oil quantity l 5,0
Oil content mg/m3 3
Air delivery pipe R1out
Noise level (Cagi Pneurop PN8NTC2.2, ±3dB) dB(A) 83
Compressor weight kg 225
4
02.02.2000
Operating principles
Compressor unit
Main components of the compressor unit:

Air end body (1), two screw rotors (2,3) mounted on bearings in air end body (1) and inlet
flange (4), and bearing cover (6).
The drive shaft is sealed with a shaft seal (5).
6
Air compressing process
02.02.2000
In a screw compressor, the air is compressed in the compressor unit driven by an electric
motor.
The meshing rotors take in air between the ridges as they pass by the intake opening.
When the rotors turn, the connection to the intake opening closes, and the space between the
ridges starts decreasing. At the end of the compression phase, the desired pressure has been
reached, and the connection to the receiver opens.
The air in the compressor unit is cooled by oil that is injected into the compressor unit.
In the compressor unit, the oil cools the air and the compressor unit.
In addition, the oil lubricates the bearings and seals the clearances between the rotors and the
rotor housing.
7
Oil circulation
02.02.2000
From the air end the mixture of compressed air and oil mist is ducted into the oil system,
where the oil is separated from the air. The oil separation process is two-phase.
Most of the oil is separated in a cyclone by centrifugal force, and the rest in oil separator
element (1). From the oil separator element the oil flows back to the circuit through return
pipe (2). Orifice (3) restricts the backward air flow to the air end.
On its way back into the air end, the hot oil flows through cooler (7) and oil filter (4). If the
oil is cold, thermostat (5) in the oil system directs it past the cooler.
This forced oil circulation is maintained by the pressure difference between oil system and air
end.
In order for the oil circulation to work whenever the compressor delivers air, there is an
output control valve (6) to prevent the oil system pressure from dropping below the pre-set
minimum (3 bar).
8
Capacity control
02.02.2000
The system is designed to regulate compressor output according to use of compressed air,
and this to minimize energy consumption per cubic metre of air produced.
Production is stepplessly regulated from nought to maximum compressor output.
Output is governed by opening or closing the intake valve.
Pilot valve (1) automatically operates the intake valve trough monitoring output pressure and
keeping it within a set range. Normally this range is 1bar, i.e. compressor output pressure
may vary by 1bar depending on air consumption.
When power unit is stopped, pressure release valve (2) opens and releases pressure in air/oil
container.
No Component Purpose
1 Pilot valve Opens and closes intake valve
2 Pneumatic valve Empties receiver at stopping
9
Instrument panel
02.02.2000
1. Network pressure gauge

2. Temperature gauge
The compressor stops if the output air temperature reaches 115°C (Cf. the page 17).
10
02.02.2000
Stocking, transporting and installing
Stocking the compressor

If the compressor is stocked for a long time, the stock room must be dry and warm.
Is reasonable to slack or loosen the V-belts for the period of stocking.
Lifting the compressor

Notice the center of gravity of the compressor. Cf. dimensions drawing (p.5).
Don’t go under the load.
11
Moving the compressor with a forklift truck
02.02.2000
Observe special caution during lifting and transporting.

A forklift pallet should be used.
Installing
Installing location
1. The compressor must be installed on an even surface, bearing in mind the compressor’s
weight (Cf. Technical specifications). Observe the need for draining (oil separating well or
a separate container) for condensate water.
The water contains oil.
2. Study the dimensional drawing for the required minimum distances to walls and other
machines.
3. Make sure that the compressor room is properly ventilated. The cooling air temperature
must not be higher than +40°C, the lower value is given in the technical data-page (p.4).
Prevent recirculation of cooling air. If the compressor is provided with air ducts, observe
the required air volume and the max.pressure loss of the blower. Observe also the
possibility to the cleaning of the coolers (Cf. Technical specifications).
Notice that almost the whole input power of the compressor moves to the
cooling air of the air cooled compressor.
4. Install the temperature gauge in place (if it’s delivered loose). Connect the safety functions
of the temperature gauge (temperature alarm and stopping) Cf. separate instruction p.17.
12
Electric connection (models with electric motors) 02.02.2000
The electric connections must made according to the IEC standards. All local safety
regulations must also be observed.
Make sure that the operating volatge is correct. The voltage must be as rated, 5%.
Connect the power supply cable. Observe the power requirement (Cf. electric diagrams and
technical data).
Connecting the protective earth lead correctly is especially important.
Power supply connections are only allowed to qualified electricians.
See the connecting of the temperature gauge, separate instruction p.17 .
Connecting to pressurized air network

