WATER CIRCUIT

DD320

C 60260--3 en 0507/LH 1 (22)

WATER CIRCUIT

2 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. OPERATION OF CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2. Normal flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3. Double flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4. Pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5. Inspection of pressure switch operation . . . . . . . . . . . . . . . . . . . . . . . . 8
4. MUD SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. WATER BOOSTER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4. Operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2. Function of valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7. OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.2. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8. COOLER’S DISSIPATION FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9. FLUSHING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.2. Hydraulically controlled valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.2.1. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.2.2. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.2.3. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10. MAINTENANCE OF WATER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10.1. Anti-- freeze blowing (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10.1.1. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10.1.2. Draining and anti--freeze blowing of the water circuit . . . . . . . . . . . . . . 19
10.2. Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10.3. Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11. TROUBLESHOOTING OF WATER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

C 60260--3 en 0507/LH 3 (22)

WATER CIRCUIT

4 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

1. GENERAL
Water is used on drilling jumbos for drill hole flushing and various cooling purposes. Water
flows throught the drill steel and removes the drill cuttings from the drill hole and, at the
same time, cools down the drilling equipment. Water also flows through the oil cooler
where it cools down oil.

2. SAFETY
The electrical connection must be carried out by an authorized
electrician in accordance with local regulations.

WARNING

Never drill without adequate flushing.

CAUTION

Do not reuse the water returned from the flushing circulation.

CAUTION

Keep the pressure limits and the pressure switches in working order and
in the right settings.

CAUTION

C 60260--3 en 0507/LH 5 (22)

WATER CIRCUIT

3. OPERATION OF CIRCUIT
3.1. Components

3 5

7
6
9

10

FROM COMPRESSOR

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. Water flow switch
10. Air valve

6 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

3.2. Normal flushing

Before opening the shut--off valve (8), make sure that the mud separator screen (at the
shut--off valve) is cleaned. Water supply to the rig is opened by opening the shut--off valve
(8).
Inlet pressure of the booster pump (2) is adjusted to 4...10 bar using by pressure reducer
(3). Water pressure gauge (5) tells inlet pressure if shut off valve (8) is open and water
booster does not work. While drilling PRESSURE AFTER PRESSURE REDUCER (3) +
PUMP PRESSURE = OUTPUT PRESSURE.
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.
Pressure switch (4) and water pressure gauge (5) are connected to the line after the water
booster pump (2). From the water booster pump flushing water is led to the oil coolers (6).
From the oil coolers water flows to pilot--controlled flushing valves (7). The flushing valves
switch flushing on automatically when percussion is switched on.
The flushing system can be provided with separate flow switches (9) for each drilling unit
(option). When flushing water flow drops below the set value of the flow switch,
anti--jamming automatics is switched on. The flow control can be turned off by turning the
switch S79 to 0--position.

JB94
S705 S702 H72 H73 S77

SH703 S700 S79 S78 S73

S79

3.3. Double flushing

Systems with double flushing have two pilot--controlled flushing valves connected to the
water circuit (7) and the pneumatic circuit (10). Water flushing operates as described in
the circuit described above. The drilled hole can be blown clear with pressurized air

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.

C 60260--3 en 0507/LH 7 (22)

WATER CIRCUIT

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.
S505 H601

8 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

4. MUD SEPARATOR

The mud separator does not work properly if water which has been once
in the flushing circulation is reused.

CAUTION

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
2 2. Mud separator
3. Drain valve
4 4. Strainer

C 60260--3 en 0507/LH 9 (22)

WATER CIRCUIT

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
3
2. Pump
3. Primer / vent plug

2 4. Primer valve / drain plug

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 B 65500 “Water booster pump; Operation and
maintenance”.

10 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

6. PRESSURE REDUCING VALVE

6.1. Components

1. Body
19 17
2. Bottom cover
14 3. Spring casing
18 4. Piston
13 5. Valve sleeve
3 6. Valve disc holder
4 7. Valve disc
16
C 11 8. Valve stem
9. High pressure seal
9
20 10. High pressure seal ring
10
11. Distance piece
5
22 12. Washer
A 13. Locking ring
8
OUT 14. Adjusting screw
IN
15. Bottom cover gasket
B 7
16. Piston seal
6 17. Adjusting spring
12
15 1 18. Valve spring
19. Ball
2
21 20. Set screw
21. Cap gasket
22. Body gasket

C 60260--3 en 0507/LH 11 (22)

WATER CIRCUIT

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.

6.3. Maintenance
If the pressure acting on the pressure restrictor’s 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.

12 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

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.

C 60260--3 en 0507/LH 13 (22)

WATER CIRCUIT

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.

NOTE! New seals should be used when assembling the cooler.

