460LP Air Bk1

COMPRESSOR TRAINING MANUAL DR460
Compressor Safety
Copyright © Sandvik Mining and Construction

COMPRESSOR SAFETY DR460
COMPRESSOR SAFETY
Safety first in the work place! Before starting the work process establish a JSA or risk assessment
regarding the work to be performed.
Equipment owners, technicians and operators shall determine the needs of the intended task prior
to commencing any work.
• Arrange proper tools for the job
• Utilize appropriate PPE personnel protective equipment for the task
• Read material that may be pertinent to the task
• Communicate with co-workers and/or operators of the equipment
• Lock out and tag out the main power supply to prevent accidental start up during the work pro-
cess
• Follow site specific safety protocol
• Remember the environment, prepare with necessary containment and disposal material
It is the responsibility of the individual operator/technician to read and understand the

machine specific operator, maintenance or service manual prior to operating a drill machine.
Copyright © Sandvik Mining and Construction 1

D50KS COMPRESSOR SAFETY
LOW PRESSURE COMPRESSOR SAFETY

Applicable for rotary application drill machines.
• Operating pressures of 140 psi (9.6 bar) may be present in the air control system during a loaded condi-
tion.
Do not use high pressure air to clean the machine. Do not use compressed air for personnel
cleaning.
• Safety relief valves on air receiver tanks.

The safety relief valve must be checked periodically for proper operation, manually move the
vent handle to purge the relief valve on a monthly basis. Do not tamper with or change the relief
valve setting.
• Air hose connections are secured with safety chain restraints to prevent hose ends from being acciden-
tally disconnected or expelled.
Operating the high pressure air without hose restraints can lead to death of personnel or equip-
ment damage.
• Discharge opening of air hoses and tools.

Keep personnel out of line with and away from discharge opening of hoses or tool or other
points of air discharge, death or personnel injury may result from sudden burst of high pres-
sure air.
• Air blowdown or cleaning attachments.

Do not use air at pressures higher than 30 psi (2 bar) for cleaning purposes and then only with
effective chip guarding and personnel protective equipment PPE per OSHA standard 29 CFR
1910.242b
• Horseplay.
Do not engage in horseplay with air hoses as death or serious injury may result.
• PPE Personnel protective equipment.

Wear appropriate personnel protective equipment for the work environment to include hearing
protection and eye wear when working with compressed air.
• Batteries.
Disconnect the battery cable ground terminal or open the battery disconnect switch prior to
maintenance or compressor service.
• Fire extinguisher.
Keep a fully charged class BC or ABC fire extinguisher or extinguishers present when servic-
ing or operating a high pressure compressor system.
2 Copyright © Sandvik Mining and Construction

COMPRESSOR SAFETY DR460
HIGH PRESSURE COMPRESSOR SAFETY

Applicable for DTH application drill machines.
• Operating pressures of 400 psi (27.5 bar) may be present in the air control system during a loaded condi-
tion.
Do not use high pressure air to clean the machine. Do not use compressed air for personnel
cleaning.
• Safety relief valves on air receiver tanks.

The safety relief valve must be checked periodically for proper operation, manually move the
vent handle to purge the relief valve on a monthly basis. Do not tamper with or change the relief
valve setting.
• Air hose connections are secured with safety chain restraints to prevent hose ends from being acciden-
tally disconnected or expelled.
Operating the high pressure air without hose restraints can lead to death of personnel or equip-
ment damage.
• Discharge opening of air hoses and tools.

Keep personnel out of line with and away from discharge opening of hoses or tool or other
points of air discharge, death or personnel injury may result from sudden burst of high pres-
sure air.
• Air blowdown or cleaning attachments.

Do not use air at pressures higher than 30 psi (2 bar) for cleaning purposes and then only with
effective chip guarding and personnel protective equipment PPE per OSHA standard 29 CFR
1910.242b
• Horseplay.
Do not engage in horseplay with air hoses as death or serious injury may result.
• PPE Personnel protective equipment.

Wear appropriate personnel protective equipment for the work environment to include hearing
protection and eye wear when working with compressed air.
• Batteries.
Disconnect the battery cable ground terminal or open the battery disconnect switch prior to
maintenance or compressor service.
• Fire extinguisher.
Keep a fully charged class BC or ABC fire extinguisher or extinguishers present when servic-
ing or operating a high pressure compressor system.

1. Low Pressure Air Systems

1.1 LOW PRESSURE AIR SYSTEMS

This section introduces single stage low pressure air systems and their design parameters based
on DR460 Sandvik rotary drill machines used in rotary drilling applications.
Sandvik together with Caterpillar and Cummins engine manufactures, offer customers electronic
Tier III series engines and Sullair Corporation to offer a single stage low pressure rotary screw
compressor package to be utilized in a rotary drill application.
1.2 DESCRIPTION
Compressors are direct driven, engine mounted front and center in the machine frame.
Compressor oil lubrication and air regu- DR460 OVERVIEW

lation components are local to the com-
COMPRESSOR
pressor.
Auxiliary air options for drilling and non- machineoverview.tif

drilling features are positioned at vari-
ous areas on the machine deck.
REAR FRONT
1.3 HORSEPOWER
Engine horsepower is used to drive the combined volume and pressure from a single stage low
pressure air compressor.
Engine horsepower requirements are greater when driving a 2000 cfm air compressor verses a
1300 cfm air compressor.
DR460 equipment engine horsepower (HP) are based on engines operating at high idle speeds.
The speed ratings and horsepower ratings are noted in table 1.
Table 1: DR460 Engine Horsepower
HORSEPOWER RPM
875 HP (652 kw) C27 1800 RPM
949 HP (708 kw) QSK23 1800 RPM
1000 HP (746 kw) QST30 1800 RPM
The actual ‘TEL’ Top Engine Limit calibration will be calibrated slightly higher than 1800.
Compressor ratings are based on volumes of air discharged or SCFM standard cubic feet per min-
ute. There are many compressors available for various drilling conditions.

D50KS COMPRESSOR TRAINING MANUAL
The main concept of the compressor system is to flush drill cuttings away from the rotary type
roller, drag or claw drill bit.
DR460 compressor volumes CFM and maximum pressure ratings PSI applicable for diesel pow-
ered equipment are noted in table 2.
Table 2: DR460 Air Ends
STANDARD SPEC METRIC SPEC
2000 CFM / 100 PSI 56.6 m³ / 6.9 bar
1450 CFM / 350 PSI 41 m³ / 24 bar
Engine and compressor packages are compatible for specific drilling applications. Climactic condi-
tions and operating conditions such as altitude, are factors in selecting the proper power group
components to fit the overall site specific drilling needs.
When selecting a compressor size and drilling tools, use table 3 altitude correction chart.
Table 3: Altitude Correction Chart

ALTITUDE ALTITUDE CORRECTION
FEET METERS FACTOR
4000 1200 .86
5000 1500 .82
6000 1800 .79
7000 2100 .76
8000 2400 .73
9000 2700 .70
10000 3000 .68
11000 3400 .65
12000 3700 .63
13000 4000 .60
14000 4300 .58
Use the altitude correction chart:
• For drilling applications above 4000 feet (1200 meters).
• When determining actual compressor output or standard cubic feet per minute (SCFM).
• In selecting the correct drill pipe and drill bit dimensions for adequate up hole velocity.

Example:
2000 CFM (56.6 m³) @ 5000 ft (1500 m).

compressor output = 2000 x.82 = 1640 SCFM
2000 CFM (56.6 m³) @ 11000 ft (3400 m).

compressor output = 2000 x.65 = 1300 SCFM
1.4 ROTARY DRILLING

Principals of rotary drilling are quite simple. There are three main elements, air delivery, rotation
speed and torque and lastly feed force otherwise known as pulldown. The volume of air and the
operating pressures are essential for a successful blasthole.
Drill bits are considered consumable items attached to a drill string and utilized to advance the drill
string into earth formations for the purpose of making a blasthole or well hole. Many brand names
exist in the market. It is the users choice to purchase the best bit to optimize drill production in the
mine specific ground conditions.
1.4.1 Drill Bits
The three most common rotary drill bits are the 3 and 4 wing drag bit, the roller or tri cone bit and
the claw type drill bits.
NOZZLE
SKIRTS
ROTARY CLAW BIT

ROLLERS REPLACEABLE CARBIDE
4 WING AND 3 WING
DRAG BITS WITH OR BULLET STYLE CUTTERS
WITHOUT REPLACEABLE ROTARY ROLLER BIT
CARBIDE INSERTS MILL TOOTH ROLLERS AND/OR
CARBIDE BUTTON ROLLERS
AS SHOWN
Each application drill bit type by manufacture is designed with limitations. The limitations could be
rotation speed, feed force and air flushing. Bit manufactures design variations to with stand and
perform in differing strata. As mentioned it is the users responsibility to purchase the best bit to opti-
mize drill production in the mine specific ground conditions.