Install a shut-off valve between the compressor and the network for maintenance purposes.
Use a flexible hose to connect the compressor to the network.
If a piston type compressor is connected to the network, a pressurized air container must be
installed between the piston and screw compressor, unless the volume of the network
between them is big enough.
If the pressurized air network include after-treatment devices (as a dryer),
please connect to the distributor of Gardner Denver.
13
02.02.2000
Operation
First start of compressor

If the compressor has been stocked for a long time, check the functioning of
the belt tightening.
1. Top up compressor oil to the upper limit of the receiver (Cf. oil recommendation and oil
changing instructions).
2. Start the compressor for a second to check the compressor unit for correct direction of
rotation (marked with an arrow on the compressor unit ). Do not run the compressor
longer than 2 seconds.
Wrong direction of rotation will damage the compressor unit.
The compressor unit’s direction of rotation must be checked always when
the compressor is reconnected to the power supply network.
3. Start the compressor.
4. Adjust the operating pressure as required (Cf. separate instructions).
14
Normal starting and stopping of compressor
02.02.2000
Starting
Start the compressor.
Stopping
Push the stopping button.
Before the restart wait about 1 minute to allow the receiver to empty.
15
Adjust of modulating
02.02.2000
Output pressure can be regulated by turning the adjusting screw (B) on the valve.
Locking nut (A) must be loosened before adjusting :
turning the screw clockwise increases pressure and turning it anticlockwise lowers pressure.
Tighten the locknut after adjustments!
Do not exceed the compressor’s specified maximum pressure (Cf. Technical data).
16
Temperature gauge
02.02.2000
For temperature measuring the compressor is equipped with a temperature gauge.

At 100°C the temperature alarm lights and at 115°C the compressor will stop.
The safety functions; the temperature alarm (S1) and stopping (S2) are located in the
temperature gauge. Connect them accordingly to these wiring diagrams, which are also on
the side of the temperature gauge.
The safety functions must absolutely be connected before taking the
compressor into use.
17
02.02.2000
Maintenance
Procedures before starting maintenance

Caution: Hot surfaces immediately after stopping.
1. Stop the compressor, and make sure that the receiver is pressureless. The blow-out
function empties the receiver after stopping; wait 2 minutes.
2. Turn power off and make sure that the compressor cannot be accidentally started.
3. Close the shut-off valve between the network and the compressor.
4. Open the safety valve cap 4-5 turns.
Procedures after maintenance

1. Close the safety valve.
2. Open the shut-off valve between the network and the compressor.
3. Start the compressor.
18
Service chart
02.02.2000
Correct lubrication of motor significantly lengthens the life of the bearings.

Always fill in the operating log.
Have other maintenance work done by service personnel authorized by
Gardner Denver.
Procedure Daily Every 2000h Once a As

year 4) required
Check fault indicator de- *
vice
Check oil level 1) *
Change oil *2) *
Replace oil filter *2,3) *
Replace oil separator * *2)
cartridges
Clean oil return pipe * * *
screen
Replace air filters * * *
Clean cooler externally * * *
Check oil leaks * *
Check operation of safety *2)
valve
Check condition of hoses * *
Tighten connections and * *2)
screws
Clean inside compressor * * *
Replace belts * *2)
Replace intake valve seals * *2)
Replace discharge valve * *2)
seals
Check motor connections *3)
Check running tempera- * *
ture
Check the operation of * *
stop contact of the ther-
mometer
Lubricate electric motor Cf. Motor manual!
bearings
Service electric motor
1) Check oil level when the compressor is stopped (wait until air and oil are separated).
2) At least once a year.
3) First time after 100 h.
4) Running hours <2000h.
Note! The service intervals must be shorter in the very severe conditions.
19
Adding oil and oil change
02.02.2000
Use recommended oil types only. Do not mix different oils.

Watch out! The oil is hot right after compressor stop.
Do not remove the filler plug when the oil separator is under pressure.
Dispose of old oil according to the waste oil regulations.
Adding oil
1. Take the precautions listed on page 18.
2. Remove filler plug (1) and pour in new oil until the upper limit of the level indicator is
reached.
3. Put filler plug (1) back in its place.
4. Close safety valve (2) and open the shut-off valve between compressor and compressed-air
system.
Oil change
1. Run the compressor until the oil temperature is +40...50°C.
3. Remove filler plug (1). Open drain valve (3) and let the oil flow out.
4. Close drain valve (3) and top up the oil sump with fresh oil.
5. Put filler plug (1) back in its place.
6. Close safety valve (2) and open the shut-off valve between compressor and compressed-air
system.
20
Replacing oil filter
02.02.2000
Allow the compressor to cool down before the replacement.

