Page 1

WATER CIRCUIT

MAINTENANCE MANUAL

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
 Page 2 WATER CIRCUIT 11-10-2004 AR-RL-FL

1 PRELIMINARY REMARKS 3
1/1 SAFETY 3

1/2 ABOUT THIS BOOKLET 5

2 EXPLANATION PLAN 6

3 REPAIR DIAGNOSIS 8

4 CHECK OPERATIONS ON MAIN COMPONENTS 9

4/1 ROCK DRILL WATER HOSES 9

4/2 DRILLING ROD 9

4/3 CONTROL VALVE 9

4/4 PRESSURE SWITCHES 9

4/5 WATER SUPPLY 10

4/6 FILTER 10

4/7 PRESSURE REDUCER 10

4/8 WATER PUMP 11

4/9 COOLER 12

4/10 SAFETY RELIEF VALVE 12

5 PERIODICAL MAINTENANCE TABLE 13

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
 11-10-2004 AR-RL-FL WATER CIRCUIT Page 3

1 PRELIMINARY REMARKS

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

Remember: SAFETY FIRST!

Always observe the warnings accompanied by the following symbols.

WARNING: Operation, maintenance and adjustments are only allowed to persons with
specific training in operation and maintenance of the equipment. Read the operating
and maintenance instructions before using or servicing the equipment.

WARNING: Before starting any maintenance operation ensure that the machine is in a

! safe location with good safety, ventilation and lighting conditions. Ensure that lifting
equipments and pedestals are compatible with elements’ weight. Follow all the safety
instructions and ware safety protections as gloves, goggles, helmet, safety boots, ear
protectors.

WARNING: Before any operation stabilize and fix steadily all the elements on suitable
pedestals. Stop the power packs, switch the general power breaker. Place a tag or a
board to warn other members of the personnel that maintenance work on the machine
WARNING is in progress.

WARNING: Pressurized oil jets could cause severe injuries. Before any operation on
hydraulic circuit, STOP the power packs and release remaining pressure in
components by operating hydraulic control levers several times. Always release the
WARNING static pressure in cylinders before disassemble them.
NEVER WORK ON AN OPERATING CIRCUIT.

WARNING: While tests are in progress, do not allow any other member of the
personnel to stand in the area surrounding the machine. Stay at the control station to
be able to stop the movement and switch off the power pack.
WARNING

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

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

CAUTION: Always use suitable tools and work in a clean place when dismantling and
assembling hydraulic components. After removing cylinders the hydraulic inlet/outlet
ports must be plugged to prevent dirt and air intrusion during operation.

WARNING: The operator must always wear required personal protection, such as safety
helmet, protective overall, safety boots, hearing protectors, safety goggles etc.

WARNING: Danger of high pressure oil jets.

High pressure oil jets can cause serious personal injuries.
Release the pressure in the hydraulic circuits before opening caps or connections.
WARNING (Accumulator, Cylinder and Hydraulic circuit)

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
 Page 4 WATER CIRCUIT 11-10-2004 AR-RL-FL

WARNING: Danger of hot surface.

Hot surface can cause serious injuries.
Components rod, shank or hydraulic component can be hot and before
starting a maintenance work, please let them cool off.
The operator must have adequate wears as gloves.

WARNING: Crushing hazard : do not stay in dangerous area, for instance: central
articulation, front chassis and rear chassis.

WARNING

SAFETY

Always follow the marked safety instructions, and observe caution while working.

The following safety instructions are general rules.

Keep tools and drilling equipment clean.

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

ABOUT THE SAFETY OF REPAIRS

Certain workstages require the use of the feed mechanism during the repair. Make
sure then that:

- no danger is caused to anybody.

- the machine can be immediately stopped when necessary.
- the powerpack is stopped again before the repair-work is continued.

Before starting any repair-work move away from the area where you have just
drilled.

Use proper tools.

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

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
11-10-2004 AR-RL-FL WATER CIRCUIT Page 5

1/2 ABOUT THIS BOOKLET

The present manual is destined for the use of personnel in charge of carrying out, servicing and
maintenance operations on Jumbos.
It contains maintenance operations schedule and operating methods concerning the main elements of
the WATER CIRCUIT.
Note that servicing and maintenance operations must be carried out by personnel with the required
qualifications, technical knowledge, and proper training on the machine.