1.5 Air Delivery
Optimum drill cutting removal is based on proper drill pipe diameter in relation to drill bit diameter
(hole size). Annular area is the difference of area between the drill bit and drill pipe diameters.
Annulus:
Drill cuttings have to exit the drilled hole in order

for the bit to penetrate in the ground formation.
Annulus is the difference between the drill bit

dimension and drill pipe dimensions that allow UP HOLE
drill cuttings to exit a drilled hole. VELOCITY
ANNULUS + 5000 FPM
Air velocity charts are used to calculate bailing AREA - 10,000 FPM
air velocity typically in (FPM) feet per minute. OPTIMUM
In general optimum bailing velocity shall be

greater than 5000 fpm up to 10,000 fpm.
Insufficient Clearance > 10,000 fpm:

Binds rotation during drilling cycle.
Creates resistance to turn bit generating higher

rotation torque, tighter threads and less power.
Creates air flow restriction and easier plugging of

drill bit nozzles.
Requires higher feed system operating pres-

sures.
Accelerates drill string wear in abrasive rock

conditions due to increased up hole velocity.
Excessive clearance < 5000 fpm:
Enable bit to become unbalanced in the hole.
Leads to hole deviation and possible thread

breakage.
Reduced uphole velocity allows drill cuttings to

fall back into the hole thus contributing to regrind
and accelerating bit wear.
Reduces productivity because of drill cutting

regrind.
Can affect dust control
Table 1 and 2 are examples of up hole velocity. This process is used to establish a proper annulus
area and sizing the drill bit, drill pipe dimension and compressor size to suit the operating condition.

Table 4: 2000 CFM COMPRESSOR 7 5/8 IN 194 MM DRILL PIPE

BIT 3500 4500 5500 6500 7500 8500 9500 10500 11500
DIAMETER
11 1/4 IN
285 MM
10 5/8 IN
270 MM
9 7/8 IN
250 MM
11 1/4 inch (285 mm) drill bit with 7 5/8 inch (194 mm) drill pipe = 5400 FPM uphole velocity.
Table 5: 2000 CFM COMPRESSOR 8 5/8 IN 219 MM DRILL PIPE

BIT 4000 5000 6000 7000 8000 9000 10000 11000 12000
DIAMETER
12 1/4 IN
311 MM
11 3/4 IN
298 MM
10 5/8 IN
270 MM

1.5.1 Inspecting Drill Bits
Inspect drill bits at the beginning of each shift and as needed according to rock strata.
All roller cones must be secure to the leg

and free to rotate.
Cutting teeth or carbides must be intact.
Flushing nozzles must be same dimen-

sion.
Replace worn or damaged drill bits as

needed.
Besides lost production damaged drill bits can affect rotation mechanical components and stress
the hydraulic system.
In relation to air systems the main factors relative to bit performance are air volume, uphole velocity
and working air pressure. All components must be balanced in order to optimize the drilling costs.
SHANK WITH
TAPERED API THREAD
NOZZLE
SCREEN TUBE
BIT LEG AIR COOLING

CHANNEL
THRUST BUTTON ROLLER BEARING
BALL BEARING
CONE TOP BEARING
REAR AXIAL BEARING
Nozzle selection is a machine specific and site specific requirement.
1.5.2 Nozzle Selection
Nozzles are designed to regulate high energy air at the intersection of adjacent cones to ensure
removal of loose rock cuttings and direct air to the bearings for cooling and dust removal.
Careful consideration must be given as to the correct nozzle size to ensure correct operation of the
drill bit.

Should the nozzle size be too large in diameter the pressure drop across the drill bit will be too
small. This will result in a larger proportion of air flow being directed through the nozzles and a
small proportion being directed to the bearings for cooling. Cutting material can be forced into the
bearing area reducing the service life of the bearings.
Depending on bit design a portion of air is directed

through the air cooling channel for bearing flushing
and cooling.
To minimize dirt packing inside bit bearings it is rec-
ommended to turn flushing air on before placing bit 2000 CFM
into dirt.
200 CFM
TO THE BEARINGS
If the nozzle sizes are too small in diameter the air pressure inside the drill bit will be too high caus-
ing the compressor to frequently unload resulting in poor flushing and drill performance.
1.5.2a Air Pressure Differential

1. Blow air to atmosphere through drill pipe and bit with nozzles. Check working air pressure
gauge.
2. Blow air to atmosphere through the rotary head top sub without drill pipe and bit. Check working
air pressure gauge.
Consult your local bit supplier for recommended nozzle sizes.
Adjust nozzles sizes accordingly.
1.5.2b Remove And Replace Nozzles

Consult bit supplier regarding nozzle removal procedure. Depending on bit selection it may
be as simple as:
1. Clean the area around the spring pins and nozzles.
2. Drive the spring out using a 3/16 (5 mm) punch.
3. Remove nozzle from housing
4. Clean nozzle housing

5. Insert new nozzle into housing ensuring that the groove on the nozzle is aligned with the pin
hole.
Replace spring pin ensuring that the head of the spring pin is flush with the bit surface.

2. Power Group Components

2.1 POWER GROUP COMPONENTS

Engine, compressor, inlet air filtration and cooling systems fall under power group compo-
nents. Said components and their sub assemblies require service and maintenance.
2.2 ENGINE
Sandvik rotary drill equipment utilize Caterpillar Tier III diesel engines as primary or Cummins
Tier III series diesel engines optional based upon customer preferences.
Caterpillar C27
27 L displacement.
875 Horsepower (652 kw).
1200 rpm low idle.
1800 rpm high idle.
Engine services must be performed by end user per scheduled maintenance intervals recom-
mended by factory and respective engine manufacturer.
2.2.1 Compressor Drive
Compressors are direct drive to the customer selected engine by means of aluminum drive ring
mounted on the engine flywheel and vulcanized rubber coupling. secured to the compressor shaft
with a taperloc bushing.
Drive ring on engine flywheel:
Loctite 242 shall be used on capscrews prior to

final torque.
Manage bolt torques in a cross pattern with pre-

torque 60 ft lb (81 Nm) with final torque 75 - 85 ft
lb (102 - 115 Nm).
Replace both drive components as one unit ordered as a installation kit along with a replacement
air end.

DR460 COMPRESSOR TRAINING MANUAL
Coupling applied to compressor shaft:
Refer to service material 008674-000 taper-

lock bushing installation procedure for any
new or replacement compressor installation.
The compressor shaft and drive coupling

should rotate free after final component instal-
lation.
TAPERLOC
BUSHING
CAUTION
Using a hammer on or applying high forces on the compressor input shaft when
installing the coupling can damage the shaft seal or bearings.
2.3 COMPRESSOR
During operation a rotary drill compressor is a air pump moving air and oil mixture through
lubrication components. Air is regulated by means of a pressure reducing regulation valve,
load solenoid and inlet control valve.
2000 CFM compressor mounted to engine

and frame.
All hoses connected for lubrication and regu-
lation.
Poppet inlet valve secured with gasket seals

to compressor throat.
Long service life is obtainable with planned maintenance intervals, a secure inlet and filtration
system, clean synthetic grade compressor oil and stable operating temperature.
Note manufacture identification plates

stamped to discharge housing.

2.4 AIR FILTRATION

Compressor and engine air filtration are similar components with common primary and sec-
ondary filter elements. There is a difference in piping between the two inlets.
Outlet to compressor or engine with restriction indi-

cator monitoring inches of water relays restriction
to DMS circuit board when blockage is above 22
inches of water.
Access cover for filter service.
Perforated air inlet allows dirty air into the pre-

cleaning section.
Air passes through a cluster of Donaclone tubes

precleaning air before primary filter.
Manual dust cap may be unlatched to evacuate

dust build up and access donaclone tubes.
Routine services must be performed by end user per scheduled maintenance intervals rec-
ommended by factory. Extreme dust conditions or wet operating conditions may warrant
adjusting service interval.
2.5 COOLING
Efficient fluid transmission requires managing proper operating temperatures. A rotary drill
typically couple individual cooler components together as one assembly. There are 5 individ-
ual coolers according to application.
Welded construction AKG cooler assembly

shown.
Six individual coolers:
engine water
engine turbo air X 2
compressor oil
hydraulic oil
Routine cleaning must be performed by end as needed. Extreme dust conditions may war-
rant adjusting cleaning interval.
Operating conditions below 20 F (-6 C) may require covering cooler to generate heat and
fluid movement.

2.6 LP COMPRESSOR SYSTEM SPECIFICATIONS

Main components listed are designed purchased parts that fit Sandvik Mining and Construc-
tion rotary drill machines. The LP drilling concepts are rotary methods, using roller type drill
bits.
Table 1: Low Pressure Rotary Drill Compressor Component Spec
COMPONENT SPECIFICATION
COMPRESSOR OIL THERMOSTATS EXTEND TO CLOSE

START @ 145° F(62° C) FULL CLOSED @ 184° F(84° C)
OIL COOLER BYPASS VALVES 2 @ 50 PSI (3.5 BAR) - SULLAIR
COMPRESSOR OIL COOLER RATED FOR 350 PSI (24 BAR)

ACTUAL PASSING EQUALS SYSTEM PRESSURE
AIR RECIEVER SAFETY RELIEF VALVE 1 @ 140 PSI (9.7 BAR)
MINIMUM PRESSURE VALVE 1 @ 60 PSI (4 BAR)
UNLOAD PRESSURE 100 PSI (6.9 BAR)
SEPERATOR DIFFERENTIAL INDICATOR (CSP) 1 @ 10 PSI (.70 BAR)
MAIN OIL FILTER BYPASS VALVE (CFP2) 1 @ 35 PSI (2.4 BAR)
AIR CLEANER FILTER INDICATOR (CFP1) 1 @ 22 INCHES WATER
AIR/OIL TEMPERATURE SWITCH (CAT/ATS) 230° F (110° C) COMPRESSOR AIR TEMP

COMPRESSOR PRESSURE SWITCH (COP) 15 PSI (1 BAR) COMPRESSOR OIL PRESSURE
FACTORY FILL COMPRESSOR OIL SHELL CORENA AW32 / CORENA POA
Auxiliary air components added on as features or options using machine air are designed
purchased parts that fit Sandvik Mining and Construction rotary drill machines.
FEATURE/OPTIONS SPECIFICATION
HYDRAULIC TANK PRESSURIZATION 5 PSI (.3 BAR) RELIEF @ 12 PSI (.8 BAR)
DRY DUST COLLECTION AIR REGULATION 50 PSI (3.5 BAR) RELIEF @ 90 PSI (6.2 BAR)
BIT LUBRICATOR TANK REGULATION 60 PSI (4 BAR)
AIR BLOWDOWN REGULATION 30 PSI (2 BAR)
AUTOMATIC THREAD LUBE REGULATION 80 - 100 PSI (5.5 - 6.8 BAR)
Routine services must be performed by end user per scheduled maintenance intervals rec-
ommended by factory.