Dispose of the old filter according to the regulations on hazardous waste.
Use original Gardner Denver oil filters only.
2. Use a protective cloth as some oil will escape when the filter is being removed.
3. To remove the oil filter, turn it counter-clockwise with the help of a straining strap.
Mounting
1. Lubricate the seal of the new filter with oil.
2. Mount the filter by turning it manually clockwise.
21
Replacing air filter
02.02.2000
Allow the compressor to cool down before maintenance work.

The filter element cannot be reused or cleaned.
1. See page 18 for precautions before starting the work.

2. Remove the cover (1) and remove the old filter element (2).
3. Clean the cover on the inside.
4. Install a new air filter element (2) and the cover (1).
Replace the preventive filter (3) after two years or after four air filter replacement.
The particle remover (4) always downwards.
22
Replacing oil separator element
02.02.2000
Dispose of the old element according to the regulations on hazardous waste.

Allow the compressor to cool down before the replacement.
2. Remove output control valve (1).
3. Remove oil separator element (2).
Mounting
1. Clean output control valve (1) and the contact surfaces of the oil separator.
2. Clean orifices (3) in the hose ends.
3. Clean strainer (4) and, if necessary, the oil separator.
4. Lubricate the O ring of the oil separator and mount a new element (2).
5. Replace the O ring (5) between oil separator and output control valve.
6. Replace the seals of the output control valve with a new set. When assembling the valve,
leave nut M6 (6) about 2 mm off the valve cover.
7. Mount the assembled valve back in its place.
8. Tighten the screws alternately to equal tightness.
23
Removing drive wheel and its mounting sleeve
02.02.2000
Unscrew the screws (2 pcs), and screw one of them into the removing hole.
Tighten the screw evenly until the sleeve comes loose from the hub.
The loosened wheel and the sleeve can be removed from the shaft by hand without
hammering or otherwise damaging.
Removing the sheave of the air end

2. The thread of fastening bolt (1) is left-handed. To remove the bolt, use an Allen key.
Knock the key bar sharply with a hammer, holding the sheave in place by means of
Gardner Denver clamping tool ID=034 769 18 or big circlip tongs.
3. Pull sheave (2) from the rotor shaft with an extractor. Protect the threaded hole in the shaft
end.
4. Sleeve (3) comes off with the sheave.
5. Always replace both sleeve and shaft seal. Remove the sleeve from the sheave by
knocking it with a drift through the three holes in the sheave.
6. Pull out shaft seal (4) with an extractor. Protect the threaded hole in the shaft end.
24
Installing drive wheel and its mounting sleeve
02.02.2000
1. Remove all protective grease from the sleeve and the wheel hub. Install the sleeve to the
wheel hub and align the holes.
2. Grease the two mounting screws (1) and tighten them lightly. The positions of the
mounting screws are shown in the illustration. The thread for mounting is in the pulley.
3. Clean the shaft and mount the wheel and the sleeve onto it. When mounting the wheel,
remember that the sleeve fastens to the shaft first and, after this, the wheel moves still a
little in relation to the sleeve. Observe this when aligning the wheels.
4. Tighten the screws evenly.
5. Knock the sleeve lightly with a drift, and retighten the screws. Repeat this a few times to
make sure that the sleeve really sits tight.
6. Check the tightness of the screws from time to time.
7. Fill the extracting holes with grease to protect them from dirt.
Sleeve Tightening torque

Nm Note! Sleeve type is marked on the end of the
1610 20 sleeve.
2012 31
25
Installing the sheave of the air end
02.02.2000
1. Clean the shaft end and the seal housing carefully.

2. Apply Loctite 542 on the metallic outer surface of the shaft seal. Push the seal into the
housing with a drift.
3. Push the sleeve on the rotor shaft with a drift.
4. Apply Loctite 601 thinly on the part of the sheave that will be inserted in the sleeve. Press
the sleeve in place, and mount the sheave with the help of the fixing bolt. Hold the sheave
in place with Gardner Denver clamping tool ID=034 769 18, and tighten the bolt to 80 Nm.
26
Testing safety valve
02.02.2000
All adjusting and repair work on the safety valve must be left for a qualified
mechanic. (Observe the local regulations.)
The opening pressure of the safety valve

must be tested in a separate pressurized
air line.
The operation of the valve can be tested
by turning the cap (1) of the valve 1 - 2
turns counterclockwise.
27
Troubleshooting chart
02.02.2000
Problem Possible cause Repair