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
 Page 6 WATER CIRCUIT 11-10-2004 AR-RL-FL

2 EXPLANATION PLAN

(1) : Filter

F G
I (2) : Pressure reducer

9 (3) : Water pump

(4) : Safety relief valve

8 E
(5) : Cooler
7
(6) : «Water presence» pressure switch
6
5 (7) : «Pump start-up» pressure switch
D C
(8) : Control valve

4 (9) : Water pressure gauge

B (A) : Mine’s water supply

3
(B) : Water surplus.

(C) : Oil from rock drill

(D) : Oil to drilling oil tank.

2
(E) : Drilling control
1
(F) : Pressurized air from compressor.
A
(G) : Water or Air to rock drill nozzle.

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
11-10-2004 AR-RL-FL WATER CIRCUIT Page 7

Explanation :

• Mine’s water is connected to the water supply (2 bar needed at least), and flows to the water
pump (3) through the filter (1) and the a pressure reducer (2).
NOTE : The water pump is a multi-cellular type. It runs as a pressure booster. Therefore the
outlet pressure depends on the inlet pressure. We recommend to adjust the pressure reducer to
4 bar as a standard pressure.

• At the outlet of the water pump from the main line are connected the safety relief valve (4) which
keep the pressure to a maximum of 15 bar to protect the rock drill and the cooler against over-
pressures. The surplus of water get outside of the circuit.
NOTE : In drilling condition, the minimum high pressure needed at pump outlet is 10 bar.

• The pressure switch (6) stops the pump if the outlet pressure drops down 2 bar. It is a safety
device in case of lack of water.
NOTE : This function is assured by a flow controler on SOLO application.

• Mine’s water is used to cool down the drilling oil coming from the rock drill in the oil / water
cooler (5) .
NOTE : The cooler can be upstream or downstream of the water pump (depending on
machines).

• The main outlet line is connected to the control valve (8) operated by a pilot pressure from the
drilling control activating the pressure switch (7).
NOTE : The control can be assured by a manual ball valve to, depending on machines.

• The pressurized water flows through the rock drill flushing head. The water pressure can be
checked at the 0-25 bar gauge (9), on the tramming control panel.
NOTE : Few seconds after that the power pack has been started, the water pump and the
compressor start automatically.

- Optionnal air mist device :

On machines equiped with air mist option, air from compressor is mixed with water before the
flushing, thanks to a jet. In this case, the water circuit is the same, exept for pump’s
characteristics and adding of a water tank (in place of mine’s water connection).

- Optionnal auto return device :

With this option, the flushing is automaticaly started when the rock drill return. The water circuit is
the same, exept that air and water are carried by two separated hoses to the rock drill nozzle.

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
 Page 8 WATER CIRCUIT 11-10-2004 AR-RL-FL

3 REPAIR DIAGNOSIS

INJECTION PRESSURE
DROPS

Pressure at
C - Rock drill water hoses (§4/1)
the drilling NO H - Drilling rod (§4/2)
panel gauge E
- Control valve (§4/3)
is near C
K - Pressure switches (§4/4)
0 bar

YES

C
Pressure at - Water supply (§4/5)
Pressure at H
NO pump inlet NO
pump outlet is E - Filter (§4/6)
between 2 bar C - Pressure reducer (§4/7)
above 15 bar
and 4 bar K

C - Water pump (§4/8)

YES YES H - Control valve (§4/3)
E - Pressure switches (§4/4)
C
K - Cooler (§4/9)

Big amount C
NO - Relief valve (§4/10)
of water get out H
E - Cooler (§4/9)
through the
C - Control valve (§4/3)
relief valve K

YES
C
H - Relief valve (§4/10)
E - Cooler (§4/9)
C
K

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
11-10-2004 AR-RL-FL WATER CIRCUIT Page 9

4 CHECK OPERATIONS ON MAIN COMPONENTS

The locating of following elements are not the same on any ranges of machines.
For locating, see machine’s OPERATOR MANUAL.

4/1 ROCK DRILL WATER HOSES

Look for leaks on the water hoses between the control valve and the rock drill. Check it is in good
condition (not weared, not bended..). check that the hoses don’t hinder rock drill movement.
Replace the hoses if damaged.
Verify there is no internal leak in the rock drill too.

4/2 DRILLING ROD

In case of water pressure lack, the drilling rod can be plugged. Check the water can get through
the drilling rod removing it and cleaning flushing hole. Replace the drilling rod if necessary.