2.7 POWER GROUP HOSING

Verify machine specific power groups for exact hose routing based on compressor applica-
tion. The following 021820-006 power group is a low pressure 2000 cfm 100 psi rotary drill
application.

3. Oil Lubrication

3.1 OIL LUBRICATION

Single stage low pressure application machines utilize contained air pressure to circulate oil
from an air/oil receiver tank through hoses, valves, oil coolers and the single stage air end
returning an air oil mixture back to the receiver tank.
This section will describe oil circulation through these components.
! DANGER
Allow a minimum of 2 minutes after machine shutdown and note receiver tank pressure is
0 on gauge before starting compressor maintenance.
3.2 COMPONENTS
The following purchased parts are associated with air and oil in the compressor lubrication
circuit.
Table 1: Air/Oil Lubrication Components

AIR RECEIVER TANK OIL COOLER
FLUID LEVEL SIGHT GLASSES
SAFETY RELIEF VALVE OIL STOP VALVE
MINIMUM PRESSURE VALVE OIL FILTER WITH FILTER

RESTRICTION INDICA-
TOR
AIR FILTER RESTRICTION DISCHARGE CHECK

INDICATOR VALVE

Table 1: Air/Oil Lubrication Components

DIFFERENTIAL INDICATOR COMPRESSOR OIL
PRESSURE SWITCH
THERMAL MANIFOLD FAN SPEED SENSOR
SHUTDOWN SWITCH
TEMPERATURE SENSOR
3.2.1 Safety Relief Valve

The ASME certified safety relief valve is positioned on the horizontal section or wet side air/
oil supply. Maximum air pressure inside the tank is limited as the 003518-001 valve is preset
to 140 psi (9.7 bar).
The safety relief valve is preset and secured with safety

wire and seal #5 by the manufacturer. Removing the seal
and adjusting this valve voids all safety standards.
Temperature rated -60° - 406° F (-51° - 208° C).
ATMOSHPERIC
VENT
AIR/OIL
COURTESY OF TYCO INTERNATIONAL SERVICES AG
If this valve vents to atmosphere air and oil will discharge. Prolonged discharge affects
receiver air pressure and fluid level.
Repeated venting to atmosphere weakens relief valve which may shorten service life.
For product and personnel safety replace this valve assembly if it determined to be faulty:
leaks air/oil to atmosphere, subjected to excess heat or fire and per local regulations perti-
nent to pressure vessel test parameters.

3.2.2 Minimum Pressure Valve
The minimum pressure valve is located on top of the vertical section or ‘dry side’ of the air receiver
tank. Minimum air pressure inside the tank during the drill mode should not drop below 4 bar (60
psi). This ‘minimum’ air pressure is needed to push oil through all the lubrication and cooling sys-
tem parts.
Minimum pressure valve:
Spring to close, tank pressure greater than

minimum pressure
RECEIVER TANK
60 psi (4 bar) to open. DRY AIR
IN PISTON AND SPRING
Check valve modulates to manage reser-
voir pressure. CHECK
VALVE
O-rings seal the piston and housing.
End cap is atmospheric vented. VENT
Downstream air pressure is available when

drilling air becomes blocked at service
valve. DOWNSTREAM AIR
! DANGER
The end cap is under spring pressure. Remove all personnel from work area, place a
barrier between technician and valve, stand to the side and use caution when loosening
and removing the end cap from the valve body.
Minimum pressure valves should be free of compressor oil. Only dry air should be passing through
this valve.
3.2.2a Testing Minimum Pressure

Periodic check air receiver pressure.
1. Operate the machine at the rated high idle speed.
2. Turn the working air on and observe the air receiver pressure gauge. Gauge ports are available
at the separator differential indicator for testing receiver tank pressure.
Air pressure inside the air receiver tank should never drop below the preset spring value of the min-
imum pressure valve.
Low receiver pressure can lead to low bearing oil pressure, increased compressor temperature and
engine shutdown.

3.2.3 Separator Element
The separator element in low pressure applications passes air through the separator element from
the outer to inner surfaces. The separator element design is to slow down the air movement that
contains compressor oil. Oil particles will be trapped on the outer element diffusion case. Micro-
scopic oil will pass through the paper pleated filter media. This oil carry over must be evacuated.
Filter is suspended inside tank with top and bottom

gasket seals.
To eliminate static electricity inside the filter element the

gaskets have a staple type static ground device.
Do not remove staples from separator element

gaskets.
Scavenge tube passes air/oil mixture returning
excess oil carry over to compressor.
3.2.3a Scavenge Oil Return
An oil return system referred to as a scavenge system enables oil carry over, oil that passes
through the paper pleat separator element, to be returned to the compressor housing. The scav-
enge return line will have a strainer screen filter and sight glass with an inline orifice to control the
return oil flow.
Stainer screen inside adapter captures potential

contaminates from reservoir.
A 3/32 (2 mm) orifice reduces air/oil return and STRAINER

generates a pressure differential enabling oil circu-
lation without affecting air volume.
Scavenge strainer maintenance is recommended

at 250 service hour intervals.
ORIFICE
During run modes oil carry over is visible inside sight glass and is dependent on receiver tank pres-
sure. Expect one cup (236 ml) to one quart (.94 l) per minute circulation over the sight glass during
drilling conditions.
Excess oil movement may be a damaged separator element.
No oil present over sight glass may be a blocked strainer screen or scavenge tube damage.
Flooded sight glass no oil movement may be blocked orifice.

3.2.4 Compressor Main Oil Filters
The filter cover has a bleed port that may be opened prior to filter removal to vent the filter canister
of any residual pressure trapped inside the filter assembly after machine shutdown.
Compressor filters are on 250 hour maintenance intervals unless compressor filter light illuminates
indicating compressor filter restriction.
Two 25 micron elements clean compressor oil. CAP
One connector seals the two elements and must be ORING

intact free from defects to maintain proper sealing.
CAP SEALS
When performing filter maintenance retain all filter
seals from old elements. SPRING
Pay attention that new filters is centered onto cavity SEAL CAP
and connector before seating filters into housing.
CONNECTOR
Torque cap to 100 ft lb (135 Nm).
Bypass mechanism rated at 40 psi 92.8 bar) crack- SEALS

ing pressure differential pressure and is full open at
61 psi (4.2 bar).
INLET
PORT
OUTLET
PORT
BYPASS
VALVE
Loose or missing grommets should be located prior to reinstating the machine into service.
3.2.5 Oil Stop Valve
The oil stop valve is mounted to the outlet port of the main compressor filter assembly. The oil stop
valve receives a pilot pressure signal from the compressor discharge pipe. Pilot pressure is equal
to the receiver tank pressure.
The primary function of the oil stop valve is to maintain compressor oil in the hoses and related
components after machine shutdown.

Oil stop valve shown closed.
Pilot pressure pushes the piston open IN

for oil circulation to the compressor
manifold and bearing lubrication. IN
Without pilot pressure, the spring forces

the piston to close and seals oil from
settling during shutdown periods.
OUT OUT
A failed oil stop valve will allow oil from the cooler, filter and hoses to settle into the compres-
sor. This increased oil will affect load factors during machine starting and in some cases the
oil stop valve may allow oil mist into the compressor air filter.
3.2.6 Bearing Manifold
Past the oil stop valve, compressor oil circulates to a manifold that in design delivers compressor oil
to required lubrication points of the air end.
This bearing distribution manifold is the last point

oil injection.
This manifold supports a 1 bar (15 psi) pressure
switch designed to monitor compressor oil pres-
sure.
The manifold hoses are sized for flow require-

ments to the desired point of oil injection. Restric-
tive orifices in adapters limit oil flow to the
compressor bearings.
The COP (compressor oil pressure) switch is normally open and closes with oil pressure. Use the
common and normal open contacts. This safety switch will interrupt the machine run mode and
shut the machine down. A red light and audible alarm register on the DMS level 3, engine shutdown
will occur with a loss of compressor oil pressure.
3.2.7 Single Stage Rotary Screw Compressor
During the machine run mode the compressor oil temperatures should be maintained at a min-
imum of 37.7° C (100° F) above the ambient condition. Operators should be aware of compres-
sor operating temperatures. A sensor on the compressor discharge elbow allows visual reference
to compressor temperatures.