COMPRESSOR FAILS TO Main motor overload –check motor temperature
START
No power supply – check fuses and voltage
Compressor stopped Detect cause of overheating:
because of overheating –faulty thermostat
– insufficient cooling air
–high ambient temperature
–cooler clogged
–wrong oil type or low oil
level
INSUFFICIENT AIR OUT- Air filter clogged – replace
PUT Oil separator clogged – replace
Intake valve broken – repair or replace
Blow-out valve broken – clean or replace
Leaks in network –check network for leaks
Broken drive belts – replace
High ambient temperature –ensure air circulation
Pressure regulator adjusted –readjust
incorrectly
COMPRESSOR OVER- High ambient temperature – ensure cooling air
HEATING circulation
Cooler clogged – clean
Low oil level –add oil
Wrong oil type in – replace, Cf. oil recommend.
compressor
Oil filter clogged – replace
Broken thermostat – replace
Faulty output temp. sensor – replace
HIGH OIL CONSUMP- Orifice or screen in oil – clean
TION return pipe clogged
Oil separator broken – replace
Oil separator clogged – replace
Wrong oil type –change oil, Cf. oil
recommendation
High output temperature –detect cause, and repair
Shaft seal leaking – replace
Too much oil – reduce the oil
COMPRESSOR STARTS Low supply voltage –repair supply network
SLOWLY faults
Wrong oil type – see oil recommendation
Pressure in receiver – wait until the pressure is
let down
28
Removing from service
02.02.2000
When the compressor is removed from service, the compressor oil, the oil filter, and the oil
separator elements must be disposed of in the manner stated in local regulations.
29
Oil recommendation for Gardner Denver 02.02.2000
screw compressors in industrial use

We recommend to use motor or circulation oil(hydr. oil) of good quality stated according to
below requirements or synthetic hydrocarbon lubricator.
OUR PRIMARY RECOMMENDATION IS GARDNER DENVER F 2105

SCREW COMPRESSOR OIL. THE COMPRESSOR HAS BEEN
PREFILLED WITH THIS TYPE OF OIL.
Order number for 10 litres 033 891 41

Order number for 200 litres 033 891 43
If this product is not available there must be noticed the following factors in oil selection:
Mineral oil
Use compressor oil specially made for screw compressors, which contents antioxidants and
preventive components against rust, foaming and wearing.
Synthetic lubricant
Use compressor oil specially made for screw compressors, which contents antioxidants and
preventive components against rust, foaming and wearing.
Viscosity:
– max. 500mm2/s by starting temperature (> 0°C)
– min. 7mm2/s by running temperature of oil (= 55°C over the ambient temperature)
Flash point:
– min. 180°C (open cup)
In normal circumstances these conditons are fulfilled when using ISO VG 32...46 or
SAE 10W...20W/20 oils.
Before taking the oil in continuous use the following facts should be checked which have ef-
fect on compressor operation:
– running temperature (continuous over 90°C running temperature will half the
normal oil change intervall for mineral oil)
– oil consumption (high running temperature increases oil consumption)
– if glogged oil separators
– if varnish formation (affects the cooling and oil separation)
Varnish formation can be seen on metal levels as a brown lacquer coating.
Note! Different oil qualities must never be mixed together
30
419 1 en 2009-11-18
WATER BOOSTER PUMP WBP

Operation and maintenance
Table of Contents
1. GENERAL ...................................................................................................................................... 3
1.1. Type designation .............................................................................................................................................. 3
2. SAFETY ......................................................................................................................................... 4
3. COMPONENTS .............................................................................................................................. 5
4. CONNECTIONS ............................................................................................................................. 6
5. VENTING AND FILLING OF PUMP .............................................................................................. 7
6. CHECKING DIRECTION OF ROTATION ...................................................................................... 8
7. STARTING ..................................................................................................................................... 9
8. DISMANTLING AND FITTING OF THE CR-TYPE WATER PUMPS ............................................ 10

8.1. Removing the transport bracket and turning the motor to another position ................................... 10
8.2. Dismantling and fitting (CR 3 and CR 5) .................................................................................................... 11
8.2.1. Dismantling ..................................................................................................................................................... 11
8.2.2. Fitting ............................................................................................................................................................... 13
8.2.3. Tightening torques of the bolt nuts ............................................................................................................. 15
8.3. Dismantling and fitting (CR 10 and CR 15) ................................................................................................ 16
8.3.1. Dismantling ..................................................................................................................................................... 16
8.3.2. Fitting ............................................................................................................................................................... 19
8.3.3. Tightening torques of the bolt nuts ............................................................................................................. 22
9. LUBRICATION AND MAINTENANCE .......................................................................................... 23