NOTE! 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.
NOTE! 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.
NOTE! 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.

14 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

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.
Kw
120

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 When the oil outlet temper-

are based on a water flow
rate which is 50% of the oil
flow. For other water flow
rates, multiply the dissipa-
tion figure by the following
correction factor.
ature exceeds the water in-
let temperature by other
than 25_C, multiply the dis-
sipation figure by the follow-
ing correction factor.

25% 50% 100% 15_c 20_c 25_c 30_c 35_c

0,8 1 1,2 0,6 0,8 1 1,2 1,4

C 60260--3 en 0507/LH 15 (22)

WATER CIRCUIT

9. FLUSHING VALVE
9.1. General
The flushing valve switches water flushing automatically on when percussion is started.
Return automatics closes the flushing valve automatically when the rock drill carriage
reaches the front impulse cylinder and return movement starts.

9.2. Hydraulically controlled valve

9.2.1. Components

WPM PP
1 2 5

1. Valve body
2. Spool
3. Return spring
4. Nipple
5. Overflow duct

9.2.2. Function
When water (or air) pressure is present on the input side of the valve but drilling is not on,
the water flow passages are closed. The cooling water for the oil coolers also circulates
through this valve and, thus, cooling also operates only during drilling.
When percussion is switched on from the control panel, the pressure affects not only in
the actual percussion circuit but also in the control side of the flushing valve. The control
pressure pushes the valve spool (2) so that the flow passage through the valve opens.

16 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

When percussion is switched off, the pressure in the control side of the flushing valve also
drops and the spool is returned to rest by the spring (3), and the flow passage is closed.
Ensure that water pressure stays sufficiently high and the variation of pressure reasonably
small. Excessive variation of pressure can be caused by too small supply hose or clogged
cooler, for instance.
9.2.3. Maintenance
The valve needs attention only if water or oil comes out of the overflow duct (5), or if
flushing water flow is not stopped although the valve is closed.
All seals affecting the operation of the valve are sealing rings on the spool. They all come
out with the spool when it is pulled out of the valve block.
Disassembling of valve
1. Disconnect hoses.
2. Plug control pressure oil hose.
3. Remove nipple (4) with adapter, and pull out spring (3) and spool (2).
4. Blow passages of valve block clean with compressed air.
5. Clean spool and install new sealing rings.
6. Push spool and spring back into place.
7. Install new seal on nipple (4) also, and install nipple.
8. Reconnect hoses.

C 60260--3 en 0507/LH 17 (22)

WATER CIRCUIT

10. MAINTENANCE OF WATER CIRCUIT

10.1. Anti--freeze blowing (option)
10.1.1. Components
6
7
4 2

1
5

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

18 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

10.1.2. 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

4 position where air can enter the flushing
circuit (handle 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

9 drain cocks (9) of the oil coolers). Water is
now drained from the coolers.

4. For each boom separately, close the oil

cooler drain cocks (9) .
The flushing switch shall be in the water
flushing position (pull lever backwards).
Water flushing is on. Continue draining until
plain air comes out at the rock drill.
Powerpacks must be running in order to
provide the valves with control pressure.

5. Turn air flushing valves on for a while (push

lever forward) to expel water from the line
between the air and water valves.
Powerpacks must be running in order to
provide the valves with control pressure.

C 60260--3 en 0507/LH 19 (22)

WATER CIRCUIT

6. Stop the compressor and turn the three--way

valve (4) into the position where the filling
line is connected to the flushing line (handle
towards filling nipple).

6
7. Open the filling cap (6) and pour anti--freeze
(100%) into the flushing line. Close the filling
cap (6).

8. Open the main valve (8). Turn the three--way

4 valve (4) into the position where pressurized
air is connected to the flushing line, and start
the compressor.

9. Repeat points 6--8 until a mixture of

anti--freeze and air comes out at the rock drill
or the end of the dril steel.

The capacity of the compressor is sufficient if the flushing valves are opened one
at a time!
NOTE! 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.

CAUTION

Make sure that is nobody in front of rock drill or drill rod during blowing.

WARNING

20 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

10.2. Draining
In cold conditions always remember to drain the water circuit for the time
of a longer shut--down.

CAUTION

10.3. 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.
CAUTION

C 60260--3 en 0507/LH 21 (22)

WATER CIRCUIT

11. TROUBLESHOOTING OF WATER CIRCUIT

Problem Possible cause

Pump not starting No current. Water pump switch (at elec-
tric cabinet) in position ”0”.

Motor protector switch triggered.

Motor protector switch contact points or

electromagnet faulty.

Control voltage circuit faulty.

Motor protector switch triggered (trig- Motor protector switch contact points
gered right after starting) faulty.