It is common to see low pressure compressor temperatures operate between 82° - 98.8° C (180 °-
210° F) during the loaded drilling cycle. Operating the machine in extreme ambient conditions may
require special cooling system components and it may be necessary to:
• Upgrade the fluid viscosity using either iso 32 or iso 46 grades.
• Upgrade compressor thermal valve temperature values.
• Change the cooling fan system parameters by slowing or increasing the fan rpm.
• Restrict air flow over the oil cooler with a cooler curtain.
Low pressure compressed air is made available from a matched set of rotating rotor assemblies.
Radial and thrust bearings in a stator housing support one male and one female rotor.
Output from the air end is dependant upon rotor and stator diameter, length, gear ratio, driven
speed and oil lubrication.
As the rotors turn, filtered air is directed into the

inlet cavity at rotor ends as the inlet cycle.
Air flow passes between the rotors and stator
housing in the compression cycle. single stage air end
Compression develops heat, so oil is injected into

the stator housing to compress and cool the air
molecules as the oil injection cycle.
Compressed air and oil are discharged to the out-

let port through a discharge check valve as the
discharge cycle.
COURTESY OF SULLAIR CORP
All compressors produce condensation when operating. Environmental conditions such as humidity
and rain may increase water retention. Manually draining this condensed water from the receiver
tank and managing stable operating temperatures will minimize water contamination and extend oil
life.
Water is an enemy of compressor oil and bearings. Water mixed with the oil is a contaminant that
makes oil cloudy or discolored. Water in the oil can also produce foam which may hinder oil move-
ment through the oil cooler and result increased oil temperature. When the compressor is not oper-
ating, water can develop rust and initiate bearing failure.

3.2.7a Removing Condensation From Contaminated Oil:
There are two ways to remove water the from receiver tank.
A. Level the machine. Stop machine and allow the system to rest a minimum of 30 minutes. Longer
periods are preferred. DAILY, remove the drain plug and open the ball valve connected to the bot-
tom of the receiver tank to remove condensation.
B. Maintain a constant compressor oil temperature greater than 100° C (212° F) and turn the work-
ing air on to blow air to atmosphere.
When oil sampling is administered ask the lab to provide a Carl Fisher water test to verify water
content in the oil sample. The Carl Fisher water test details water content in ppm. Less than 500
ppm water is desired.
3.2.7b New Air Ends
New and remanufactured air end units are available from your Sandvik regional office. You will
need to verify the machine model and serial number when ordering for machine specific compres-
sor specifications.
During the warranty period, all air ends or compressors must be handled through standard war-
ranty.
3.2.8 Discharge Check Valve
The discharge check valve is mounted on the compressor outlet flange with a discharge elbow and
hose connection to the reservoir.
Discharge check valves stop oil in the receiver

tank return hose from settling back into the
compressor after the machine is shutdown.
Discharge check valves are one way flow

valves allowing free flow oil out of the com- sullair discharge check valve
pressor housing to the discharge hose with hot
air and oil returning to the air receiver tank
under pressure.
Note that air pressure may be as high as 9.7

bar (140 psi) with oil temperatures capable of
110° C (230° F).
A failled discharge check valve allows fluctuating oil levels, oil collection on air filter elements, and
may enable the compressor to reverse run after machine shutdown.

3.2.9 Cold Oil Circulation

3.2.10 Oil Cooling
The compressor oil cooling manifold, located near the oil filter, has two thermal valves and bypass
valves. The manifold also contains test ports for measuring pressure drops as needed.
Cold oil thermal valves bypass the cooler

and allow oil to circulate from tank to filter. TWO THERMAL VALVES AND TWO
BYPASS VALVES
As oil temperature reaches 62° C (145° F)
thermal valves begin to shift restricting
FILTER
flow. 184°F 184°F
Through the temperature range, oil begins FC

a flow path to the oil cooler.
Both thermal valves extend approximately

15 mm (5/8 inch).
As the oil temperature reaches 82° C (184° ART

TC
F) the thermal valve button seals the port
forces the hot oil to the cooler. ART = air receiver tank
TC = to oil cooler
005167-003 thermal valve uses one seal FC = from oil cooler
FIL = schroeder KZ25 micron filters
ring per thermostat.
In cold ambient conditions, when cold oil or fluid viscosity is high during the start cycle, two 3.5 bar
(50 psi) valves can open to allow free flow cold oil 4 flow paths to the filter assembly and single
stage compressor.
The cooling manifold with sample test port

COMPRESSOR OIL FILTER
shown.
In some applications this manifold may be

rotated 90° using the same hose routing.
TEST PORT
3.2.11 Oil Cooler
Oil coolers are high quality aluminum header and turbulator tube design. Pressure in the cooler is
dependant upon the regulated system pressure. When testing oil cooler pressures the gauge read-
ings will register same as receiver tank pressure 4 to 7.9 bar (60 psi up to 110 psi). Dependent on
air regulator settings, the air receiver tank may see as much as 140 psi (9.7 bar).
As mentioned above, flow to the oil cooler is dependant upon the position of the thermal valves, oil
temperature, oil viscosity, and bypass valve status.

Shown is an AKG high ambient cooler

assembly.
The compressor section rated for 350 psi (24

bar).
COMPRESSOR
SECTION
It may become necessary during cold ambient operating conditions to cover the entire cooler cores
with a curtain. A cooler curtain will restrict external cold airflow through the oil cooler which will
assist in heat generation and initiate oil circulation through the internal turbulator tubes therefore
decreasing oil cooler pressure drops.
Expected oil cooler pressure drop can be measured from the cooling manifold test port. This differ-
ential pressure drop through the oil cooler can be read as:
• less than 0.3 to 1 bar (5 to 15 psi) hot oil passing through cooler.
• less than 1 to 2.4 bar (15 to 35 psi) warm oil partial oil passing through cooler.
• above 2.4 to 3.4 bar (35 to 50 psi) cold oil and cold air movement no oil passing through cooler.
Expected oil temperature drop, measured as differential temperature drop through the oil cooler.
• - 6° to + 4.4° C (20° to 40° F)

3.2.12 Hot Oil Circulation

3.3 AIR COMPRESSOR LUBRICANT RECOMMENDATIONS
Sandvik Mining and Construction encourages the user to participate in an oil analysis program with
the oil supplier. This could result in an oil change interval differing from what is stated in these
tables.
NOTE!
Mixing synthetic oils with a mineral base oil may lead to operational problems, foaming, or plugging
of orifices. Do not mix different types of fluids.
AMBIENT CHANGE LUBRICANT

ISO
TEMPERATURE INTERVAL DESCRIPTION
-40°F to +95°F (-40°C to +35°C) 1000 Hours 32 Mobil SHC-624, 924 & 1024
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Mobil Rarus 424
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron HiPerSYN
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Chevron Tegra Synthetic
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Factory Fill Shell Corena AW32
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Royco 432
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Conoco Syncon R&O
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Texaco Cetus PAO
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Valvoline Syn Guard CP
-40°F to +100°F (-40°C to +38°C) 1000 Hours 32 Petro-Canada Super SCF32
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Chevron HiPerSYN
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Citgo CompressorGuard
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Conoco Syncon R&O
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Petro-Canada Super SCF46
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Royco 446
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Texaco Cetus PAO
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Valvoline Syn Guard CP
+30°F to +100°F (-1°C to +38°C) 1000 Hours 46 Mobil Rarus 425
+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Conoco Syncon R&O
+80°F to +120°F (+27°C to +49°C) 1000 Hours 68 Mobil SHC-626, 926 & 1026
Oil Change
Changing fluid brands or manufacture from factory fill Shell Corena to a local supplier requires user
to drain and flush fluid from reservoir, hoses, cooler. New main oil filter and separator element are
recommended.

4. Compressor Maintenance

4.1 COMPRESSOR MAINTENANCE

Refer to the machine specific Maintenance Manual regarding recommended service inter-
vals.
This section describes oil change and separator element maintenance.
! DANGER
Allow a minimum of 2 minutes after machine shutdown and note receiver tank pressure is
0 on gauge before starting compressor maintenance.
4.2 OIL CHANGE

The following procedure was written for low and high pressure compressors and should be used:
• When a total system cleaning is necessary.
• Severe duty applications.
• Changing brand name, type or viscosity of compressor fluids.
Sandvik rotary drilling machines are shipped from the Alachua factory with Shell Corena AW32 in
the compressor system.
In certain areas of the world, this oil may not be available. If this is the case it will be necessary to
change to the local available oil. When this occurs it is mandatory to clean the system of the original
oil.
Mixing of two different oils can cause operational problems:
• Oil Foaming, big air bubbles can cause cavitation on components and make air pockets in the
oil cooler restricting oil flow.
• Overheating, compressor fluids not flowing through the oil cooler will not dissipate heat.
• Excessive Oil Carry Over through the separator element wasting the oil down the drill pipe.
These problems can be reduced or will be non-existent when following the prescribed procedure.