9.1. Frost protection ................................................................................................................................................ 23
9.2. Inspection ........................................................................................................................................................... 23
10. TROUBLESHOOTING ................................................................................................................... 24

ID: 419 1 en 2009-11-18
ID: 419 1 en 2009-11-18
1. GENERAL ID: 24363
The water booster pump is used when the pressure of the water supply network is not sufficient to
ensure proper flushing.
1.1. Type designation ID: 24364
The following key indicates the meaning of the letters and figures of the type designation, e.g. CR
10-10.
A Multistage centrifugal pump

B In-line version
C Nominal flow rate [m³/h]
A B C D
D Number of stages
ID: 25186

ID: 419 1 en 2009-11-18
2. SAFETY ID: 24365
The electrical connection must be carried out by an authorized

electrician in accordance with local regulations.

ID: 419 1 en 2009-11-18
3. COMPONENTS ID: 24366
1 Motor
2 Pump
3 Primer- / vent plug 3 1
4 Primer valve- / drain plug
ID: 24810

ID: 419 1 en 2009-11-18
4. CONNECTIONS ID: 24367
The arrows on the base of the pump indicate the direction of flow of the water. If protective caps are
installed to the pump’s hose connectors for transport or storage, remove them before connecting the
hoses. Always check that the hoses are clean on the inside.

ID: 419 1 en 2009-11-18
5. VENTING AND FILLING OF PUMP ID: 24368
Do not start the pump until it has been vented and filled with
water.
1. Close the pump isolating valve(s).

2. Open the venting valve (A) (pumps with the
venting valve) or remove the primer plug (B)
(pumps without the venting valve) from the
pump head.
3. Gradually open the isolating valve in the
suction pipe until a steady stream ofwater runs
out the primer port. A B
4. Close the venting valve (A) (pumps with the
venting valve) or assembly the primer plug (B)
(pumps without the venting valve) and tighten
securely..
ID: 25187

ID: 419 1 en 2009-11-18
6. CHECKING DIRECTION OF ROTATION ID: 24369
1. Switch off the power supply.

2. Check that the pump is filled with water and that there is no air in it.
3. Check that the electrical connections are in accordance with the wiring diagram in the motor
terminal box cover and the starting procedure used.
4. Check that the pump runs freely. Turn the shaft by means of a screwdriver or a similar tool inserted
through the motor fan cover or turn the coupling by hand after having removed one of the coupling
guards which are kept in position by spring tension.
5. Start the pump and observe the direction of rotation (see the fan). The correct direction of rotation
is shown by arrows on the pump head and on a label on the motor fan cover.When seen from
the top, the pump should rotate counterclockwise.
6. If the direction of rotation is incorrect, stop waterpump and switch off the power supply from main
switch, interchange any two of the incoming supply wires (may only be carried out by an authorized
electrician). On single-phase motors, check details inside the motor terminal box cover.
7. Switch on the power again and check for proper motor direction.

ID: 419 1 en 2009-11-18
7. STARTING ID: 24370
Before starting the pump check that:

• The pump is completely filled with water.
• The pump runs freely.
• The direction of rotation is correct.
• All hose fittings are tight and the hoses are adequately supported.
1. Open the isolating valve in the suction line.

2. Measure the power consumption of the motor if possible. Adjust the motor overload switch if
required.
3. Check the operating pressures.
4. Check all controls for proper operation.

ID: 419 1 en 2009-11-18
8. DISMANTLING AND FITTING OF THE CR-TYPE WATER PUMPS ID: 24371
8.1. Removing the transport bracket and turning the motor to another
position ID: 24372
Read these instructions carefully before removing the transport

bracket or before turning the motor to another position.
When removing the transport bracket, or turning the motor to

an other position, this instruction MUST be followed. If the
transport bracket is not removed correctly, or the motor is not
turned correctly, the pump bearing and/or shaft seal may be
damaged.
1. Remove the screws (2) together with the

coupling guards (1), if fitted. 1
25
2. Remove three of the screws (4) from the
coupling halves (3) and the shaft pin (13). 12
2
3. Slacken the last screw (4) but do not unscrew
it completely. 3
4. Hit the end of the hexagon key carefully with 13
the flat of the hand to loosen one of the 4
coupling halves (3).
5. Remove the last screw (4) and remove the first
coupling half (3).
6. Hit the flat part of the second coupling half (3)
very carefully on the pump shaft end.
7. Remove the second coupling half (3).
8. Remove the screws and the nuts from the
transport bracket (25) and remove the ID: 24811
transport bracket. If you are going to turn the

motor to another position, remove the screws
(12).