4/3 CONTROL VALVE

Check hydraulic connections of the control valve.

Try to force the control valve openning to test the functionning.

4/4 PRESSURE SWITCHES

1 3 2 The pressure switches can be checked manually :

- Operate the adjusting screw (1) to the 0 bar to force the contact.
- Apply a pressure at the hydraulic inlet (2) to test the
functionning of the switch.
If the contact don’t happen, replace the pressure switch.

«Water presence» pressure switch must indicate 2 bar on the adjusting indicator (3).
It is connected to a signaling light on the drilling control panel («Drilling fault»). This light must
switch off after the start-up of the pump.

«Pump start-up» pressure switch must indicate 15 bar on the adjusting indicator (3).

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
 Page 10 WATER CIRCUIT 11-10-2004 AR-RL-FL

4/5 WATER SUPPLY

Check mine’s water supply pressure witch must be > 2 bar

Check the connection.

4/6 FILTER

The water filter at the inlet of the circuit must be clean each
week to not clog. The filter element (1) must be replace if
1 damaged.
2

Warning : The filter must be down positioned to function (2).

You can have a ball valve in place of the plug, to clean the filter element easier (option).

4/7 PRESSURE REDUCER

The pressure reducer must be adjusted to obtain a pump inlet

1
pressure of 4 bar. Operate the adjusting screw (1) to adjust
pressure.

(Unscrew to make outlet pressure increase).

=> Check pressure at water pump inlet : P < 4 bar

=> Check pressure reducer functionning : Pressure must vary when operating the adjusting
screw.

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
11-10-2004 AR-RL-FL WATER CIRCUIT Page 11

4/8 WATER PUMP

Four differents pumps can be mounted on machines :

- Machines with single boom :
2 PUMP CR3 19 (GRUNDFOS)
- Machines with two booms :
PUMP CR5 16 (GRUNDFOS)
1
- Machines XLP :
PUMP CR1 11 (GRUNDFOS)
- Machines equiped with air mist option :
PUMP 3CP 1140 (CAT)

The pump must be vented after each operation on the water

circuit : Let a small amount of water get through the pump, and
slowly open the vent valve (1).

=> Check pressure at water pump outlet : P = 15 bar

=> Look for leaks on water pump. Check motor connections
Water pump CR3 19 shown
and functionning.

See SUPPLIERS DOCUMENTATION included in this manual for diagnosis, repair and
maintenance instructions.
Main operations : - When replacing the pump motor, respect the space of 1.5mm between the
coupling and the pump.
- Grease regularily the coupling (grease nipple on the moto-pump group).

Note : On AXERA5, ROBOLT5 and SOLO5 machines, it possible force the pump starting-up
thanks to the switch S501 (see electric shematic). It can be use to test pump functionning.

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
 Page 12 WATER CIRCUIT 11-10-2004 AR-RL-FL

4/9 COOLER

2 (1) : Water inlet

(2) : Water outlet
(3) : Oil inlet
(4) : Oil outlet
3
Pressure must be the same at inlets and outlets.

In case of faults on pressure or oil temperature, without fault in

the rest of the circuits, replace the cooler.
4

4/10 SAFETY RELIEF VALVE

1 The safety relief valve must be adjusted to obtain a pressure of

15 bar maximum in the high pressure circuit. Operate the
adjusting screw (1) to adjust pressure.

(Unscrew to make outlet pressure increase).

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
 11-10-2004 AR-RL-FL WATER CIRCUIT Page 13

5 PERIODICAL MAINTENANCE TABLE

CHECK LUBRICATE CLEAN CHANGE

TEST FLUSH SERVICE
REPLACE

When
FREQUENCY (PERCUSSION HOURS)
completed
WATER CIRCUIT Y N
Daily 50 200 600 1200 1800 2400 3600
yes no

Leakage

All equipments condition

Freedom and condition of moooving parts

Hoses / Union / Fitting

Water pump coupling : One grease nipple

Filter element : check and clean

Motor / pump coupling : Greasing

Vent the water pump AT EACH OPERATION ON CIRCUIT

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80
Page 14 WATER CIRCUIT 11-10-2004 AR-RL-FL

SANDVIK TAMROCK SECOMA S.A.S

19 avenue De Lattre-de-Tassigny - ZI
B.P. 46 - 69881 MEYZIEU Cedex
Tel : (33) 472 45 22 00 Fax : (33) 478 31 79 80