4.2.1 Oil Change Procedure
Before changing brand name oil, refer to recommended oil list. Contact your Sandvik Mining and
Construction Region Office with the specifications of the oil to be used if local oil is not on recom-
mended list. This step is to determine if the oil is correct for the specified compressor.
4.2.1a Draining Oil
Depending on the ambient temperature, it may be necessary to start the machine and warm the
compressor prior to changing fluid.
1. Once compressor oil is warm, shut off the machine and remove the key from key switch.
2. Utilize 2 clean 208 liter (55 U.S.gallon) containers.
3. Connect a hose to the drain valve located on the bottom of the air/oil receiver tank.
4. Open the ball valve to drain compressor oil into the containers. Follow applicable laws pre-
scribed for waste oil recovery.
CAUTION
Starting the engine when the compressor oil has been drained will damage the
compressor. Do not allow the engine to start! Lock-Out and Tag-Out!
5. Apply the emergency stop switches to disable engine starting.
6. Place the key into the key switch, engage a emergency stop button and roll the engine and
compressor over two (2) or three (3) times. This will push out any residual oil that was left in
compressor into receiver tank for manual draining.
7. Remove top and bottom hose from compressor oil cooler to enable oil to drain out of the cooler.
8. Remove the separator filter. Replacing the separator element is dependent on service hour
interval. When in doubt or service hours are unknown, replace the separator element.
9. Remove scavenge return line and allow to drain, remove and clean strainer screen, replace
screen and tighten.
10. Remove the main compressor filters. The filter canister may be unthreaded from the housing in
order to drain oil from filter canister.
11. Remove and drain the pilot hose at the oil stop valve.
12. Remove all oil cooler and tank lines from compressor to drain any oil that may have been left in
system.
13. Remove intake piping at compressor inlet.
New flange O-rings will be needed for connecting hose ends that have been removed for this pro-
cedure.

4.2.1b Adding Oil

1. Pour some new clean compressor oil into the top of the oil cooler permitting it to push any of the
existing oil from cooler. Once new oil is coming through oil cooler, attach the top cooler hose.
2. Pour some new clean compressor oil into the intake of the compressor to flush out any original
oil.
3. When applicable install the discharge check valve and all hoses that were removed.
4. Pour some oil into the receiver tank to push out any existing oil.
5. Close the drain valve.
6. Install separator filter, with a new gasket, do not remove the static staple that is clipped in the
separator gasket. No additional sealants are necessary.
7. Mount the receiver tank cover, torque bolts to spec.
8. For low pressure applications install the scavenge return tube and tighten adapters.
9. Connect scavenge return hose to appropriate ports.
10. Install compressor filters making sure the plastic connection piece is installed between the two
Schroeder KZ25 series filter elements.
11. Connect pilot hose to the oil stop valve.
12. Fill air receiver tank with new clean oil to the required level sight glass port, install the fill plug
and tighten.
13. Engage emergency stop button, roll over engine and compressor and check for any leaks. If
evident, repair prior to starting the machine.
14. Start engine and run at low idle and check for any leaks.
15. Permit compressor to run until compressor temperature comes to operating temperature.
Approximately 160° to 200°F (71° to 93° C).
16. Shut machine down and let set for 15-20 minutes and recheck compressor oil level.
17. Add oil as needed to the proper fluid level sight glass.
18. After several hours of operation and if a foaming problem exists, you may need to drain the oil
from the separator tank and refill.
Oil may be transferred from air receiver tank to clean drums using a portable filtration cart as
shown. If the oil still has service life use the filtration cart to transfer clean oil back to the air receiver
tank.

Portable filtration cart:
Sandvik p/n 023912-001
4.3 Air Receiver Reservoir Separator Maintenance
Routine maintenance of air receiver reservoirs requires a skilled maintenance person with knowl-
edge of compressed air systems, using safe maintenance principals and clean work habits to mini-
mize contamination entry into the system.
There are different reservoirs for high pressure and low pressure compressors. Therefore, the max-
imum pressure ratings and operating temperature specifications will differ.
4.3.1 Reservoir Certification
Pressure vessels such as compressor receiver tanks may require local periodic inspections and
recertification. This inspection and/or recertification may only be performed with a qualified test pro-
cedure by a qualified engineer.
Due to the complexity of such laws worldwide Sandvik asks that the customer bare this responsibil-
ity as a company standard operating procedure.
In the event of reservoir damage Sandvik recommends total replacement vs repair.
If the damage is minimal; repair may be performed by a certified welder qualified in pressure vessel
repair and recertified by a local pressure vessel engineering facility.
Sandvik Alachua holds the machine specific air reservoir certification document.
4.3.2 Static Discharge
Compressor oil under heat from compression, and velocity may develop static electricity inside the
air receiver tank during operating conditions. All models of Sandvik rotary drill machines will use a
static discharge spring or staple. This device makes a secure electrical ground for the separator fil-
ter element.

• High pressure applications require a spring installed on the bottom end filter holddown bolt.
Refer to product support bulletin
• Low pressure applications require a static staple installed on the sealing gasket for the top
cover.
! DANGER
Contained static electricity may have the capacity to ignite oil and cause the compressor
to flash. A machine fire can occur when static spring or staples are removed !
Refer to Sandvik Service Bulletin SB284 concerning reservoir grounding.
DR460 low pressure application.
Remove scavenge hose and tube prior to

separator maintenance.
Clean cover and tank seal surface.
Place new gaskets with static staples below

and above new separator element.
Cover bolts 3/4 x 10 UNC grade 8

Torque 200 ft lb (271 Nm).
Replace scavenge tube and hose after reser-

voir cover is secured in place.
Do not use a gasket sealant on the reservoir or cover surfaces as this may hinder proper ele-
ment grounding.

5. Air System Regulation

5.1 COMPRESSOR CONTROL

The following component descriptions applicable to DR460 low pressure air control systems
with single Sullair poppet inlet valves.
! DANGER
Allow a minimum of 2 minutes after machine shutdown and note receiver
tank pressure is 0 on gauge before starting compressor maintenance.
5.2 AIR CONTROL COMPONENT DESCRIPTIONS

The components used in a DR460 low pressure compressor system are detailed in Table 1.
Table 1: Air Control Components
DESCRIPTION COMPONENT
Poppet valves are piston type inlet valves with two cavities. One cavity
to ‘load’ referenced as P2 and one cavity to ‘unload’ referenced as P1.
P1 port is with compressor oil to lubricate the piston O-ring. The poppet
valve assembly has two ports exposed to vacuum.
A pressure reducing valve enables air supply for inlet valve opening
(loading) conditions. Some air passes this valve at all times during
machine operation.
PRV is adjustable: it can be calibrated with standard hand tools and
shop air.

Table 1: Air Control Components
DESCRIPTION COMPONENT
A subtractive pilot valve enables air supply for inlet valve closing
(unload) conditions. This valve remains closed until receiver air pres-
sure reaches the preset value.
SPV is adjustable: it can be calibrated with standard hand tools and
shop air.
Compressor bypass solenoid is engaged at start up mode to direct

receiver air pressure to close the poppet inlet valve. This feature
reduces compressor load and engine horsepower requirements during
start cycle.
Anti-rumble valve (running blowdown in other applications) is normally

closed without pilot. With pilot receiver air opens to compressor inlet
recirculating air when poppet valve is closed. This function serves to
protect the compressor during unload conditions.
Without this valve function and a closed inlet valve the compressor
bearings would cavitate thus a rumble noise would be noticed. Contin-
ued run in this condition would fail the compressors bearings.
Compressor blowdown valve coil receives electric input from a engine

oil pressure switch. Air receiver tank pressure is closed to atmosphere.
The valve opens at machine shutdown to empty the air receiver tank, as
air vents to atmosphere it is silenced with a muffler mounted to the valve
outlet port.
Ensure the vent muffler is clean of mud, oil residue and rock dust. A
restricted muffler creates back pressure inside the air receiver tank.
Allow approximately two minutes for the air pressure in the receiver tank
to empty to atmosphere after shutdown.

5.3 AIR SYSTEM REGULATION

The following component descriptions are applicable to DR460 low pressure air control systems
with single Sullair poppet inlet valves used for rotary drill applications.
This air system is standard low pressure application, applicable for all Sandvik rotary drill equip-
ment. The DR460 version components remain the same with some variations with component loca-
tions.
FIGURE 1
BASIC SCHEMATIC
Figure 1 schematic illustrates the valves shown in normal condition for all air regulating compo-
nents. This closed inlet valve air control system is in an ‘unload’ condition.

5.4.1 Air Control Valves
V1
The poppet inlet valve is closed for start
up and no load conditions (not drilling)
PILOT AIR (P1)
The P1 cavity holds compressor oil to
lubricate piston O-ring.
The poppet inlet control valves should be
serviced during 250 hour maintenance
procedures with no more than 355 ml (0.75
US pint) clean compressor oil.
P2
V2
V1
The poppet inlet valve opens, loading
the compressor during drilling condi-
tion.
P2 PILOT
AIR
V2
The subtractive pilot valve is normally closed

vented to atmosphere, passing air above calibrated
value. A reduced air pressure gets directed to pop-
pet valves P1 port to unload compressor.