ID: 419 1 en 2009-11-18
8.2. Dismantling and fitting (CR 3 and CR 5) ID: 24374
8.2.1. Dismantling ID: 24373

coupling guards (1).
coupling halves (3) and the shaft pin (13).
10
it completely.
the flat of the hand to loosen one of the
11
5. Remove the last screw (4) and remove the first 2
coupling half (3). 12
very carefully on the pump shaft end. 4
13
8. Remove the screws (12).
9. Lift the motor (10) off the pump head (11).
3
ID: 24812
10. Slacken the three screws (5) by approx. 1/4 of

a turn so that the shaft seal is just free of the
shaft.
ID: 24813

ID: 419 1 en 2009-11-18
11. Slacken the shaft seal (6) using the box

spanner (7) (or similar tool) until the thread is 7
completely free of the pump head. 6
12. Pull the shaft seal (6) off the pump shaft.
ID: 24814
13. Remove the nuts (8) together with the washers

(9). 11
14. Loosen the pump head (11) with a light blow
8
on the edge and lift it free of the staybolts (14).
20
14
ID: 24815
15. Loosen the top guide vanes/discharge (17)

with a light blow of a rubber mallet (if it was not
removed with the pump head). 18
16. Remove the outer sleeve (18).
17
17. Lift the chamber stack (15) off the base (16). If
the bottom chamber (19) is removed with the
15
chamber stack (15), loosen it from the
chamber stack (otherwise loosen it from the
19
base (16)).
20
16
ID: 24816

ID: 419 1 en 2009-11-18
8.2.2. Fitting ID: 24375
1. Lubricate the O-ring (20) with Rocol 22 (or

equivalent).
2. Fit the chamber stack (15) in the base (16). 18
The smooth shaft end must be upwards.
17
3. Fit the outer sleeve (18) in the base and press
it home in the base.
15
4. Press the top guide vanes/discharge (17) into
the recess of the top chamber (15). 19
20
16
ID: 25130

equivalent). 11
6. Fit the pump head (11).
8
7. Lubricate the threads of the staybolts (14) with
Thread--Eze (or equivalent).
9
8. Fit the washers (9) and the nuts (8).
9. Tighten the nuts (8) diagonally with the torque
of 50 Nm.
20
14
ID: 25131
10. Moisten the shaft end with soapy water.
ID: 25132

ID: 419 1 en 2009-11-18
11. Place the shaft seal (6) in the box spanner (21)
and press it down on the shaft. 21
12. Screw the shaft seal (6) into the pump head
(11) and tighten it with the torque of 35 Nm.
6
11
ID: 25133
13. Fit the motor (10) to the pump head (11).

14. Fit the screws (12), lubricate them and tighten 10
them diagonally (with the torque shown in the
picture).
12
11
ID: 25134
15. Insert the shaft pin (13) into the shaft hole and
fit the coupling halves (3) on the shaft.
16. Lubricate the four screws (4) with Thread--Eze
(or equivalent).
4
17. Fit the screws (4). Tighten and leave loose.
18. Check that the gaps on both sides of the
3
coupling halves are equal.
13
ID: 25135
19. Note.! Two persons are needed for this

operation. Insert a suitable screwdriver
between the bottom of the coupling (3) and the
shaft seal (6) and raise the pump shaft/ 4
coupling against the stop and simultaneously
press themotor shaft (e.g. with a screwdriver)
through the fan grille in order to push themotor
shaft to its lower position (Normally the
propellant spring at the lower end of the motor
holds the motor shaft in the upper position.). 3
20. Lower the pump shaft/coupling to half of height
(X).
21. Hold the pump shaft/coupling in the position of
step 19 and tighten the four screws (4) (with 6
the torque shown in the picture).
ID: 25136
coupling halves are equal.

ID: 419 1 en 2009-11-18
23. Tighten the three screws (5) with the torque of

2,5 Nm.
24. Fit the coupling guards (1) and the screws (2).
Tighten the screws.
1
ID: 25137
8.2.3. Tightening torques of the bolt nuts ID: 25165
The four bolt nuts (M12) (8) must be tightened

every once in a while, because they may become
loose during operation. The required tightening 8
torque is 50 Nm.
ID: 25194