Loose or faulty cable connection.

Motor winding faulty.

Pump mechanically blocked.

Set value too low.

Motor protector switch triggered erratical- Set value too low.
ly Fluctuation in voltage.
Mains voltage too low.
Motor protector switch not triggered but No current. Water pump switch (at elec-
pump still not running tric cabinet) in position ”0”.
Control voltage circuit faulty.
Pump output varying Too small supply hose for pump output.
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.
Mud separator partly blocked

22 (22) C 60260--3 en 0507/LH

 WATER CIRCUIT

PVM / KUKA SYY MUUTOKSEEN TEHDYT MUUTOKSET

1000/ANKO Päivitys Muutettu Axeroihin sopiviksi(Universal ohje)
11007ANKO Lisäys Tekstimuutoksia+kuviin pieniä lisäyksiä ja muutenkin muutettu
siten että sopii kaikkiin Axeroihin.
2=>3 /210502/ TMK Tero Yli--H. Vesipumpun täyttö ennen käyttöä osuus muokattu.
3=>4/260505/TL Päivitys Vesipumpun osuutta muutettu.

C 60260--3 en 0507/LH 23 (22)

 AIR CIRCUIT

CONTENTS
1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Circuit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Use of compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Air cleaner IP5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Air receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

B 61220--2 en 0507/LH 1 (8)

AIR CIRCUIT

1. SAFETY

Service and adjustment procedures are only allowed to persons

who have been given specific service training.

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.
WARNING Unauthorized persons are not allowed near the rig during the
repair work.

Suspected leaks should be searched visually or by listening. Do

not touch pressurized hoses with bare hands. Hoses may have
unnoticeable pin-- holes to let out a thin air flow which might
WARNING penetrate through the skin 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
WARNING breakage may cause personal injuries.

2 (8) B 61220--2 en 0507/LH

 AIR CIRCUIT

2. GENERAL
Pressurized air on the DT/DD/DB 06 drilling rig is mainly used for:
1. Rock drill shank lubrication.
2. To blow the hole clean after drilling.
3. 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 stops
drilling

Neglecting proper shank lubrication will result in serious

damages on the equipment.

CAUTION

B 61220--2 en 0507/LH 3 (8)

AIR CIRCUIT

5
3

1. Compressor
2. Pressure switch
3. Water separator
5. Drainage valve
7. Flushing valve
2 8. Air receiver
9. Restrictor
12 12. Air cleaner IP5
13. Water drainage valve
9

13

1 8

4 (8) B 61220--2 en 0507/LH

 AIR CIRCUIT

3. 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 power
CAUTION pack will stop and the drilling is thus prevented.

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.
The air can be taken through the flushing valve (7) to blow the drilled hole clean
or to flush the hole if the water--mist flushing (option) is used. To function
properly, the water--mist flushing usually requires extra pressurized air from the
mine air network (see below).

PRESSURIZED AIR FROM THE AIR NETWORK

The pressurized air can also be taken into the circuit from the mine own air lines.
The air flows through shut--off valve to the separate air cleaner IP5 (12) which
cleans the air and removes the possible water content before the air enters into
the circuit. The IP5 is equipped with a water drainage valve (13). Otherwise the
circuit operates as described in chapter ”Pressurized air from compressor”.

B 61220--2 en 0507/LH 5 (8)

AIR CIRCUIT

4. 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. Pressure monitoring is activated also then when compressor is
not running. Position 0 is 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.

6 (8) B 61220--2 en 0507/LH

 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

5. 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.

Open the drain valve of the cleaner at least once during each shift.

CAUTION

B 61220--2 en 0507/LH 7 (8)

AIR CIRCUIT

6. AIR RECEIVER
For blowing the hole clean, the DT/DD/DB 06 device uses an air receiver (8). The purging
speed of the receicer can be regulated using a restrictor (9). Using a pressure relief valve,
the maximum receiver pressure has been restricted to 8 bar.

8 (8) B 61220--2 en 0507/LH

 LUBRIFICADOR CENTRAL A ÓLEO; Ajuste e manutenção

INDICE
1 GENERALIDADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 LUBRIFICADOR A ÓLEO NO CIRCUITO DE PRESSÃO . . . . . . . . . . . . 2
3 LUBRIFICADOR CENTRAL A ÓLEO EM OPERAÇÃO . . . . . . . . . . . . . . 3
4 COMPONENTES PRINCIPAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5 INSTRUÇÕES DE UTILIZAÇÃO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.1 Enchimento do depósito do lubrificador . . . . . . . . . . . . . . . . . . . 4
5.2 Ajuste da mistura óleo / ar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

C 63150--2 pt 0607 / MS 1 (5)