The subtractive pilot valve is set with shop air.
6.9 bar (100 psi) ‘in’ 3.4 bar (50 psi) ‘out’ as
shown.
The pressure reducing valve is normally open,

passing air continually. Reduced air pressure gets
directed to poppet valves P1 or P2 port according
to compressor bypass solenoid position.
P1 port to unload compressor at start up.
P2 port to load compressor during drill modes.
For best results make pressure adjustments with an external air source. Use shop or service truck
supply air as long as the supply pressure is above desired subtractive pilot valve requirement.
The pressure reducing valve is set with shop

air.
6.9 bar (100 psi) ‘in’ 3.8 bar (55 psi) ‘out’ as
shown.
Calibration of either regulator:
• Attach supply air to the valve inlet port with 20 bar (300 psi) pressure gauge
• Attach a 10 bar (150 psi) pressure gauge to the outlet port. The outlet side has to be in a ‘dead
head’ pressure condition
• Utilize shop air to simulate machine spec maximum receiver tank pressure

! WARNING
Utilize all safe operating principals when servicing air regulation parts. Discharge
any un-used air from hoses or adapter ports prior to component removal.
RESERVOIR
PILOT
SIGNAL
POPPET V1 PORT
An anti-rumble valve (running blowdown valve) is supplied as normally closed. The piston end
requires a separate pilot signal to open the piston to allow vent air from the inlet to outlet port.
During machine ‘run’ mode, the anti-rumble valve is spring set closed until a pilot signal is received
at the valves pilot port. Pressure reducing valve and load solenoid air serves as pilot signal to open
the anti rumble valve. Compressed air recirculates from the receiver tank to the poppet inlet control
valve (V1) vacuum port, minimizing rotor rattle when the poppet valve is closed.
Maintenance of this valve is limited to internal seals and O-rings, no adjustments are required.
The compressor blowdown valve CBV is nor-

mally open to atmospheric conditions.
Input command is based on program parame-

ters noted in the schematic details.
Maintenance of this valve is limited to electrical connections, internal seals and orings, no adjust-
ments required.

FIGURE 2
CRANKING MODE 1
Cranking mode 1
Crank mode 1 is defined as 0 - 650 engine rpm.
• Operator engages bypass switch for machine start

• Compressor bypass valve energized
The poppet valve opens 10% with compressor rotation. Reservoir air passes through the pressure
reducing valve and energized bypass solenoid. Air along with oil and spring force in the P1 cavity
minimize poppet valve opening during engine cranking 0 - 650 RPM range. Compressor blowdown
valve with coil power closes reservoir air vent to atmosphere.
The expected air pressure for start-up mode is 15 to 20 psi (1 - 1.4 bar) during cranking with the
bypass solenoid energized. Low air pressure reduces parasitic load for the compressor and engine
load factor during the critical start-up mode. Pressure contained in the air receiver tank pushes
compressor oil through the oil lubrication parts to the single stage air end for bearing and stator
lubrication.
Figure 3 shows cranking mode 2.

FIGURE 3
CRANKING MODE 2
Cranking mode 2
Crank mode 2 is defined as 650 - 1200 engine rpm.
• Operator releases bypass switch

• Compressor bypass valve de-energized
• Compressor blowdown valve energized with > 35 psi (2.4 bar) engine oil pressure
As air receiver pressure raises from 15 - 20 psi (1 - 1.4 bar) up to the 100 psi (6.9 bar) air pressure
passes through the pressure reducing regulator and bypass solenoid increase. The reduced air
pressure directed to the P2 cavity on the poppet valve maintains poppet open for load condition.
Reduced pressure also pilot anti rumble valve to open. The anti rumble valve must be open when
the poppet is in unload position to recirculate air.
A.090 orifice inside P2 port enables restriction for controlled load feature and venting during
unloading compressor.
Figure 4 shows start mode no load not drilling.

FIGURE 4
ENGINE AT LOW IDLE OR HIGH IDLE
NO LOAD
Low idle is defined as engine 1200 rpm.
High idle is defined as engine 1800 rpm.
• Compressor blowdown valve energized with > 35 psi (2.4 bar) engine oil pressure
Receiver air pressure will be 100 psi up to 110 psi (6.9 - 7.6 bar) according to regulator adjusted
values. With poppet valve closed, anti rumble valve piloted open to recirculate air limiting compres-
sor inlet vacuum to 26 inches water.
Figure 5 shows loaded drilling condition with less than 100 psi (6.9 bar).

FIGURE 5
LOADED DRILLING
No load condition is high idle engine 1800 rpm and working air off: inlet vacuum 26”
Loaded condition is high idle engine 1800 rpm and working air on: Inlet vacuum 0”
During the drilling cycle typical air receiver tank

pressure is 60 to 75 psi (4 - 5.2 bar).
Receiver pressures may vary from stated values

due to drill tool utilization, bit orifices and drilling
conditions such as hole depth or back pressure
from water in the hole.
Bit air or flushing air for drilling depends on what

restrictions are in the drill string and what type of
drilling tools are being utilized.
Working air pressure is typically 10 to 20 psi (.7 to

1.4 bar) lower than air receiver tank air pressure.
Figure 6 shows shutdown condition.

FIGURE 6
SHUTDOWN
Engage idle speed switch for low idle 1200 rpm. Receiver tank air pressure is 100 - 110 psi (6.9 -
7.6 bar) with poppet valve closed and anti rumble valve open.
Upon shutdown and loss of engine oil pressure CBV de-energizes and receiver air vents all air
pressure to atmosphere.
Allow approximately two minutes for the air pressure in the air system components and hoses to
empty to atmosphere after shutdown.
Oil stop valve closes to maintain oil in hoses after machine shutdown.
Poppet valve is closed by spring force to stop air/oil mixture from entering into air filtration.

5.4.2 Troubleshooting Single Poppet Valve Inlet Control Systems
Low pressure compressor systems that require field mechanical adjustments most often have
either been tampered with or have worn components.
Pressure reducing valve:
When calibrating a pressure reducing valve small turns on the set screw change the outlet air pres-
sure. Turning the set screw in will increase the outlet supply air value. It may be necessary to mod-
ify the factory pressure reducing valve setting of 55 psi (3.8 bar) to achieve a full piston sequence.
Pressure reducing valve settings will affect vacuum readings.
Vacuum check:
When testing the low pressure poppet intake system it may be necessary to connect a vacuum
gauge to the compressor throat. Components shall include a ball valve, short length of hose and
vacuum gauge. Close the ball valve for machine start-up and shut down modes.
Vacuum readings may differ according to:

• Altitude conditions above sea level
• Climactic conditions
• Compressor condition or wear
• Poppet valve condition or wear
Readings shown base at 360 ft above sea level:

• At start up 20 - 22 hg
• At low engine idle speed no load 24 - 26 hg
• At high engine idle speed no load 28 - 28 hg not drilling
• At high engine idle speed loaded 0 - 2 hg drilling
Check the poppet valve oil level often. When the oil level is low the piston responds slower and
receiver air pressure may overrun the regulated value. If oil levels are continually low, requiring
constant refill a seal may be leaking the oil out of the piston valve chamber. This condition may give
symptoms of air regulation problems as well.
During cold weather conditions ice build-up inside the poppet valve may lead to operational prob-
lems. It may become necessary to install one 022462-001 coalescing filter to the main air line. This
filter is used to remove unwanted condensation that typically collects in the air components.

Drill Bit Restriction
Nozzle size or orifices in the air delivery restrict air flow. Check with drill bit manufactures for appro-
priate nozzle sizes for the mine specific drilling conditions. Some bit designs do not have air flow
restriction.
NOZZEL
SKIRTS
ROLLERS ROTARY CLAW BIT

REPLACEABLE CARBIDE
ROTARY ROLLER BIT BULLET STYLE CUTTERS
MILL TOOTH ROLLERS AND LARGE FLUSHING HOLE
CARBIDE BUTTON ROLLERS
Optimum air flushing during the drilling cycle shall be greater than 4000 fpm and up to 9000 fpm of
uphole velocity.
High bailing velocity or flushing leads to excess wear on drill tools while in the hole. Drill bit skirts,
roller sections, bit subs and lower sections of drill pipe may become sandblasted by abrasive rock
conditions

6. Auxilliary Air Components

6.1 AUXILLIARY AIR COMPONENTS

The following features and optional equipment are available to assist the drilling or maintenance
functions of most of the rotary drill product line:
• Dry Dust Collecting Systems
• Thread Greasing System
• Automatic Lubrication Systems
• Blow Down Cleaning Attachments
• Bit Lubrication System
• Chain Lubrication System**
6.2 DUST CONTROL

Suppressing drilling dust is a necessary part of equipment operator safety. The two available
means for suppressing drill dust are:
• DRY DUST COLLECTING systems by way of seals, curtains, suction fan, filter media, collec-
tion box with a manual drop vent. Dry dust collection systems are one means of suppressing
fine drill dust particles omitted during the drilling cycle.
• WATER INJECTION systems with seals, curtains, various water tank sizes and a water pump
with relief valve.
Daily and when required maintenance for either system is the responsibility of the end user.
There are many sizes and styles of dust collectors used in the drilling industry. The concept of drill
dust control is common throughout.
6.2.1 Dust Collector
Dust collection systems have to be tuned and adjusted for the ground conditions and material being
drilled. Certain applications require special attention to customize the dust collecting components
and one size dust collector will not fit all applications.
Stand alone dust collector fitted to left side frame.
dustoptions.tif
Dust collectors for rotary drill machines are Drilplex or Tipton models with 6, 8 or 9 filter elements.

Open door panels to access filter elements.
Dust filters must have a good seal to the housing. Each

filter must be hand tightened with a sealed wing nut.
A loose filter, bad filter seal or damaged filter element

will emit dust out the fan housing. Dust blow-by will
damage the dust collector fan and fan housings.
Maintain good door seals. Tighten each door to main-

tain adequate vacuum inside the dust collector.
The filter elements are purged with reduced air pressure from the machines air system.
NOTE!
The dust collector air regulator may be backed out to zero air pressure for transportation purpose.
Open the ball valve and adjust the regulator prior to drilling and collecting dust.
The dust collector regulator is set to 3.5 bar (50 psi).