ID: 419 1 en 2009-11-18
8.3. Dismantling and fitting (CR 10 and CR 15) ID: 25155
8.3.1. Dismantling ID: 25213

coupling guards (1).
coupling halves (3) and the shaft pin (13).
10
it completely.
the flat of the hand to loosen one of the
11
5. Remove the last screw (4) and remove the first 2
coupling half (3). 12
very carefully on the pump shaft end. 4
13
8. Remove the screws (12).
9. Lift the motor (10) off the pump head (11).
3
ID: 24812
10. Slacken the three screws (5) by approx. 1/4 of

a turn so that the shaft seal is just free of the
shaft.
ID: 24813

ID: 419 1 en 2009-11-18
11. Slacken the shaft seal (6) using the ring insert
tool (22) (or similar tool) until the thread is
completely free of the pump head.
12. Pull the shaft seal (6) off the shaft.
6
22
ID: 25252
13. Remove the nuts (8) together with the washers

(9). 11 8
14. Loosen the pump head (11) with a light blow
on the edge and lift it free of the staybolts (14). 9
20
14
ID: 25253

ID: 419 1 en 2009-11-18
15. Remove the outer sleeve (18).

18
16. Lift the chamber stack (15) off the base (16).
15
20
16
ID: 25254

ID: 419 1 en 2009-11-18
8.3.2. Fitting ID: 25157

equivalent). 18
2. Fit the chamber stack (15) in the base (16)

taking care that the heads of the screws for 15
strips do not touch the inlet pipe in the base.
3. Fit the outer sleeve (18) in the base and press
it home in the base.
20
16
ID: 25265

equivalent). 11 8
5. Check that the rubber springs (23) are in the

pump head (11). 9
6. Fit the pump head (11).
23
7. Lubricate the threads of the staybolts (14) with
Thread-Eze (or equivalent).
8. Fit the washers (9) and the nuts (8). 20
9. Tighten the nuts (8) diagonally with the torque
of 80 Nm. 14
ID: 25266
10. Moisten the shaft end with soapy water.
ID: 25132

ID: 419 1 en 2009-11-18
11. Press the shaft seal (6) on the pump shaft.

12. Screw the shaft seal (6) into the pump head 6
(11) and tighten it with the torque of 35 Nm
using the ring insert tool (22) (or similar tool). 11
22
ID: 25267
13. Tighten the three screws (5) with the torque of

2,5 Nm.
ID: 25268
14. Lift the chamber stack by inserting a

screwdriver (or similar tool) in the hole for the
pin in the pump shaft and fit the adjusting fork
(24), which is fitted to one of the coupling 24
guards (1).
ID: 25269
15. Fit the motor (10) to the pump head (11).

16. Fit the screws (12), lubricate them and tighten 10
them diagonally (with the torque shown in the
picture).
12
11
ID: 25134

ID: 419 1 en 2009-11-18
17. Fit the shaft pin (13) and the two coupling
halves (3).
18. Lubricate the four screws (4) with Thread-Eze
(or equivalent).
19. Fit the screws (4). Tighten and leave loose.
20. Check that the gaps on both sides of the 4
coupling halves (3) are equal.
21. Press themotor shaft (e.g. with a screwdriver) 3
through the fan grille in order to push themotor
13
shaft to its lower position (Normally the
propellant spring at the lower end of the motor
holds the motor shaft in the upper position.).
22. Tighten the screws (4) (with the torque shown ID: 25270
in the picture).
coupling halves (3) are equal.
24. Remove the adjusting fork (24).
24
ID: 25271
25. Check that the pump shaft rotates freely and noiselessly.
26. Place the adjusting fork (24) inside one of the
coupling guards (1). 24
27. Fit the coupling guards (1) and the screws (2).
2
ID: 25272

ID: 419 1 en 2009-11-18
8.3.3. Tightening torques of the bolt nuts ID: 25164
The four bolt nuts (M16) (8) must be tightened

every once in a while, because they may become
loose during operation. The required tightening 8
torque is 80 Nm.
ID: 25194

ID: 419 1 en 2009-11-18
9. LUBRICATION AND MAINTENANCE ID: 25158
Pumps installed in accordance with these instructions will operate efficiently with very little
maintenance. The mechanical shaft seal is self-adjusting and has wear-resistant seal faces which
are lubricated and cooled by the pumped water. Pump bearings are lubricated by the pumped water
as well.
Motors without grease nipples have ball bearings which are lubricated for life with a heat-resisting
grease. No additional lubrication is required.
Motors with grease cups (nipples) can be lubricated with a lithium based grease.
TYPE: ESSO BEACON 3 or similar types.
Additional greasing is only recommended under exacting operating conditions. Overgreasing may
result in motor failure. In case of seasonal operation (out of operation for more than 6 months), it is
recommended to grease the motor, when it is taken out of operation.
9.1. Frost protection ID: 25159
Under the conditions where the temperature of the surroundings can go below 0 °C, the flushing
system must be protected against the freezing of the flushing water, by blowing some anti-freezing
liquid through the flushing line.
9.2. Inspection ID: 25160
At regular intervals, depending on the conditions and time of operation, the following checks should
be made:
• Possible leaks.
• Remove and clean all filters fitted to the installation.
• Tripping time for the motor overload unit.