LUBRIFICADOR CENTRAL A ÓLEO; Ajuste e manutenção

1. GENERALIDADES
O lubrificador central a óleo tem como função efectuar a lubrificação da haste da
perfuradora de rocha. O óleo lubrificante é enviado para a perfuradora misturado com ar
comprimido. A pressurização do ar pode ser feita com o compressor próprio da máquina
ou o ar pode ser obtido num circuito exterior de ar comprimido.
Para a perfuradora de rocha a lubrificação da haste é da maior importância e por isso a
pressão do ar é controlada por um pressostato. Se a pressão desce abaixo de um valor
fixado, o que significa possível perturbação na lubrificação da haste, o pressostato
mencionado atrás corta a corrente das unidades hidráulicas tornando naturalmente
impossível a perfuração sem reparar o sistema.
Como foi dito, uma lubrificação da haste a funcionar em perfeitas condições é da maior
importância para a perfuradora. Uma lubrificação insuficiente pode ser causada por três
razões diferentes:
-- Mau funcionamento do circuito de ar. Contra isso encontra--se instalado um
pressostato. O sistema automático impede a perfuração em caso de baixa
pressão do ar.
Há no entanto uma excepção. Se houver uma danificação da mangueira entre o
lubrificador central e a perfuradora, a lubrificação pode ser perturbada durante a
perfuração sem qualquer reacção dos controlos automáticos.

-- Falta ou má qualidade do óleo. O nível de óleo não causará problemas se o

lubrificador for cheio regularmente e a proporção óleo/ar for ajustada
correctamente. Por outras palavras o reservatório não pode ficar vazio durante um
turno, se a mistura óleo/ar estiver correcta (0,2 l/h de óleo para todas as
perfuradoras). A viscosidade do óleo tem muita influência quando se fala de
ajustar a mistura óleo/ar correcta. Deste modo devem ser sempre usadas as
qualidades de óleo mencionadas na “Recomendação de lubrificantes”.
-- Água no depósito do lubrificador. A água pode ter entrado no reservatório pelo
circuito de ar ou por condensação.
Recomenda-- se que seja feita a drenagem da água antes de cada turno.

ATENÇÃO

2. LUBRIFICADOR A ÓLEO NO CIRCUITO DE PRESSÃO

O lubrificador foi colocado no circuito de pressão imediatamente antes da perfuradora.
Esta localização é muito natural porque apenas a perfuradora necessita do ar misturado
com óleo. A partir da perfuradora o ar pode ser deixado sair livremente ou ser canalizado
para lubrificar também o avanço de corrente.

2 (5) C 63150--2 pt 0607 / MS

 LUBRIFICADOR CENTRAL A ÓLEO; Ajuste e manutenção

3. LUBRIFICADOR CENTRAL A ÓLEO EM OPERAÇÃO

O ar comprimido misturado com óleo não apenas lubrifica a haste mas também impede
que água e sujidade entrem na perfuradora. O ar que entra é dividido no distribuidor (7)
em linhas de saída separadas e para o depósito (1). A velocidade do ar aumenta ao
passar no distribuidor e em consequência a pressão baixa. Então, em virtude da pressão
mais alta no depósito do que no distribuidor, algum óleo é forçado através da válvula de
regulação (9), óleo que se mistura com o ar em passagem. A quantidade de óleo que se
mistura com o ar pode ser ajustada rodando o botão da válvula de ajuste. Durante o ajuste
a válvula deve ser desligada do distribuidor. Isto porque só assim é possível estimar a
quantidade de óleo que passa pela válvula.

4. COMPONENTES PRINCIPAIS

2
8

3
6
4
11 12
8

1
10

13
11
5

1 Depósito 7 Distribuidor
2 Tampão de enchimento de óleo 8 Entrada do ar
3 Manómetro 9 Válvula reguladora do caudal de óleo
4 Vareta de nível 10 Saída de ar
5 Válvula de drenagem 11 Bases de fixação
6 Mangueira de óleo 12 Visor de inspecção
13 Placa de tipo

C 63150--2 pt 0607 / MS 3 (5)

LUBRIFICADOR CENTRAL A ÓLEO; Ajuste e manutenção

5. INSTRUÇÕES DE UTILIZAÇÃO
5.1. Enchimento do depósito do lubrificador
Perigo de injecção de ar a alta pressão. Pode causar lesões graves.
Descarregue a pressão antes de retirar o tampão de enchimento ou
acessórios.
AVISO

-- Pare o compressor e espere até o manómetro indicar 0 bar. Nessa altura

pode abrir o tampão de enchimento. Retire o filtro de enchimento
(imediatamente por baixo do tampão) e limpe--o.
-- Coloque de novo o filtro no seu lugar e encha o depósito.
-- O nível de óleo pode ser verificado com a vareta de nível.
O nível de óleo nunca pode descer abaixo da marca “MIN“. No entanto é
altamente recomendável encher o depósito antes de cada turno. É
também aconselhável drenar a água ao mesmo tempo.
ATENÇÃO

ITambém é importante verificar que para cada perfuradora é enviada

uma quantidade adequada de óleo. Se o nível de óleo não descer no
depósito, deve ser procurada imediatamente a razão.
ATENÇÃO

5.2. Ajuste da mistura óleo/ar

-- Desaperte do distribuidor a válvula reguladora.