This regulator also contains a coalescing filter inside
the bowl to separate condensation from air. The filter
can be washed as needed.
LP APPLICATION
Adjustment control may be set and locked to position. REGULATOR
x
DCT
Shown is the dust control filter element flushing

schematic:
50 A
Regulated air is directed to flushing valves and PSI
electric solenoids inside the dust collector. F
A
Filter flushing is based on program parameters 90
and a timer on/off sequence. Electric power to PSI F
the solenoids is a timed system by means of a
A
circuit board.
F
)(

Flushing valve repair kits are available. SOLENOID

VALVES
Maintain good door seals. Tighten each door to
maintain adequate vacuum inside the dust collec-
tor.
FLUSHING
VALVES
The timer circuit board is located inside the sealed junction box.
The timer distributes an ‘off time’ and ‘on time’ sequence

to one filter at a time.
• Adjust ‘on’ time to enable a quick burst of air to the

dust filter. The ‘on’ time should be 300 ms.
• Adjust the ‘off’ time according to material collected.
Typical setting is 6 seconds off time.
The circuit board powers one solenoid and LED per

flushing valve. The LED illuminates to indicate when it
receives a on cycle.
Maintain good door seals on the junction box. Tighten

the door to minimize dust and water entry.
Reference machine specific electrical schematic

034666-000
A hydraulic motor and fan produce a vacuum inside the dust collector housing. The motor speed is
partially responsible to manage dust control.

Oil supply to the motor is unrestricted. Adjustment of flow con- FLOW CONTROL
trol may be adjusted to drain oil flow and limit motor speed. VALVE
Fan speed should not exceed 3000 rpm, measured at the fan
exhaust port.
Faster fan speeds may overload the filters and not let the fil-
ters clean adequately.
Adjust the speed according to ground material.
Turn the dust collector fan off between rod changes. Because filter purging continues after the fan
is off, the best filter cleaning occurs when the fan is not turning.
6.2.2 Dust Hood
Cylinder actuated dust hoods and dust hood doors allow adequate seals for dust suppression
under most drilling conditions.
Depending on the application, dust skirts may need to be modified.
It may be necessary to use two dust skirts and overlap them at the corners to enable a relief for drill
cutting accumulation.
Dust curtains and drill pipe seals must be maintained

for efficient dust control.
The dust curtain must touch the ground to properly

contain dust and drill cuttings.
Angle drilling may require additional curtain lengths.
Operators use a cab chair control push button to turn the dust collector or water injection systems
on. Additional controls allow dust hood travel and dust hood door options.

The right operator panel shown offers dust collector/

water injection control switch.
Choose dry dust control or wet water injection.
The left operator panel offers two joystick controls for

dust hood travel and dust hood door actuation.
The drill dust collecting system; fan motor speed, air pressurization, and electrical timed pulse set-
tings are detailed in service literature 007702-000.
6.3 THREAD GREASING SYSTEM

The old method of operators applying thread grease to the drill pipe with a brush still exists and in
some cases may be best option.
This machine allows the operator to remain in the operator cab and still apply thread grease the drill
pipe. Drill pipe thread grease can be pumped by air actuation through a hose and adapters onto the
drill pipe thread box or pin ends.
Brand name thread grease:
• Texaco Threadtex
• Kopper Koat by Jet lube
• J89 by Jet lube

• Sandvik Copper - Part Number 024178-003
Metered air directs thread grease to drill pipe threads POSITION GREASE NOZZLE
near the table bushing. TO DRILL PIPE THREAD

Add thread grease to the container, position the follower

plate and pump into the grease and secure the container
cover. ckthrgrsr.tif
Reference machine specific electrical schematic 034666-

000
Adjustable flow control valves at this pump, meter regulated air pressure to the grease pump and to
the injector nozzle located near the table bushing.
Lock the flow control valve position.
Regulated air pressure for this pump is between 2.7 bar (40 psi).
x
Shown is the thread grease system sche-
matic:
Regulated air is directed to solenoid valve

waiting input from operator. 40
PSI
Adjust the flow control valves to meter grease
flow through nozzle.
)(
)(
)(
AIR FLOW CONTROL
Maintenance for the thread grease system is limited to grease capacity and flow control adjust-
ments.
Operator controls the thread grease application with cab joystick.

Left operator panel feed joystick top push button

controls thread grease.
6.4 Bit Lubrication System
Bit lubrication injects oil into the working air. Low pressure application machines may be fitted with
2 sizes of reservoirs holding 38 liter (10 gallon) or 114 liter (30 gallon) of special lubricant oil
referred to as rock drill oil.
When selecting an oil to lubricate bit bearings it is recommended to consider the following;
• Ambient Condition
• Operating Temperature
The lubrication cycle may be adjusted for oil quantity or flow and a timed cycle to inject. Oil is
injected into the air system after the service valve.
Service literature 011362-000 details the adjust-

ments available to operator and mechanical per- FILTER AND
sonnel. Tune the oil injection rate to provide a fine SOLENOID
mist or a slight visual film of oil inside the drill pipe RDOregulation.tif
or drill bit rollers.
With the machine running, the lubricator air regula-

tion system should be stable at 2.7 bar (40 psi).

034666-000 PUMP
REGULATOR
Factory setting on the pump flow control valve is 10 turns out or 1/2 piston volume.
Lubricator timers have adjustable ‘on’ and ‘off’ time cycles. Timer relays are located in the lubricator
junction box or cab panel.
• ON cycle is the duration of time regulated air pressure is directed to the lube pump and should
be set for 2 second intervals
• OFF cycle is the time between oil injecting and should be set for 6 to 10 second intervals

Bit lubrication schematic:

60
PSI
5u LTR
LS
Check the oil level in the tank daily. Use sealed and approved clean containers for transporting rock
drill oils.
Contaminants inside the lubricator tank may block oil flow to the lubricator pump supply port.
Lubricator Pump 011353-000 Service Manual literature details the pump service procedures.
NOTE!
Allow adequate pump chamber fill time for the viscosity of rock drill oil being used.
Fast pump cycle times will not allow some grades of rock drill oil (due to viscosity and temperature)
to completely fill the pump chamber.
Too fast cycle times will overload the piston springs. Spring breakage may occur which will lead to
loss of oil flow to the drill bit.
During normal operating, rock drill oil will be visual inside the drill pipe connections. It is normal to
use 0.95 liter (1 quart) per hour of oil during the drilling cycle.
6.5 Automatic Grease System
The automatic greasing system delivers NLGI series grade 1 or 2 grease to pivoting components
on the machine.
The three greasing system options are: manual, at central points or manifolds, electric or program-
able. With all options maintenance is required to assure grease is received at all points.
All point lubrication grease systems are available to lubricate cylinder pins, bushings, and rotating
bearings for sprockets.
In all options stated manual grease points still exist. Points that are not lubricated by the automatic
system are:

• Rotating Drive Shaft Yoke and U-joint Assemblies
• Feed System Traveling Carrier Sprockets
• Air Swivel Joint On Rotary Head Air Piping
Automatic grease system components may differ

from shown.
4
1 Air regulator 3
autogreaseparts.tif
2
2 Water filter
1
3 Lubricator
4 Solenoid
Depending on the compressor application the items shown here may be configured slightly differ-
ently.
The grease pump requires air line lubricant and reduced air pressure. A solenoid will open air to the
grease pump from either the electric timer or the program module.
Service literature 006113-000 details grease system

components.
Electrical power is 24 VDC and may be calibrated to

inject grease on a preset timed interval.

034666-000

x
(HP)
(LP)
40
PSI
Automatic grease system schematic:
Open the water separator drain tap daily to

empty condensation.
It is recommended to fill the lubricator bowl daily

with a quality air line lubricant, SAE 10w or an
equivalent air line lubrication oil.
)( LT
LS
6.6 Chain Lubrication System
Chain manufacturers prefer to lubricate moving chain sections with a periodic low volume concen-
tration of chain lubricant.
The chain lubricant can be petroleum based, engine, machine or chain oil proper for the ambient
operating condition. Synthetic oil may be utilized in sever operating conditions.
In normal conditions a SAE 20 to SAE 40 weight lubricant is sufficient.
Daily inspection of oil capacity is a must to assure lube pump does not draw air and loose prime.
Fill the reservoir as needed based on oil consumption.
Regulated air supply with two solenoids.
One LAS lube air solenoid used to supply air for chain
flushing or cleaning.
One LOS lube oil solenoid used in conjunction with LAS to

supply regulated air to the pump for oil disbursement,
along with air supply from LAS.
Reference machine specific electrical schematic 034666-

000.

Chain lube reservoir assembly 023192 con-

sists of: PUMP
Reservoir
REGULATED AIR
SUPPLY
Pneumatic pump
2 each solenoid valves SOLENOIDS
Air regulation
Flow control valve
Immersion heater
IMERSION
HEATER
Chain lubrication systems are air activated with reduced air pressure from the reservoir. Expected
air pressure shall be 40 psi 92.7 bar) to operate the pump.
Four nozzles positioned in the mast are pointed toward pull-down and hoist chains to spray lubri-
cant according to selected command.
Operators control the chain lube cycles by a cab mounted double throw toggle switch.
Chain lube group 023182 shown.
The feed system must be free to travel full travel up and down the mast to perform proper chain
maintenance.

Control the toggle switch to air mode while operating feed full travel. This cycle pre-cleans the
chains with compressed air.
Control the toggle switch to oil mode while operating feed full travel. This cycle lubricates the chains
with oil.
Operate the toggle switch to air mode while operating feed full travel. This cycle purges oil from the
mast hoses.
6.7 Air Line Filtration
Arctic and cold ambient conditions may require air line filtration to separate condensation moisture
in the air supply lines.
Coalescing filter spare part number 022462-001 may be connected in line for any of the mentioned
air regulated components.