ID: 419 1 en 2009-11-18
10. TROUBLESHOOTING ID: 25161
Problem Possible cause

Pump not starting No current. Water pump switch (at electric
cabinet) in position ”0”.
Motor protector switch triggered.
Motor protector switch contact points or
electromagnet faulty.
Motor protector switch triggered (triggered right Motor protector switch contact points faulty.
after starting) Loose or faulty cable connection.
Motor winding faulty.
Pump mechanically blocked.
Set value too low.
Motor protector switch triggered erratically Set value too low.
Fluctuation in voltage.
Mains voltage too low.
Motor protector switch not triggered but pump still No current.
not running Water pump switch (at electric cabinet) in
position ”0”.
Pump output varying Water supply capacity too small for pump output.
Water inlet pressure too low with respect to
temperature, flow disturbances, and flow volume.
Supply line partly blocked.

ID: 419 1 en 2009-11-18
www.sandvik.com

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Original instructions

WATER CIRCUIT, DL3 SERIES AND DL4 SERIES

3. OPERATION OF CIRCUIT ............................................................................................................. 7

4. MUD SEPARATOR ........................................................................................................................ 10

5. WATER BOOSTER PUMP ............................................................................................................ 11

6. PRESSURE REDUCING VALVE ................................................................................................... 12

7. OIL COOLER ................................................................................................................................. 15

8. COOLER'S DISSIPATION FIGURES ............................................................................................ 17

9. ELECTRICALLY CONTROLLED VALVE ..................................................................................... 18

Copyright © Sandvik Mining and Construction 3 (36)

11. MAINTENANCE OF WATER CIRCUIT ......................................................................................... 32

12. TROUBLESHOOTING OF WATER CIRCUIT ............................................................................... 35

4 (36) Copyright © Sandvik Mining and Construction

Copyright © Sandvik Mining and Construction 5 (36)

The electrical connection must be carried out by an authorized

Never drill without adequate flushing.

Do not reuse the water returned from the flushing circulation.

Keep the pressure limits and the pressure switches in working

6 (36) Copyright © Sandvik Mining and Construction

1 Drain valve and mud separator

Copyright © Sandvik Mining and Construction 7 (36)

S421 BOOT WASHER

Solo with canopy

HIGH PRESSURE WASHER

1 Drain valve and mud separator

8 (36) Copyright © Sandvik Mining and Construction

3.2. Normal flushing

3.3. Double flushing

3.4. Pressure settings

3.5. Inspection of pressure switch operation

Copyright © Sandvik Mining and Construction 9 (36)

When cleaning, observe the following:

1 Shut-off valve (option)

10 (36) Copyright © Sandvik Mining and Construction

5. WATER BOOSTER PUMP

5.4. Operation and maintenance

Copyright © Sandvik Mining and Construction 11 (36)

6. PRESSURE REDUCING VALVE

6.2. Function of valve

12 (36) Copyright © Sandvik Mining and Construction

Copyright © Sandvik Mining and Construction 13 (36)

6.4. Adjusting of pressure

HLX 5 HL 700 HL 800 HL 1000 HL 1500

14 (36) Copyright © Sandvik Mining and Construction

Copyright © Sandvik Mining and Construction 15 (36)

Be careful not to overtighten the bolts. The tightening torque (37

If the cooler’s hoses are loose, care should be taken of their

16 (36) Copyright © Sandvik Mining and Construction

8. COOLER'S DISSIPATION FIGURES

Cooler’s nominal dissipation:

25 50 75 100 125 150 175 200 225 250 275 300

25% 50% 100%

Copyright © Sandvik Mining and Construction 17 (36)

9. ELECTRICALLY CONTROLLED VALVE

18 (36) Copyright © Sandvik Mining and Construction

9.3. Disassembly and assembly

Disconnect hoses and wires from the flushing valve.

Copyright © Sandvik Mining and Construction 19 (36)

7. Reconnect the connectors and reinstall the plugs.

20 (36) Copyright © Sandvik Mining and Construction

9.4. Changing the seals to water valve

Copyright © Sandvik Mining and Construction 21 (36)

22 (36) Copyright © Sandvik Mining and Construction