-- Arranque o compressor e verifique a pressão do depósito do lubrificador.
-- Abra a válvula reguladora de modo que o óleo passe através dela a cerca de 0,2
l/h, o que significa cerca de 30 gotas por minuto.
-- Observe o caudal de óleo o tempo suficiente para o caudal estabilizar.
-- Uma vez feito o ajuste, pode ser apertada a contra--porca. Aperte a válvula de
regulação e verifique que a junta não tem fugas depois de arrancar novamente o
compressor.

4 (5) C 63150--2 pt 0607 / MS

 LUBRIFICADOR CENTRAL A ÓLEO; Ajuste e manutenção

Ateste o depósito do lubrificador em cada turno.

ATENÇÃO

Verifique sempre que o tipo de óleo que utiliza para o enchimento é

adequado para as condições presentes de perfuração (Ver
“Recomendação do lubrificante”). Verifique o tipo e também a
ATENÇÃO viscosidade.
Tenha cuidado que a quantidade de óleo enviada para a perfuradora seja
correcta. Durante a perfuração verifique através do visor de inspecção
que a lubrificação funciona.
ATENÇÃO

Se o nível de óleo não descer nada durante a perfuração, a razão deve ser
procurada imediatamente.

ATENÇÃO

A razão pode ser:

-- A separação de óleo do compressor não funciona
-- A válvula de regulação está mal ajustada
-- A canalização de ar está entupida e por isso o óleo não tem ”meio de transporte”.
-- A viscosidade do óleo é muito alta para as circunstâncias presentes. Por outras
palavras: o óleo é muito espesso.

C 63150--2 pt 0607 / MS 5 (5)

 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
 09.02.1999
To the user

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
 09.02.1999
Safety
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
 02.02.2000
Technical spesification

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
Speed of rotation 60Hz rpm 3470
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
 02.02.2000
Technical spesification

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
Speed of rotation 50Hz rpm 2910
Speed of rotation 60Hz rpm 3515
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
 02.02.2000
Air compressing process

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
 02.02.2000
Oil circulation
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
 02.02.2000
Capacity control

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
 02.02.2000
Instrument panel
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
 02.02.2000
Moving the compressor with a forklift truck
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
 02.02.2000
Normal starting and stopping of compressor
Starting
Start the compressor.

Stopping
Push the stopping button.
Before the restart wait about 1 minute to allow the receiver to empty.

15
 02.02.2000
Adjust of modulating
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
 02.02.2000
Temperature gauge
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
 02.02.2000
Service chart
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
 02.02.2000
Adding oil and oil change
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.
2. Take the precautions listed on page 18.
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
 02.02.2000
Replacing oil filter
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.
1. Take the precautions listed on page 18.
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
 02.02.2000
Replacing air filter
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
 02.02.2000
Replacing oil separator element
Dispose of the old element according to the regulations on hazardous waste.
Allow the compressor to cool down before the replacement.
1. Take the precautions listed on page 18.
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
 02.02.2000
Removing drive wheel and its mounting sleeve

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

1. Take the precautions listed on page 18.

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
 02.02.2000
Installing drive wheel and its mounting sleeve

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
 02.02.2000
Installing the sheave of the air end

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
 02.02.2000
Testing safety valve
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
 02.02.2000
Troubleshooting chart

Problem Possible cause Repair

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

28
 02.02.2000
Removing from service
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
 02.02.2000
Oil recommendation for Gardner Denver
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
 WATER BOOSTER PUMP WBP; Operation and maintenance

B 65500--6 en 0607/LH 1 (20)

WATER BOOSTER PUMP WBP

2 (20) B 65500--6 en 0607/LH

 WATER BOOSTER PUMP WBP; Operation and maintenance

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1. Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. FILLING OF PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1. Pumps with the venting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2. Pumps without the venting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. CHECKING DIRECTION OF ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8. DISMANTLING AND FITTING OF THE CR--TYPE WATER PUMPS . . . . . . . . 8
8.1. Removing the transport bracket and turning the motor to
another position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8.2. Dismantling and fitting (CR 3 and CR 5) . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.2.1. Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.2.2. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.2.3. Tightening torques of the bolt nuts (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.3. Dismantling and fitting (CR 10 and CR 15) . . . . . . . . . . . . . . . . . . . . . . 14
8.3.1. Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.3.2. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.3.3. Tightening torques of the bolt nuts (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9. LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.1. Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.2. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

B 65500--6 en 0607/LH 3 (20)

WATER BOOSTER PUMP WBP

4 (20) B 65500--6 en 0607/LH

 WATER BOOSTER PUMP WBP; Operation and maintenance

1. GENERAL
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

The key below indicates the meaning of the letters and figures of the type designation, e.g.
CR 10--10.
CR 10--10

Multistage centrifugal pump

In--line version
Nominal flow rate m#/h
Number of stages

2. SAFETY

The electrical connection must be carried out by an authorized

electrician in accordance with local regulations.

WARNING

3. COMPONENTS

1. Motor
3
2. Pump
3. Primer-- / vent plug
2 4. Primer valve-- / drain plug

B 65500--6 en 0607/LH 5 (20)

WATER BOOSTER PUMP WBP

4. 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. FILLING OF PUMP

Do not start the pump until it has been filled with water.

CAUTION

5.1. Pumps with the venting valve

High water pressure
A

1. Close the pump isolating valve(s).

2. Open the venting valve (A).
3. Gradually open the isolating valve in the suction pipe
until a steady stream of water runs out the primer port.
4. Close the venting valve (A).

A. Venting valve

5.2. Pumps without the venting valve

High water pressure

1. Close the pump isolating valve(s).

2. Remove the primer plug (A) from the pump head.
3. Gradually open the isolating valve in the suction pipe
until a steady stream of water runs out the primer port.
4. Assembly the plug (A) and tighten securely.

6 (20) B 65500--6 en 0607/LH

 WATER BOOSTER PUMP WBP; Operation and maintenance

6. CHECKING DIRECTION OF ROTATION

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.

7. STARTING
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.

B 65500--6 en 0607/LH 7 (20)

WATER BOOSTER PUMP WBP

8. DISMANTLING AND FITTING OF THE CR--TYPE WATER PUMPS

8.1. Removing the transport bracket and turning the motor to
another position

Read these instructions carefully before removing the transport

bracket or before turning the motor to another position.

CAUTION

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.
2. Remove three of the screws (4) from the coupling halves (3) and the shaft pin (13).
3. Slacken the last screw (4) but do not unscrew it completely.
4. Hit the end of the hexagon key carefully with the flat of the hand to loosen one of
the 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
transport bracket. If you are going to turn the motor to another position, remove
the screws (12).

1 2
25
12
3

4 13

8 (20) B 65500--6 en 0607/LH

 WATER BOOSTER PUMP WBP; Operation and maintenance

8.2. Dismantling and fitting (CR 3 and CR 5)

8.2.1. Dismantling
1. Remove the screws (2) together with the coupling guards (1). (Figure 1)
2. Remove three of the screws (4) from the coupling halves (3) and the shaft pin (13).
(Figure 1)
3. Slacken the last screw (4) but do not unscrew it completely. (Figure 1)
4. Hit the end of the hexagon key carefully with the flat of the hand to loosen one of
the coupling halves (3). (Figure 1)
5. Remove the last screw (4) and remove the first coupling half (3). (Figure 1)
6. Hit the flat part of the second coupling half (3) very carefully on the pump shaft end.
(Figure 1)
7. Remove the second coupling half (3). (Figure 1)
8. Remove the screws (12). (Figure 1)
9. Lift the motor (10) off the pump head (11). (Figure 1)
10. Slacken the three screws (5) by approx. 1/4 of a turn so that the shaft seal is just
free of the shaft. (Figure 2)

10

1 5
2

11
12

4
13

3
Figure 1 Figure 2

B 65500--6 en 0607/LH 9 (20)

WATER BOOSTER PUMP WBP

11. Slacken the shaft seal (6) using the box spanner (7) (or similar tool) until the thread
is completely free of the pump head. (Figure 3)
12. Pull the shaft seal (6) off the pump shaft. (Figure 3)
13. Remove the nuts (8) together with the washers (9). (Figure 4)
14. Loosen the pump head (11) with a light blow on the edge and lift it free of the
staybolts (14). (Figure 4)

7 11
8
9

20

14

Figure 3 Figure 4

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). (Figure 5)
16. Remove the outer sleeve (18). (Figure 5)
17. Lift the chamber stack (15) off the base (16). If the bottom chamber (19) is removed
with the chamber stack (15), loosen it from the chamber stack (otherwise loosen
it from the base (16). (Figure 5)

18

17

15
19
20

16
Figure 5

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 WATER BOOSTER PUMP WBP; Operation and maintenance

8.2.2. Fitting
1. Lubricate the O--rings (20) with Rocol 22 (or equivalent). (Figures 6 and 7)
2. Fit the chamber stack (15) in the base (16). The smooth shaft end must be
upwards. (Figure 6)
3. Fit the outer sleeve (18) in the base and press it home in the base. (Figure 6)
4. Press the top guide vanes/discharge (17) into the recess of the top chamber (15).
(Figure 6)
5. Fit the pump head (11). (Figure 7)
6. Lubricate the threads of the staybolts (14) with Thread--Eze (or equivalent).
(Figure 7)
7. Fit the washers (9) and the nuts (8). (Figure 7)
8. Tighten the nuts (8) diagonally with the torque of 50 Nm.

M12 -- 50Nm
18 11 8
17 9

15
19
20 20

14
16

Figure 6 Figure 7

9. Moisten the shaft end with soapy water. (Figure 8)

10. Place the shaft seal (6) in the box spanner (21) and press it down on the shaft.
(Figure 9)
11. Screw the shaft seal (6) into the pump head (11) and tighten it with the torque of
35 Nm. (Figure 9)

21 35 Nm
SOAP

6
11

Figure 8 Figure 9

B 65500--6 en 0607/LH 11 (20)

WATER BOOSTER PUMP WBP

12. Fit the motor (10) to the pump head (11). (Figure 10)
13. Fit the screws (12), lubricate them and tighten them diagonally (with the torque
shown in the picture). (Figure 10)
14. Insert the shaft pin (13) into the shaft hole and fit the coupling halves (3) on the
shaft. (Figure 11)
15. Lubricate the four screws (4) with Thread--Eze (or equivalent). (Figure 11)
16. Fit the screws (4). Tighten and leave loose. (Figure 11)
17. Check that the gaps on both sides of the coupling halves are equal. (Figure 11)

10

M8 -- 12Nm
M12 -- 40Nm
11

12 4 3

13
Figure 10 Figure 11
18. 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/coupling against the stop and simultaneously
press the motor shaft (e.g. with a screwdriver) through the fan grille in order to push
the motor shaft to its lower position (Normally the propellant spring at the lower end
of the motor holds the motor shaft in the upper position.). (Figure 12)
19. Lower the pump shaft/coupling to half of height (X). (Figure 12)
20. Hold the pump shaft/coupling in the position of step 19 and tighten the four screws
(4) (with the torque shown in the picture). (Figure 12)
21. Check that the gaps on both sides of the coupling halves are equal. (Figure 12)
22. Tighten the three screws (5) with the torque of 2,5 Nm. (Figure 13)
23. Fit the coupling guards (1) and the screws (2). Tighten the screws. (Figure 13)

M6 -- 13 Nm
M8 -- 31 Nm
M10 -- 62 Nm 1

2
3
5 M5 -- 2.5 Nm
x
0.5x

6
Figure 12 Figure 13

12 (20) B 65500--6 en 0607/LH

 WATER BOOSTER PUMP WBP; Operation and maintenance

8.2.3. Tightening torques of the bolt nuts (8)

8. Bolt nuts
The four bolt nuts (M12) must be tightened
every once in a while, because they may
become loose during operation. The re- 8
quired tightening torque is 50 Nm.

B 65500--6 en 0607/LH 13 (20)

WATER BOOSTER PUMP WBP

8.3. Dismantling and fitting (CR 10 and CR 15)

8.3.1. Dismantling
1. Remove the screws (2) together with the coupling guards (1). (Figure 14)
2. Remove three of the screws (4) from the coupling halves (3) and the shaft pin (13).
(Figure 14)
3. Slacken the last screw (4) but do not unscrew it completely. (Figure 14)
4. Hit the end of the hexagon key carefully with the flat of the hand to loosen one of
the coupling halves (3). (Figure 14)
5. Remove the last screw (4) and remove the first coupling half (3). (Figure 14)
6. Hit the flat part of the second coupling half (3) very carefully on the pump shaft end.
(Figure 14)
7. Remove the second coupling half (3). (Figure 14)
8. Remove the screws (12). (Figure 14)
9. Lift the motor (10) off the pump head (11). (Figure 14)
10. Slacken the three screws (5) by approx. 1/4 of a turn so that the shaft seal is just
free of the shaft. (Figure 15)

10

1 5
2

11
12

4
13

3
Figure 14 Figure 15

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 WATER BOOSTER PUMP WBP; Operation and maintenance

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. (Figure 16)
12. Pull the shaft seal (6) off the shaft. (Figure 16)
13. Remove the nuts (8) together with the washers (9). (Figure 17)
14. Loosen the pump head (11) with a light blow on the edge and lift it free of the
staybolts (14). (Figure 17)

11 8

20
22 6

14

Figure 16 Figure 17

15. Remove the outer sleeve (18). (Figure 18)

16. Lift the chamber stack (15) off the base (16). (Figure 18)

18

15

20

16

Figure 18

B 65500--6 en 0607/LH 15 (20)

WATER BOOSTER PUMP WBP

8.3.2. Fitting
1. Lubricate the O--rings (20) with Rocol 22 (or equivalent). (Figures 19 and 20)
2. Fit the chamber stack (15) in the base (16) taking care that the heads of the screws
for strips do not touch the inlet pipe in the base. (Figure 19)
3. Fit the outer sleeve (18) in the base and press it home in the base. (Figure 19)
4. Check that the rubber springs (23) are in the pump head (11). (Figure 20)
5. Fit the pump head (11). (Figure 20)
6. Lubricate the threads of the staybolts (14) with Thread--Eze (or equivalent).
(Figure 20)
7. Fit the washers (9) and the nuts (8). (Figure 20)
8. Tighten the nuts (8) diagonally with the torque of 80 Nm.

M16 -- 80Nm
18 11 8
9
15
23
20 20

14
16

Figure 19 Figure 20

9. Moisten the shaft end with soapy water. (Figure 21)

10. Press the shaft seal (6) on the pump shaft. (Figure 22)
11. Screw the shaft seal (6) into the pump head (11) and tighten it with the torque of
35 Nm using the ring insert tool (22) (or similar tool). (Figure 22)

6
SOAP

11
22

35 Nm

Figure 21 Figure 22

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 WATER BOOSTER PUMP WBP; Operation and maintenance

12. Tighten the three screws (5) with the torque of 2,5 Nm. (Figure 23)
13. 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 guards (1). (Figure 24)

24

M5 -- 2.5 Nm
Figure 23 Figure 24

14. Fit the motor (10) to the pump head (11). (Figure 25)
15. Fit the screws (12), lubricate them and tighten them diagonally (with the torque
shown in the picture). (Figure 25)
16. Fit the shaft pin (13) and the two coupling halves (3). (Figure 26)
17. Lubricate the four screws (4) with Thread--Eze (or equivalent). (Figure 26)
18. Fit the screws (4). Tighten and leave loose. (Figure 26)
19. Check that the gaps on both sides of the coupling halves (3) are equal. (Figure 26)
20. Press the motor shaft (e.g. with a screwdriver) through the fan grille in order to push
the motor shaft to its lower position (Normally the propellant spring at the lower end
of the motor holds the motor shaft in the upper position.). (Figure 26)
21. Tighten the screws (4) (with the torque shown in the picture). (Figure 26)
22. Check that the gaps on both sides of the coupling halves (3) are equal. (Figure 26)

10

M8 -- 12Nm
M12 -- 40Nm 11
4
12
3
13

M6 -- 13 Nm
Figure 25 Figure 26 M8 -- 31 Nm
M10 -- 62 Nm

B 65500--6 en 0607/LH 17 (20)

WATER BOOSTER PUMP WBP

23. Remove the adjusting fork (24). (Figure 27)

24. Check that the pump shaft rotates freely and noiselessly.
25. Place the adjusting fork (24) inside one of the coupling guards (1). (Figure 28)
26. Fit the coupling guards (1) and the screws (2). (Figure 28)

24

24
Figure 27 Figure 28

8.3.3. Tightening torques of the bolt nuts (8)

8. Bolt nuts
The four bolt nuts (M16) must be tightened
evety once in a while, because they may be-
come loose during operation. The required 8
tightening torque is 80 Nm.

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 WATER BOOSTER PUMP WBP

9. LUBRICATION AND MAINTENANCE

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 ballbearings 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

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
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.

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WATER BOOSTER PUMP WBP

10. TROUBLESHOOTING
Problem Possible cause
Pump not starting No current. Water pump switch (at elec-
tric cabinet) in position ”0”.

Motor protector switch triggered.

Motor protector switch contact points or

electromagnet faulty.

Control voltage circuit faulty.

Motor protector switch triggered (trig- Motor protector switch contact points
gered right after starting) faulty.

Loose or faulty cable connection.

Motor winding faulty.

Pump mechanically blocked.

Set value too low.

Motor protector switch triggered erratical- Set value too low.
ly
Fluctuation in voltage.

Mains voltage too low.

Motor protector switch not triggered but No current.
pump still not running
Water pump switch (at electric cabinet) in
position ”0”.

Control voltage circuit faulty.

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.

20 (20) B 65500--6 en 0607/LH