7. Compressor Troubleshooting

7.1 TROUBLESHOOTING LOW PRESSURE COMPRESSOR SYSTEMS
SYMPTOM PROBABLE CAUSE ACTION

Machine shuts down with air demand Air end low oil pressure and/or high Check bearing manifold pressure
present air/oil temperature switch may be and air/oil discharge temperature.
defective
Check low oil pressure shut down
switch on lube manifold
Airflow through oil cooler insufficient Check fan RPM, system pressure
and air flow across cooler
Low oil level in receiver tank Check center sight gauge on receiver
tank and see if oil level is in correct
Dirty oil filters, restriction generates Change main oil filters

light
Incorrect oil for ambient condition
Faulty thermostats Remove thermostats and check,

replace as needed
Faulty safety shut down circuit Check shut down switches
Cooler by-pass valves open Remove and check by-pass valves,

replace as needed
Machine will not build up full dis- Check service lines for external air
charge pressure leaks, open valves and/or bad hoses
in control circuit including dust collec-
tor systems
Dirty air filter Check air intake filters, change if

needed
Pressure reducing regulator Check pressure regulator dia-

phragm(s) for damage, repair and
adjust if needed
Defective pressure reducing regula- Repair or replace regulator

tor
Faulty minimum pressure valve Remove and inspect minimum pres-
sure valve for piston movement,
check seal and repair as needed
Shutdown/Running blow down valve Remove, inspect and repair as

needed
Air demand greater then supply Compressor not sized correctly for
drill application
Check bit dimension vs pipe dimen-

sion
Poppet inlet valve Test inlet vacuum
Ice build up in control signal hoses,

install a 022462-001 coalescing filter

Improper unloading with excess Pressure regulator(s) Check pressure regulator(s) setting.
pressure buildup causing tank safety Repair or adjust as needed
relief valve to open
Poppet inlet control Incorrect setting of pressure reducing
valve
Compressor blowdown valve Check input power to compressor

blowdown valve
Momentary remove electric connec-

tor to compressor blowdown valve
Insufficient air delivery Intake filter Check filter and change as needed
Separator filter Plugged air/oil separator, change as

needed
Pressure reducing regulator Check, adjust or replace as needed
Engine Check high idle speed
Poppet Inlet valve Test inlet vacuum
Compressor blowdown valve Check, clean, rebuild as needed
Control line Check for plugged, loose or leaking

control line(s), condensation freeze
up
Inline check valve Inspect check valve, repair as

needed
Air pipe restrictions, rust develop- Clean air pipe with abrasive projectile
ment inside mast air piping as needed
Excess oil consumption Separator element Plugged scavenge line strainer or

fixed orifice
Damaged separator element
Oil Incorrect oil
Foaming of oil
Oil level too high
Contaminated oil, drain, flush and

refill complete system per procedure

Compressor overheating Oil cooler External surface dirty
Plugged or partially plugged with dirt

build-up
Weather Oil jelling in cooler due to cold

weather conditions.
Cooler may need covered or a oil vis-
cosity correction for the ambient con-
ditions
Thermostats Broken thermostats remove and

replace as needed
Incorrect temperature rating for

ambient condition
Wear on thermal manifold seat
Worn valve, replace as needed
Oil Low sump oil level
Incorrect oil for ambient condition
Oil contaminated with water or other

matter
Mixing of two different oils
Cooling fan Low fan speed, check RPM
Low fan system pressure
Fan pump oil flow to fan motor low
Bad fan motor
Fan blade wear
Engine RPM low, check rpm is to

spec
Fan direction turns CCW acting as a

“sucker”
Fan shrouding on cooler letting air

around fan blade slip
Faulty hydraulic hoses from fan

pump to fan motor
Faulty oil stop valve
Compressor Restriction in bearing injection lines
Collapsed hose or restriction in oil

cooling hosing

Compressor system will not load Control circuit electrics load solenoid Defective solenoid valve or dirt in
control valves
Defective load command
Defective wiring from switch to sole-

noid
Pressure reducing valve adjustment
Defective poppet inlet control, regu-

lator adjustment
Compressor oil dumps out air filter Improper shutdown procedure Machine shutting down at high idle
during shutdown RPM during loaded drilling condition
Compressor components Faulty oil stop valve
Faulty discharge check valve
Excessive foaming oil
Oil level in sump over full

8. Service and Repair Literature

8.1 SERVICE and REPAIR LITERATURE

The table below references service materials found in Sandvik rotary drill Service and Repair man-
uals for high pressure and low pressure air systems. When component adjustments, overhaul or
repairs are needed it is advisable to use service procedures.
Machine specific service procedures are supplied to original equipment purchasers.
Not all service procedures will be made available to end users for a specific machine. Only those
procedures that apply to said machine will be available in end users manual.
This section may be updated as new procedures are written.
Table 1: Service Procedures
DESCRIPTION P/N
Air Cleaner 001036-000
LP Air End Shaft Seal Instructions 001044-173
Swivel Seal Housing Packing 001111-000
Air Piping Swivel (Chiksan) 001217-000
Air Piping Swivel (Dover) 001217-001
Hydraulic Tank Pressurization 001658-000
Pressure Relief Vent 001670-002
HP Air End Shaft Seal Instructions 001958-121
Air Filter/regulator Instructions 002428-000
Side Mount Swivel (CRS) Instructions 003751-000
Air Inlet Valve Adjustment 004320-000
Hydraulic Tank Pressurization 004756-000
Centralized Lube Systems 006113-000
Centralized Lube Systems 006113-010
Air Cleaner Engine/compressor 006307-000
Compressor Clutch Assembly 006477-000
Dust Collector Service 007702-000
Taperlock Bushing Installation 008674-000
Air Inlet Valve Adjustment 010119-000
Dust Collector Service (Tipton) 010756-101
Centralized Lubrication 011060-000
DTH Lube Oil Pump Instructions 011353-000
Lube Oil Injection Instructions 011362-000

Table 1: Service Procedures
DESCRIPTION P/N
LP Air End Shaft Seal Instructions 012457-000
DMS Instructions/troubleshooting 015702-000
Connector Expansion Instructions 017144-000
Air End Shaft Seal Instruction 017239-000
Turn Valve Assembly 90 Series 019602-052
Dust Collector Service (Qmp) 020247-000
Dual Poppet Inlet Valves 90 Series 020845-001
Drill Monitor System DMS 020965-000
DMS Dip Switch Chart 021531-001
Cooler Assembly 021740-000
Variable Speed Control 023260-01A

460LP Air Bk1

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COMPRESSOR TRAINING MANUAL DR460

Copyright © Sandvik Mining and Construction

• Arrange proper tools for the job

• Utilize appropriate PPE personnel protective equipment for the task

• Read material that may be pertinent to the task

• Communicate with co-workers and/or operators of the equipment

It is the responsibility of the individual operator/technician to read and understand the

Copyright © Sandvik Mining and Construction 1

LOW PRESSURE COMPRESSOR SAFETY

• Safety relief valves on air receiver tanks.

• Discharge opening of air hoses and tools.

• Air blowdown or cleaning attachments.

• PPE Personnel protective equipment.

2 Copyright © Sandvik Mining and Construction

HIGH PRESSURE COMPRESSOR SAFETY

• Safety relief valves on air receiver tanks.

• Discharge opening of air hoses and tools.

• Air blowdown or cleaning attachments.

• PPE Personnel protective equipment.

Copyright © Sandvik Mining and Construction 3

1. Low Pressure Air Systems

Copyright © Sandvik Mining and Construction

1.1 LOW PRESSURE AIR SYSTEMS

Compressor oil lubrication and air regu- DR460 OVERVIEW

Auxiliary air options for drilling and non- machineoverview.tif

Table 1: DR460 Engine Horsepower

875 HP (652 kw) C27 1800 RPM

949 HP (708 kw) QSK23 1800 RPM

1000 HP (746 kw) QST30 1800 RPM

Copyright © Sandvik Mining and Construction 1

Table 2: DR460 Air Ends

STANDARD SPEC METRIC SPEC

2000 CFM / 100 PSI 56.6 m³ / 6.9 bar

1450 CFM / 350 PSI 41 m³ / 24 bar

Table 3: Altitude Correction Chart

5000 1500 .82

6000 1800 .79

7000 2100 .76

8000 2400 .73

9000 2700 .70

10000 3000 .68

11000 3400 .65

12000 3700 .63

13000 4000 .60

14000 4300 .58

Use the altitude correction chart:

• For drilling applications above 4000 feet (1200 meters).

2 Copyright © Sandvik Mining and Construction

2000 CFM (56.6 m³) @ 5000 ft (1500 m).

2000 CFM (56.6 m³) @ 11000 ft (3400 m).

1.4 ROTARY DRILLING

1.4.1 Drill Bits

ROTARY CLAW BIT

Copyright © Sandvik Mining and Construction 3

1.5 Air Delivery

Drill cuttings have to exit the drilled hole in order

Annulus is the difference between the drill bit

In general optimum bailing velocity shall be

Insufficient Clearance > 10,000 fpm:

Creates resistance to turn bit generating higher

Creates air flow restriction and easier plugging of

Requires higher feed system operating pres-

Accelerates drill string wear in abrasive rock

Excessive clearance < 5000 fpm: