Original instructions

en-US 4 2022-05-16

Flushing Circuit
DL432i

GUID-687D247E-6385-4C6B-B033-74174D6A9FF9
Flushing Circuit DL432i

WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and follow
operator's and maintenance manuals before installing, inspecting,
operating, servicing, testing, cleaning, transporting, storing,
dismantling or disposing of the product or a part or accessory of the
product. Keep this publication for future reference.

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Flushing Circuit DL432i

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Flushing Circuit DL432i

Table of Contents
1 Introduction.......................................................................9
1.1 The purpose of these instructions............................................................ 9
1.1.1 Validity of the manuals...................................................................... 9
1.2 General.........................................................................................................9

2 Safety and Environmental Instructions........................ 11

2.1 Safety..........................................................................................................11

3 Main Components.......................................................... 13
3.1 Air circuit components............................................................................. 13
3.2 Air circuit diagram.................................................................................... 14
3.3 Water circuit components........................................................................ 20
3.4 Water circuit diagram................................................................................22
3.5 Air-mist (optional) circuit components................................................... 29
3.6 Air-mist circuit diagram............................................................................30

4 Air Circuit Operation...................................................... 35

4.1 Air Circuit Operation.................................................................................35
4.2 Air Circuit Operation (OWA).....................................................................36
4.3 Compressor pressure shut down bleed valve....................................... 37
4.4 Water separator (optional)........................................................................37

5 Water Circuit Operation................................................. 39

5.1 Water circuit operation............................................................................. 39
5.2 Water circuit operation (OWA)................................................................. 40
5.3 Pressure reducing valve...........................................................................42
5.4 Water booster pump................................................................................. 43
5.4.1 Operation and maintenance............................................................ 43
5.5 Oil cooler....................................................................................................43

6 Air-Mist Circuit Operation..............................................45

6.1 Air-mist circuit operation......................................................................... 45

7 Operator's Maintenance Procedures............................ 47

7.1 Water circuit...............................................................................................47
7.1.1 Checking the water circuit for leaks.................................................47
7.1.2 Cleaning the mud separator............................................................ 47
7.1.3 Checking the operation of the pressure reducing valve.................. 47
7.1.4 Bleeding the water booster pump....................................................48
7.1.5 Checking the operation of the oil cooler(s) (oil-water).....................48
7.1.6 Checking the oil cooler (oil-air)........................................................49
7.1.7 Adjusting the mine's inlet pressure..................................................49
7.2 Air circuit................................................................................................... 50
7.2.1 Draining the water separator (optional)........................................... 50
7.2.2 Draining the water separator........................................................... 50
7.2.3 Draining the air receiver (optional).................................................. 51

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Flushing Circuit DL432i
7.3 Compressor............................................................................................... 51
7.3.1 Checking the correct running temperature...................................... 51
7.3.2 Checking the cooling air fan............................................................ 51
7.3.3 Checking the compressor oil level...................................................51
7.3.4 Checking for oil leaks...................................................................... 51
7.4 Compressor CT60/CT80/CT100................................................................51
7.4.1 Checking the correct running temperature...................................... 51
7.4.2 Checking the compressor oil level...................................................52
7.4.3 Checking the compressor cooler.....................................................52
7.4.4 Checking the oil leaks..................................................................... 53
7.4.5 Checking the condition of the oil hoses...........................................53
7.4.6 Cleaning the compressor air filter pre-cleaner................................ 53
7.5 SLU............................................................................................................. 53
7.5.1 Checking the oil level...................................................................... 53
7.5.2 Emptying the shank lubrication return oil tank (DL422iE, DL432i).. 54

8 Periodic Maintenance Procedures................................55

8.1 Water circuit...............................................................................................55
8.1.1 Replacing the mud separator strainer............................................. 55
8.1.2 Adjusting the thermostat valve........................................................ 55
8.2 Air circuit................................................................................................... 56
8.2.1 Cleaning the cooler for shank lubrication air (optional)................... 56
8.2.2 Checking the condition of the air receiver (optional)....................... 57
8.3 Compressor............................................................................................... 57
8.3.1 Procedures prior to compressor maintenance................................ 57
8.3.2 Changing the compressor oil...........................................................58
8.3.3 Replacing the compressor oil filter.................................................. 59
8.3.4 Checking and retightening main motor cables................................ 59
8.3.5 Replacing the compressor air filters................................................ 59
8.3.6 Cleaning the cooler externally......................................................... 60
8.3.7 Cleaning the compressor externally with a cloth............................. 60
8.3.8 Replacing the compressor belts...................................................... 60
8.3.9 Replacing the compressor oil separator cartridge...........................61
8.3.10 Cleaning the oil return line...............................................................63
8.3.11 Lubricating the electric motor bearings (CT compressor)............... 63
8.3.12 Checking the operation of the compressor relief valve................... 63
8.3.13 Replacing the seal kit of the inlet valve........................................... 64
8.3.14 Checking the function of the thermometer safety limits...................64
8.3.15 Checking the condition of the compressor hoses........................... 64
8.3.16 Replacing the blow-down valve.......................................................65
8.3.17 Replacing the oil thermostat............................................................65
8.3.18 Replacing the motor bearings......................................................... 66
8.3.19 Replacing the shaft seal kit............................................................. 66
8.3.20 Replacing the air end...................................................................... 66
8.4 Compressor CT60/CT80/CT100................................................................66
8.4.1 Procedures prior to compressor maintenance................................ 66
8.4.2 Changing the compressor oil...........................................................66
8.4.3 Replacing the compressor oil filter.................................................. 69
8.4.4 Replacing the compressor air filter..................................................70
8.4.5 Cleaning the compressor cooler......................................................71

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Flushing Circuit DL432i
8.4.6 Cleaning the compressor externally................................................ 72
8.4.7 Adjusting the connectors and bolts................................................. 72
8.4.8 Checking the function of the thermometer safety limits...................72
8.4.9 Replacing the compressor belts...................................................... 72
8.4.10 Replacing the compressor oil separator cartridge...........................73
8.4.11 Checking the operation of the pressure relief valve........................ 74
8.4.12 Replacing the seal kits of the inlet and the discharge valve............75
8.4.13 Cleaning the strainer of the oil return line........................................75
8.4.14 Adjusting the compressor cooler fan............................................... 75
8.5 SLU............................................................................................................. 76
8.5.1 Draining the condensed water.........................................................76
8.5.2 Checking the condition of the water separator................................ 76
8.5.3 Changing the water separator filter element................................... 77
8.5.4 Cleaning the tank............................................................................ 78
8.5.5 Replacing the breather.................................................................... 78

9 Maintenance and Repair Instructions...........................79

9.1 Checking the operation of the air-mist flushing control valve............. 79
9.2 Changing the control needle of the air-mist flushing control valve.....79
9.3 Changing the control needle seals of the air-mist flushing control
valve........................................................................................................... 82
9.4 Adjusting the restrictor valve.................................................................. 84
9.5 Adjusting the air line flow meter (optional)............................................ 85
9.6 Checking the water flow sensor settings............................................... 88

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Flushing Circuit DL432i

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Copyright © Sandvik
ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
Flushing Circuit DL432i

1 INTRODUCTION
1.1 The purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
These instructions must be followed along with other manuals of the rig,
any instructions given in local laws and regulations, any orders given by
local authorities, and all protective measures specific for the site.
Before operating, or performing maintenance or repair procedures for the
component or system described in this manual, read and understand the
information in operator´s and maintenance manuals supplied with the
machine. Pay special attention to the safety information in chapter Safety
and environmental instructions of those manuals.
1.1.1 Validity of the manuals
This manual, and especially the safety information, is valid only if no
unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include information
on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.

1.2 General
Compressed air is used for two main purposes:
• shank lubrication
• blowing the drill hole clean after drilling
The compressed air is taken from the compressor or from the pneumatic
network at the drilling site.
Water is used for two main purposes:
• flushing the drill hole
• various cooling operations
The water is conveyed to the bottom of the hole through the aperture in the
drill rod. As it flows upward, the flushing water conveys with it the cuttings
while simultaneously cooling the drilling equipment. Before flowing to the
drill rod, the water flows through the oil cooler, thus cooling the drilling
hydraulic oil.
In air mist flushing (optional), water is sprayed into the flushing air. The
amount of water is adjusted according to hole size, drilling direction, and
rock type.

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Flushing Circuit DL432i

When using water flushing, check that the volume of the water is sufficient.
When using the air mist flushing, check that the volume of the air is
sufficient.
When the mine water supply is limited or the rock conditions prevent using
water, the main flushing media is compressed air. Air mist is only used to
avoid the excessive dust building.

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Flushing Circuit DL432i

2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1 Safety

DANGER
ELECTRICAL HAZARD!
Failure to strictly follow instructions will lead to death and/or severe
injury and/or property damage.
Work on electrical equipment or devices is to be performed only by
persons with the expertise and qualifications required by the
authorities, or under the supervision of a person meeting these
requirements.

WARNING
PERSONAL INJURY HAZARD!
Moving machine could cause death or severe injury.
Maintenance and repair work should only be done when the rig is out
of operation. Make sure that it cannot be accidentally started (open
the main power switch, for instance) during the repair work.
Unauthorized persons are not allowed near the rig during the repair
work.

WARNING
SKIN INJECTION HAZARD!
High-pressure hydraulic fluid can penetrate the skin, causing severe
injury.
Do not try to locate a leak on a hydraulic hose with your hand! Use a
piece of cardboard or equivalent. If hydraulic fluid penetrates your
skin, seek medical advice immediately!

WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and obey
following instructions before operating the equipment.
Service and adjustment procedures must be carried out by
personnel with specialized operation and service training.
Carefully plan your work beforehand to minimize risk of damage or
injury.

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Flushing Circuit DL432i

RISK OF EQUIPMENT DAMAGE!

NOTICE If the water is allowed to freeze it can damage the cleaner.
In cold weather any water in the air separator(s) has to be drained.

RISK OF EQUIPMENT DAMAGE!

Inadequate operation of the flushing quickly causes serious damage
to the drill bit and difficulties during drilling.
NOTICE Do not drill without adequate flushing.
Do not reuse the water returned from the flushing circulation.
Keep the pressure limits and the pressure switches in working order
and in the right settings.

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Flushing Circuit DL432i

3 MAIN COMPONENTS
3.1 Air circuit components
1 6 2
12

4 5
7
10

11
9

1
Water separator 2 SLU oil receiver
3
SLU control unit 4 Automatic drain valve
5
Manual drain valve 6 SLU air valve
7
Compressor 8 Temperature sensor
9
Cooler for shank lubrication 10 Water separator (optional)
air (optional)
11 Air receiver (optional) 12 Air flushing valve

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 3.2

14 (92)
To feed rail washing To drilling module To drilling module
valve, port P connection plate, port F connection plate, port W

1"

3/8"
1/2"
Carrier/drilling Boom
connection plate, Carrier W1 F W
front carrier

3/8"
3/8" 3/8"
OUT OUT

1 1/4"

1"
Flushing Circuit

OUT IN IN
1-10 l/min 1-10 l/min

3/8"

3/8"
OPTION IN
B B
To bit changer

0.1 bar
gripping tool Y210A MB Y210B MB

1 1/4"

To shank lubrication
air and oli collecting
piece, port 1

To shank lubrication
air and oli collecting
piece, port 2
From drilling module
connection plate, port SR
12 OUT
A
To unpressurized
8 bar

3/4"
Y10 Y9

1/4"
1/2"
M MA M MA 3/8" collector, port 3
X Y A X Y A
P
3/8"
Y9
Carrier/drilling 21 From drilling control
Boom
connection plate, 3/8" 1/4" block, port X
SL/O SL/A SR
Carrier front carrier DR IN
1/4"
Air circuit diagram

3/8"

3/8"
1 1/4"
1/2"

1/4"
1/2" 3/8"
4
8 7 left
1" 1" 3 5

Air circuit diagram

6 2

1
3/8"
1/2" 3/8"
19 right

3/4"
3/4"

Only with bit changer

11.5 11.4 11.2

1/4"
20

1/2"
OUT
50°C Y506
16 B10F 11.3

1 1/4" With OA-cooler

1 1/4" With OW-cooler
Y127 IN 8 bar
1B127P 1/4" 1/4"
6 3/4"
P A
2.8 bar

Copyright © Sandvik
1 3/4" 3/4"
ø3 mm A P
OUT IN
11.1 WA

1/2"
WB WD 1/4" 3/4"
DRAIN

3/4"
17

1 1/4"

1/4"
1 1/4"

2 5 DRAIN L2
1/2"
11 L3 L6 B230P
1B277F 2 1 L5 L8
1 L4 L7
Y129 Connection plate, 25 bar
OL BR CT7 L1
rear carrier 3 2 1/2", 1/2" 3/4" 3/4"
L 2 OUT OUT
IN

3/4"
CT1 CT2 1 1/4" To high pressure washer, port S
VENT

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3/4"
1 1/4"
3.5 bar 0.2 bar 4 With antifreeze filling PIPE ø20x2
S S SC air
M

1/4"
CT3
DRAIN
With antifreeze blowing PIPE ø20x2 IN
DRAIN CT4

With SLU air cooler

2
OUT
CT5.1 5 7 3
D OPTION
8 13
1Y277 M 6 4 To grease pump DRAIN/ 3/4"
1/4"
PIPE ø38x3

3/4"

9 1 3/8" BREATHING
CT6.1 CT8 PC OUT
IN 2 1-7 bar Hose only with CT60/CT80
3/4"

0.5 bar
3 18 IN
TG

Without SLU air cooler

TC

3/4"
P T 1 OUT
Y466 DRAIN
10 With SLU air cooler 14 3/4" 3/4"
3/4"

IN

1"
With antifreeze filling With antifreeze blowing 8 bar
A4 1/2"
3/4"

P A
1 1/4" 1 1/4" PIPE ø30x3 A1 PIPE ø30x3 OUT
A2

3/8"
3/8"
A3 3 bar
Without water hose reel
1 1/2"

From drilling B240T 14.1

To unpressurized
control block,
collector, port 2 10.3 10.2
1 1/2"

port X

1/2"
10.1 8 bar M 8 B

leak
1/2"
X
A
1"
IN 7 Without water hose reel
15 bar
DL432i
Flushing Circuit DL432i

ID Component Function
Removes condensed water from the air and improves air
1 Water separator
quality for shank lubrication
2 SLU oil receiver Oil tank for shank lubrication functions
Controls SLU unit functions and sends/receives information
3 SLU control unit
to/from the control system
Automatic drain valve Opens automatically every five minutes and drains water
4
(Y129) from the water separator (1)
Used when manual draining of the water separator (1) is
5 Manual drain valve
needed
6 SLU air valve (Y127) Controls the air flow of the shank lubrication
Produces compressed air required for drilling, shank lubrica-
7 Compressor
tion, greasing and anti-freeze system (optional)
Monitors the compressor (7) temperature. Sends a notice to
Temperature sensor
8 GUI when temperature rises to 105 °C, shuts down the com-
(B240T)
pressor when the temperature rises to 115 °C
Cooler for shank lubrication
9 Cools down shank lubrication air in SLU air line
air (optional)
Cleans the air which comes from the site air network and
10 Air cleaner (optional)
separates water from the air
The manually operated ball valve (10.1) is used for draining
10.1 Drain valve
the air receiver
10.2 Check valve
10.3 Air inlet valve
11 Air receiver (optional) Provides air for hole blowing and operates as an air storage
11.1 Drain valve Used when manual draining of the air receiver is needed
11.2 Pressure relief valve Limits the maximum pressure in the air receiver to 8 bars
11.3 Pressure gauge Displays the air pressure in the air receiver
Stores the pressurized air which is used for blowing the hole
11.4 Air receiver
clean
11.5 Throttle valve Adjusts the filling speed of the receiver
On/off type valve which allows/prevents the air flow to the
12 Air flushing valve (Y10)
rock drill flushing circuit
13 Distributor Distributes air in main air circuit
Compressor pressure shut Unloads the air line pressure when the compressor (7) shuts
14
down bleed valve (Y446) down
Reduces the noise level when air is unloaded from the air cir-
14.1 Exhaust silencer
cuit

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Flushing Circuit DL432i

ID Component Function
SLU air line pressure sen-
16 Monitors the air pressure in SLU air line
sor (B127P)
Ensures that proper air flow is always available for shank lu-
17 SLU air line restrictor
brication functions
Ensures that adequate air flow is always available for shank
18 Restrictor valve
lubrication functions
Shank lubrication return oil
19 Storages used shank lubrication oil from rock drill
tank (machine frame)
Drain valve for shank lubri- Is used to drain the shank lubrication return oil tank for sepa-
20
cation return oil tank rate receiver
21 Air outlet

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Flushing Circuit DL432i

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 18 (92)
To feed rail washing To drilling module To drilling module
valve, port P connection plate, port F connection plate, port W

1"

3/8"
1/2"
Carrier/drilling Boom
connection plate, Carrier W1 F W
front carrier

3/8"
3/8" 3/8"
OUT
Flushing Circuit

OUT

1 1/4"

1"
IN IN
1-10 l/min 3/8" 1-10 l/min

3/8"
OPTION B B
To bit changer

0.1 bar
gripping tool Y210A MB Y210B MB

1 1/4"

To shank lubrication
air and oli collecting
piece, port 1

To shank lubrication
air and oli collecting
piece, port 2
From drilling module
connection plate, port SR
12 OUT
A
To unpressurized
8 bar

3/4"
Y10 Y9

1/4"
1/2"
M MA M MA 3/8" collector, port 3
X Y A X Y A
P
3/8"
Y9
Carrier/drilling 21 From drilling control
Boom
connection plate, 3/8" 1/4" block, port X
SL/O SL/A SR
Carrier front carrier DR IN
1/4"
3/8"

3/8"
1 1/4"
1/2"

1/4"
1/2" 3/8"
4
8 7 left
1" 1" B10F 3 5
6 2

1
3/8"
1/2" 3/8"
3/4"

19 right

3/4"
50°C

Air circuit diagram (OWA)

Only with bit changer
With OA-cooler
With OW-cooler

1/4"
20

1/2"
Y506
16
Y127 3/4"
1 1/4"
1 1/4"

1B127P 1/4" 1/4"

Copyright © Sandvik
6 P A
2.8 bar 1 WA
ø3 mm A P
OUT IN WB WD 1/4"

1 1/4"
DRAIN
3/4"
1 1/4"

17 L2
1/2"

1/4"
3/4"
3/4"
2 L3 L6 B230P
5 L5 L8 25 bar
L4 L7
L1
1/2", 1/2"
1B277F 1 3/8"
OL BR CT7
Y129 To high pressure washer, port S
4 PIPE
3/4" 3/4"
L 2 OUT

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16

CT1 CT2 3/8" 3/8"
VENT
3.5 bar 0.2 bar 3/8"

With SLU air cooler

M

Without SLU air cooler

S S SC OUT

1/4"
CT3
DRAIN
IN
DRAIN CT4 M With anti-freeze blowing Y751 PIPE 3/4"
9
IN
CT5.1 PIPE
D
Y466
1 1/2"

1Y277 14.1 1/4"

14 3/4"
CT6.1 CT8 PC Hose only with CT60/CT80
13

3/4"
1-7 bar
0.5 bar
TG TC
3 3/4" PIPE 3/4"
P T
DRAIN
OPTION
8 bar
3/8" To grease pump PIPE 3/4"
With anti-freeze blowing 3/4"

1 1/4"
B240P
PIPE 3/4"

3/8"
3/8"
7 1 1/2"
8 15 bar
From drilling B240T
1 1/2"

To unpressurized
control block,
collector, port 2
port X
3/4"

14 bar
PIPE

To compressor OA 1"
With water hose reel

cooler, port IN1 3/4"

From compressor OA 1"
cooler, port OUT2 With water hose reel
DL432i
Flushing Circuit DL432i

ID Component Function
Removes condensed water from the air and improves air
1 Water separator
quality for shank lubrication
2 SLU oil receiver Oil tank for shank lubrication functions
Controls SLU unit functions and sends/receives information
3 SLU control unit
to/from the control system
Opens automatically every five minutes and drains water
4 Automatic drain valve (Y129)
from the water separator (1)
Used when manual draining of the water separator (1) is
5 Manual drain valve
needed
6 SLU air valve (Y127) Controls the air flow of the shank lubrication
Produces compressed air required for drilling, shank lubrica-
7 Compressor
tion, greasing and anti-freeze system (optional)
Monitors the compressor (7) temperature. Sends a notice to
8 Temperature sensor (B240T) GUI when temperature rises to 105 °C, shuts down the
compressor when the temperature rises to 115 °C
Cooler for shank lubrication
9 Cools down shank lubrication air in SLU air line
air (optional)
On/off type valve which allows/prevents the air flow to the
12 Air flushing valve (Y10)
rock drill flushing circuit
13 Distributor Distributes air in main air circuit
Compressor pressure shut Unloads the air line pressure when the compressor (7)
14
down bleed valve (Y446) shuts down
Reduces the noise level when air is unloaded from the air
14.1 Exhaust silencer
circuit
SLU air line pressure sensor
16 Monitors the air pressure in SLU air line
(B127P)
Ensures that proper air flow is always available for shank lu-
17 SLU air line restrictor
brication functions
Shank lubrication return oil
19 Storages used shank lubrication oil from rock drill
tank (machine frame)
Drain valve for shank lubri- Is used to drain the shank lubrication return oil tank for sep-
20
cation return oil tank arate receiver
21 Air outlet

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Flushing Circuit DL432i

3.3 Water circuit components

37
36
25

24 27

28

26
35
29
34

30

33
38
32

31

43 32

31

24 Water booster pump 25 Bleeding valve

26 Distributor 27 Pressure relief valve
28 Pressure transducer 29 Water hose reel (optional)
30 Pressure relief valve 31 Mud separator assembly
32 Pressure reducing valve 33 Water hose reel control
valve (optional)
34 High pressure washer 35 Boot washer
36 Water flushing valve 37 Oil cooler

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Flushing Circuit DL432i

38 Anti-freeze filling valve as- 43 Anti-freeze blowing assem-

sembly (optional) bly (optional)

Copyright © Sandvik 21 (92)

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 3.4

22 (92)
To feed rail washing To drilling module To drilling module
valve, port P connection plate, port F connection plate, port W

1"

3/8"
1/2"
Carrier/drilling Boom
connection plate, Carrier W1 F W
front carrier

3/8"
3/8" 3/8"
OUT OUT

1 1/4"

1"
Flushing Circuit

OUT IN IN
1-10 l/min 1-10 l/min

3/8"

3/8"
OPTION IN
41 B B
To bit changer

0.1 bar
gripping tool Y210A MB Y210B MB

1 1/4"

To shank lubrication
air and oli collecting
piece, port 1

To shank lubrication
air and oli collecting
piece, port 2
From drilling module
connection plate, port SR
OUT
A
To unpressurized
8 bar

3/4"
Y10 Y9

1/4"
1/2"
M MA M MA 3/8" collector, port 3
X Y A X Y A
P
3/8"
Y9
Carrier/drilling From drilling control
Boom
connection plate, 3/8" 1/4" block, port X
SL/O SL/A SR
Carrier front carrier DR IN
1/4"
3/8"

3/8"
36

1 1/4"
1/2"

1/4"
1/2" 3/8"
4
8 7
Water circuit diagram

left
1" 1" 3 5
6 2

1
35
3/8"
40 1/2" 3/8"

Water circuit diagram

right

3/4"
3/4"
39

Only with bit changer

1/4"
1/2"
OUT
50°C Y506
B10F
33

1 1/4" With OA-cooler

1 1/4" With OW-cooler
Y127 IN 8 bar
1B127P 1/4" 1/4"
37.1 P A
3/4"
2.8 bar

Copyright © Sandvik
3/4" 3/4" 37
ø3 mm A P
OUT IN
WA

1/2"
WB WD 1/4" 3/4"
DRAIN 34

3/4"
1 1/4"

1/4"
1 1/4"

DRAIN L2
28
1/2"
L3 L6 B230P
1B277F 2 1 26 L5 L8
1 L4 L7
Y129 Connection plate, 25 bar 27
OL BR CT7 L1
rear carrier 38 3 2 1/2", 1/2" 3/4" 3/4"
L 2 OUT OUT
IN

3/4"
CT1 CT2 1 1/4" To high pressure washer, port S
VENT

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16

3/4"
1 1/4"
3.5 bar 0.2 bar With antifreeze filling PIPE ø20x2
S S SC air
M

1/4"
CT3 25 24 32.1 42
DRAIN
With antifreeze blowing PIPE ø20x2 IN
DRAIN CT4

With SLU air cooler

2
OUT
CT5.1 5 7 3
D OPTION
8
1Y277 M 6 4 To grease pump 31.2 DRAIN/ 3/4"
1/4"
PIPE ø38x3

3/4"

1 3/8" 32 BREATHING
CT6.1 CT8 PC OUT
IN 2 1-7 bar Hose only with CT60/CT80
3/4"

0.5 bar
IN
TG

Without SLU air cooler

TC 31.3

3/4"
P T 1 OUT
Y466 DRAIN
3/4" 3/4"
With SLU air cooler
3/4"

IN 31

1"
With antifreeze filling With antifreeze blowing 8 bar
A4 1/2"
3/4"

P A
1 1/4" 1 1/4" PIPE ø30x3 A1 PIPE ø30x3 OUT
A2

3/8"
3/8"
A3 3 bar
Without water hose reel
31.1
1 1/2"

From drilling B240T

To unpressurized
control block,
collector, port 2
1 1/2"

port X

1/2"
8 bar M B

30 29 leak
1/2"
X
A
1"
IN 29.1
Without water hose reel
15 bar
DL432i
Flushing Circuit DL432i

ID Component Function
Raises the water pressure when the pressure from the site
24 Water booster pump
water network is not sufficient to ensure proper flushing
The manually operated ball valve is used for bleeding the wa-
25 Manual bleeding valve
ter booster pump (24)
From the distributor, water hose run to flushing circuit and to
26 Distributor
high pressure washer
27 Pressure relief valve Limits the maximum pressure of the system (25 bars)
Pressure transducer Measures the water pressure after the water booster pump
28
(B230P) (24)
Makes it possible for the drill rig to proceed from the water
29 Water hose reel (optional)
connection point to drilling point
Water hose reel hydraulic
29.1 Rotates the water hose reel
motor
Protects the rig water system from the network pressure
30 Pressure relief valve spikes and limits the maximum water pressure before the mud
separator (31) to 15 bars
31 Mud separator assembly
31.1 Shut-off valve Closes/opens the water supply line
Separates impurities from water before it flows to the water
31.2 Mud separator
booster pump (24)
The manually operated ball valve is used for cleaning the mud
31.3 Drain valve
separator
The valve is used to lower the feed pressure to the water
booster pump (24) to approximately 1-7 bars if the pressure in
32 Pressure reducing valve
the mine water system is higher. Defines the maximum pres-
sure the water booster pump (24) can produce
32.1 Pressure gauge Indicates the water booster pump feed pressure
Cabin front window wash-
33 Controls the front window washer water on/off
er valve (Y506, optional)
34 Water outlet Water outlet for external use through the manual ball valve
35 Boot washer
36 Water flushing valve (Y9) Controls the flushing water flow to the rock drill
Flushing water cools down the drilling hydraulics oil (from oil to
37 Oil cooler
water type)
37.1 Drain valve Manual drain valve to drain water from the cooler
Anti-freeze filling valve as-
38
sembly (optional)

Copyright © Sandvik 23 (92)

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
Flushing Circuit DL432i

ID Component Function
Gives additional water flow for oil cooler (37) when return oil
39 Thermostat valve (water) temperature from the cooler exceeds temperature limit of the
thermostat valve
40 Water circuit distributor Distributes water in the main water circuit
Measures water flow and sends information to the control sys-
41 Water flow sensor (B9F)
tem
42 Washing hose with reel Washer with handle for low pressure washing

24 (92) Copyright © Sandvik

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
Flushing Circuit DL432i

This page is intentionally left blank

25 (92) Copyright © Sandvik

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
 26 (92)
To feed rail washing To drilling module To drilling module
valve, port P connection plate, port F connection plate, port W

1"

3/8"
1/2"
Carrier/drilling Boom
connection plate, Carrier W1 F W
front carrier

3/8"
3/8" 3/8"
OUT
Flushing Circuit

OUT

1 1/4"

1"
IN IN
1-10 l/min 3/8" 1-10 l/min

3/8"
OPTION B B
To bit changer
41

0.1 bar
gripping tool Y210A MB Y210B MB

1 1/4"

To shank lubrication
air and oli collecting
piece, port 1

To shank lubrication
air and oli collecting
piece, port 2
From drilling module
connection plate, port SR
OUT
A
To unpressurized
8 bar

3/4"
Y10 Y9

1/4"
1/2"
M MA M MA 3/8" collector, port 3
X Y A X Y A
P
3/8"
Y9
Carrier/drilling From drilling control
Boom
connection plate, 3/8" 1/4" block, port X
SL/O SL/A SR
Carrier front carrier DR IN
1/4"
3/8"

3/8"
36

1 1/4"
1/2"

1/4"
1/2" 3/8"
4
8 7 left
1" 1" B10F 3 5
6 2

3/8" 1
35
40 1/2" 3/8"
3/4"

39 right

3/4"
50°C

Only with bit changer

With OA-cooler
With OW-cooler

1/4"
1/2"
Y506 33

Water circuit diagram (OWA)

Y127 3/4"
1 1/4"
1 1/4"

1B127P 1/4" 1/4"

Copyright © Sandvik
37.1 P A
2.8 bar
WA
37
ø3 mm A P
45
OUT IN WB WD 1/4"

1 1/4"
DRAIN
3/4"
1 1/4"

L2 28 34
1/2"

1/4"
3/4"
3/4"
44 L3 L6 B230P
L5 L8 25 bar
45.1 26 L4 L7 42
L1
1/2", 1/2"
27
1B277F 1 3/8"
OL BR CT7
Y129 To high pressure washer, port S
PIPE
3/4" 3/4"
L 2 OUT

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16

CT1 CT2 3/8" 3/8"
VENT
3.5 bar 0.2 bar 3/8"

With SLU air cooler

25 M

Without SLU air cooler

S S SC 24 32.1
OUT

1/4"
CT3
DRAIN
IN
DRAIN CT4 M With anti-freeze blowing Y751 PIPE 3/4"

IN
CT5.1 PIPE 43
D
Y466
1 1/2"

1Y277 31.2 1/4"

32 3/4"
CT6.1 CT8 PC Hose only with CT60/CT80

3/4"
1-7 bar
0.5 bar
TG TC 3/4" PIPE 3/4"
P T 31.3 DRAIN
OPTION 31 8 bar
3/8" To grease pump PIPE 3/4"
With anti-freeze blowing 3/4"

1 1/4"
B240P 30 PIPE 3/4"
31.1

3/8"
3/8"
1 1/2"
15 bar
From drilling B240T
1 1/2"

To unpressurized
control block, 29
collector, port 2
port X
3/4"

14 bar
PIPE

To compressor OA 1"
With water hose reel

cooler, port IN1 3/4"

From compressor OA 1" 29.1
cooler, port OUT2 With water hose reel
DL432i
Flushing Circuit DL432i

ID Component Function
Raises the water pressure when the pressure from the site wa-
24 Water booster pump
ter network is not sufficient to ensure proper flushing
The manually operated ball valve is used for bleeding the water
25 Manual bleeding valve
booster pump (24)
From the distributor, water hose run to flushing circuit and to
26 Distributor
high pressure washer
27 Pressure relief valve Limits the maximum pressure of the system (25 bars)
Pressure transducer
28 Measures the water pressure after the water booster pump (24)
(B230P)
Water hose reel (option- Makes it possible for the drill rig to proceed from the water con-
29
al) nection point to drilling point
Water hose reel hydraul-
29.1 Rotates the water hose reel
ic motor
Protects the rig water system from the network pressure spikes
30 Pressure relief valve and limits the maximum water pressure before the mud separa-
tor (31) to 15 bars
Mud separator assem-
31
bly
31.1 Shut-off valve Closes/opens the water supply line
Separates impurities from water before it flows to the water
31.2 Mud separator
booster pump (24)
The manually operated ball valve is used for cleaning the mud
31.3 Drain valve
separator
The valve is used to lower the feed pressure to the water boos-
ter pump (24) to approximately 1-7 bars if the pressure in the
32 Pressure reducing valve
mine water system is higher. Defines the maximum pressure the
water booster pump (24) can produce
32.1 Pressure gauge Indicates the water booster pump feed pressure
Cabin front window
33 washer valve (Y506, op- Controls the front window washer water on/off
tional)
34 Water outlet Water outlet for external use through the manual ball valve
35 Boot washer
Water flushing valve
36 Controls the flushing water flow to the rock drill
(Y9)
Flushing water cools down the drilling hydraulics oil (from oil to
37 Oil cooler
water type)
37.1 Drain valve Manual drain valve to drain water from the cooler

Copyright © Sandvik 27 (92)

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
Flushing Circuit DL432i

ID Component Function
Gives additional water flow for oil cooler (37) when return oil
Thermostat valve (wa-
39 temperature from the cooler exceeds temperature limit of the
ter)
thermostat valve
40 Water circuit distributor Distributes water in the main water circuit
Measures water flow and sends information to the control sys-
41 Water flow sensor (B9F)
tem
42 Washing hose with reel Washer with handle for low pressure washing
Anti-freeze blowing as-
43 Is used to add anti-freeze agent to the water system
sembly
Bleeds the air from the upper part of the water booster pump
44 Bleeding valve (24) always when the pump is started and at regular intervals
during operation
Separates impurities from water after it flows from to the water
45 Mud separator
booster pump (24)
The manually operated ball valve is used for cleaning the mud
45.1 Drain valve
separator

28 (92) Copyright © Sandvik

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
Flushing Circuit DL432i

3.5 Air-mist (optional) circuit components

12

50

52

51
54 53

12 Air flushing valve 50 Air-mist water flow meter

(left)
51 Air-mist water flow meter 52 Air-mist flushing water valve
(right) (left, Y210A)
53 Air-mist flushing water valve 54 Air line flow meter
(right, Y210B)

Copyright © Sandvik 29 (92)

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
 3.6

30 (92)
To feed rail washing To drilling module To drilling module
valve, port P connection plate, port F connection plate, port W

1"

3/8"
1/2"
Carrier/drilling Boom
connection plate, Carrier W1 F W
front carrier

3/8"
3/8" 3/8"
50 OUT OUT
51

1 1/4"

1"
Flushing Circuit

OUT IN IN
1-10 l/min 1-10 l/min

3/8"

3/8"
OPTION IN
B B
To bit changer 52 53

0.1 bar
gripping tool Y210A MB Y210B MB

1 1/4"

To shank lubrication
air and oli collecting
piece, port 1

To shank lubrication
air and oli collecting
piece, port 2
From drilling module
connection plate, port SR
OUT
12 A
To unpressurized
8 bar

3/4"
Y10 Y9

1/4"
1/2"
M MA M MA 3/8" collector, port 3
X Y A X Y A
P
3/8"
Y9
Carrier/drilling From drilling control
Boom
connection plate, 3/8" 1/4" block, port X
SL/O SL/A SR
Carrier front carrier DR IN
1/4"
3/8"

3/8"
1 1/4"
1/2"

1/4"
1/2" 3/8"
4
8 7 left
1" 1" 3 5
6 2

1
3/8"
Air-mist circuit diagram

1/2" 3/8"
right

Air-mist circuit diagram

3/4"
3/4"

Only with bit changer

1/4"
1/2"
OUT
50°C Y506
B10F

1 1/4" With OA-cooler

1 1/4" With OW-cooler
Y127 IN
54 8 bar
1B127P 1/4" 1/4"
P A
3/4"
2.8 bar

Copyright © Sandvik
3/4" 3/4"
ø3 mm A P
OUT IN
WA

1/2"
WB WD 1/4" 3/4"
DRAIN

3/4"
1 1/4"

1/4"
1 1/4"

DRAIN L2
1/2"
L3 L6 B230P
1B277F 2 1 L5 L8
1 L4 L7
Y129 Connection plate, 25 bar
OL BR CT7 L1
rear carrier 3 2 1/2", 1/2" 3/4" 3/4"
L 2 OUT OUT
IN

3/4"
CT1 CT2 1 1/4" To high pressure washer, port S
VENT

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16

3/4"
1 1/4"
3.5 bar 0.2 bar With antifreeze filling PIPE ø20x2
S S SC air
M

1/4"
CT3
DRAIN
With antifreeze blowing PIPE ø20x2 IN
DRAIN CT4

With SLU air cooler

2
OUT
CT5.1 5 7 3
D OPTION
8
1Y277 M 6 4 To grease pump DRAIN/ 3/4"
1/4"
PIPE ø38x3

3/4"

1 3/8" BREATHING
CT6.1 CT8 PC OUT
IN 2 1-7 bar Hose only with CT60/CT80
3/4"

0.5 bar
IN
TG

Without SLU air cooler

TC

3/4"
P T 1 OUT
Y466 DRAIN
3/4" 3/4"
With SLU air cooler
3/4"

IN

1"
With antifreeze filling With antifreeze blowing 8 bar
A4 1/2"
3/4"

P A
1 1/4" 1 1/4" PIPE ø30x3 A1 PIPE ø30x3 OUT
A2

3/8"
3/8"
A3 3 bar
Without water hose reel
1 1/2"

From drilling B240T

To unpressurized
control block,
collector, port 2
1 1/2"

port X

1/2"
8 bar M B

leak
1/2"
X
A
1"
IN
Without water hose reel
15 bar
DL432i
Flushing Circuit DL432i

ID Component Function
On/off type valve which allows/prevents the air flow to/
12 Air flushing valve (Y10)
from the rock drill flushing circuit
Displays the amount of water flow (L/min) during air-mist
50 Air-mist water flow meter (left)
flushing
Air-mist water flow meter Displays the amount of water flow (L/min) during air-mist
51
(right) flushing
Air-mist flushing water valve
52 Adjusts proportionally water flow during air-mist flushing
(left, Y210A)
Air-mist flushing water valve
53 Adjusts proportionally water flow during air-mist flushing
(right, Y210B)
Measures air flow and sends information to the control
54 Air line flow meter (B10F)
system during air-mist flushing

Copyright © Sandvik 31 (92)

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
 32 (92)
To feed rail washing To drilling module To drilling module
valve, port P connection plate, port F connection plate, port W

1"

3/8"
1/2"
Carrier/drilling Boom
connection plate, Carrier W1 F W
front carrier

3/8"
3/8" 3/8"
50 OUT
51
Flushing Circuit

OUT

1 1/4"

1"
IN IN
1-10 l/min 3/8" 1-10 l/min

3/8"
OPTION B B
To bit changer 52 53

0.1 bar
gripping tool Y210A MB Y210B MB

1 1/4"

To shank lubrication
air and oli collecting
piece, port 1

To shank lubrication
air and oli collecting
piece, port 2
From drilling module
connection plate, port SR
OUT
12 A
To unpressurized
8 bar

3/4"
Y10 Y9

1/4"
1/2"
M MA M MA 3/8" collector, port 3
X Y A X Y A
P
3/8"
Y9
Carrier/drilling From drilling control
Boom
connection plate, 3/8" 1/4" block, port X
SL/O SL/A SR
Carrier front carrier DR IN
1/4"
3/8"

3/8"
1 1/4"
1/2"

1/4"
1/2" 3/8"
4
8 7 left
1" 1" B10F 3 5
54 6 2

1
3/8"
1/2" 3/8"
3/4"

right

3/4"
50°C

Only with bit changer

With OA-cooler
With OW-cooler

1/4"
1/2"
Y506

Y127 3/4"
1 1/4"
1 1/4"

1B127P

Air-mist circuit diagram (OWA)

1/4" 1/4"

Copyright © Sandvik
P A
2.8 bar
WA
ø3 mm A P
OUT IN WB WD 1/4"

1 1/4"
DRAIN
3/4"
1 1/4"

L2
1/2"

1/4"
3/4"
3/4"
L3 L6 B230P
L5 L8 25 bar
L4 L7
L1
1/2", 1/2"
1B277F 1 3/8"
OL BR CT7
Y129 To high pressure washer, port S
PIPE
3/4" 3/4"
L 2 OUT

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16

CT1 CT2 3/8" 3/8"
VENT
3.5 bar 0.2 bar 3/8"

With SLU air cooler

M

Without SLU air cooler

S S SC OUT

1/4"
CT3
DRAIN
IN
DRAIN CT4 M With anti-freeze blowing Y751 PIPE 3/4"

IN
CT5.1 PIPE
D
Y466
1 1/2"

1Y277 1/4"
3/4"
CT6.1 CT8 PC Hose only with CT60/CT80

3/4"
1-7 bar
0.5 bar
TG TC 3/4" PIPE 3/4"
P T
DRAIN
OPTION
8 bar
3/8" To grease pump PIPE 3/4"
With anti-freeze blowing 3/4"

1 1/4"
B240P
PIPE 3/4"

3/8"
3/8"
1 1/2"
15 bar
From drilling B240T
1 1/2"

To unpressurized
control block,
collector, port 2
port X
3/4"

14 bar
PIPE

To compressor OA 1"
With water hose reel

cooler, port IN1 3/4"

From compressor OA 1"
cooler, port OUT2 With water hose reel
DL432i
Flushing Circuit DL432i

ID Component Function
On/off type valve which allows/prevents the air flow to/
12 Air flushing valve (Y10)
from the rock drill flushing circuit
Displays the amount of water flow (L/min) during air-mist
50 Air-mist water flow meter (left)
flushing
Air-mist water flow meter Displays the amount of water flow (L/min) during air-mist
51
(right) flushing
Air-mist flushing water valve
52 Adjusts proportionally water flow during air-mist flushing
(left, Y210A)
Air-mist flushing water valve
53 Adjusts proportionally water flow during air-mist flushing
(right, Y210B)
Measures air flow and sends information to the control
54 Air line flow meter (B10F)
system during air-mist flushing

Copyright © Sandvik 33 (92)

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
Flushing Circuit DL432i

This page is intentionally left blank

34 (92) Copyright © Sandvik

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
Flushing Circuit DL432i

4 AIR CIRCUIT OPERATION

4.1 Air Circuit Operation
Compressed air is always required to facilitate the drilling functions. There
are two ways to supply the compressed air to the rig - from the onboard
compressor unit or from mine’s air network.
The compressor unit (7) is a screw type rotary compressor and it is started
by the user or by the control system. Temperature sensor (8) monitors the
temperature of the compressor unit. If the temperature rises above 105 °C
a notice is shown on GUI. If the temperature rises above 115 °C the control
system automatically shuts down the compressor.
A solenoid operated 2/2 shutdown bleed valve (14) is connected to the
output of the compressor unit. It is a normally open type valve and thus acts
as an unloading valve in the air circuit. In uncontrolled position the valve
connects the air circuit to the atmosphere and unloads the pressure from
the air circuit via exhaust silencer (14.1) always when the compressor unit
is not rotating or it is shut down.
The compressed air produced by the compressor (7) reaches air line
restrictor valve (18). This valve restricts the air flow in the main line air line
and forces a portion of air to flow to water separator (1) of the shank
lubrication line. The purpose of the water separator is to remove condensed
water from the air.
The shank lubrication air valve (6) opens when forced air flushing is
activated or drilling is started. The air begins to flow through the shank
lubrication air valve (6) and SLU air line restrictor (17). The fixed restrictor
(17) ensures and limits an adequate air flow for shank lubrication. While air
valve (6) is open, SLU air line pressure sensor (16) monitors the air
pressure in shank lubrication air line. Too low air pressure gives an alert on
GUI.
From the SLU air line restrictor (17) the air continues to flow shank
lubrication’s collecting piece which combines the lines coming from the air
circuit and the shank lubrication oil line coming from the SLU unit’s oil
receiver (2). The amount of shank lubrication oil pumped to shank
lubrication oil line is controlled by the SLU control unit (3). From the
collecting piece air and oil continues toward the rock drill in separate hoses
which are connected coaxial, oil flows in a smaller plastic hose inside the
bigger air hose. Finally the oil and air are mixed 500 millimeters before the
rock drill. The mixture continues to the rock drill and finally lubricates the
shank.
Alternatively the pressurized air can be taken from the mine’s pneumatic
network. When the air is taken from mine’s network it first flows through the
air inlet valve (10.3) and after that through the air cleaner (10). 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. Air cleaner (10) works on a cyclone
principle and it removes impurities and water from the air. The impurities
and water can be removed manually from the bottom of the cleaner with a

Copyright © Sandvik 35 (92)

ID:GUID-687D247E-6385-4C6B-B033-74174D6A9FF9 en-US 4 2022-05-16
Flushing Circuit DL432i

drain valve (10.1). From the air cleaner air flows to main air line distributor
block (13). From the distributor block portion of air flows through the air line
restrictor valve (18) to shank lubrication circuit. After the restrictor valve
(18) the operation of the shank lubrication system is similar as described in
the previous chapter. From the distributor (13) air is also supplied to
optional functions such as antifreeze filling and grease pump. Rig’s main air
line continues from the distributor block (13). An optional air receiver (11)
provides air for the hole blowing.

11.5 11.2

11.4 11.1 11.3

The loading speed of the air receiver tank (11.4) can be adjusted by the
two-port throttle valve (11.5). The throttle valve is equipped with a check
valve that allows the air to unload from the receiver faster than it is loaded.
Air receiver tank can be drained with a manually operated drain valve (11.1)
and a pressure relief valve (11.2) limits the tank maximum pressure to 8
bars. Air receiver's pressure level can be checked from the pressure gauge
(11.3). The air receiver (11) is connected to rig’s main air line after the
distributor block (13).
The air flushing valve (12) is activated by the operator or by the control
system. When the air flushing valve (12) is opened, the air flows onward to
the rock drill.

4.2 Air Circuit Operation (OWA)

Compressed air is supplied to the rig from the onboard compressor unit.
The compressor unit (7) is a screw type rotary compressor and it is started
by the user or by the control system. Temperature sensor (8) monitors the
temperature of the compressor unit. If the temperature rises above 105 °C
a notice is shown on drilling display. If the temperature rises above 115 °C
the control system automatically shuts down the compressor. The
compressor oil cooling heat exchanger is cooled down by an external fan
driven by a hydraulic motor. The cooling fan motor is supplied by a drilling
power pack hydraulic pump (HPP1).
A solenoid operated 2/2 shutdown bleed valve (14) is connected to the
output of the compressor unit. It is a normally open type valve and thus acts
as an unloading valve in the air circuit. In uncontrolled position the valve

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connects the air circuit to the atmosphere and unloads the pressure from
the air circuit via exhaust silencer (14.1) always when the compressor unit
is not rotating or it is shut down.
The compressed air produced by the compressor (7) reaches distributor
block (13) and a portion of air flows to water separator (1) of the shank
lubrication line. The purpose of the water separator is to remove condensed
water from the air.
The shank lubrication air valve (6) opens when forced air flushing is
activated or drilling is started. The air begins to flow through the shank
lubrication air valve (6) and SLU air line restrictor (17). The fixed restrictor
(17) ensures and limits an adequate air flow for shank lubrication. While air
valve (6) is open, SLU air line pressure sensor (16) monitors the air
pressure in shank lubrication air line. Too low air pressure gives an alert on
drilling display.
From the SLU air line restrictor (17) the air continues to flow shank
lubrication’s collecting piece which combines the lines coming from the air
circuit and the shank lubrication oil line coming from the SLU unit’s oil
receiver (2). The amount of shank lubrication oil pumped to shank
lubrication oil line is controlled by the SLU control unit (3). From the
collecting piece air and oil continues toward the rock drill in separate hoses
which are connected coaxial, oil flows in a smaller plastic hose inside the
bigger air hose. Finally the oil and air are mixed 500 millimeters before the
rock drill. The mixture continues to the rock drill and finally lubricates the
shank.
The air flushing valve (12) is activated by the operator or by the control
system. When the air flushing valve (12) is opened, the air flows onward to
the rock drill.

4.3 Compressor pressure shut down bleed valve

If the air circuit is equipped with air receiver (optional), the system
depressurizes longer than normally. Make sure that the system is
non-pressurized before maintenance.

Pressure shut down bleed valve Y446 operates normally as an open-type

valve which reliefs the pressure from the air circuit. When the compressor
or the hydraulic power pack is switched on, the bleed valve is activated, in
which case the valve shuts down and the system is pressurized by the
compressor line.

4.4 Water separator (optional)

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. When the air comes from
an air network at the drilling site, a separate water separator is used. The
water separator not only cleans the air from impurities but also separates
water from the air.

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The water separator operates with the cyclone principle and all air that
flows through the separator is cleaned. The impurities and water can be
removed manually from the bottom of the separator with a drain valve.

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5 WATER CIRCUIT OPERATION

5.1 Water circuit operation
Water is supplied to the rig from the mine’s water network. Once the water
is connected to the rig, water reaches the shut-off valve (31.1) of the water
circuit’s mud separator assembly (31). Water flows to shut-off valve directly
via a water inlet line hose or via an optional hydraulically controlled water
hose reel (29). The water hose reel is rotated by the hydraulic motor (29.1).
The force, direction and speed of the hydraulic motor is controlled with
water hose reel control valve assembly. For adjustment instructions of the
water hose reel (29), please refer to technical manual "Basic adjustment of
the cable reel and water hose reel".
A 15 bar pressure relief valve (30) is always installed in the water inlet line.
Its purpose is to protect rig’s water system against the possible pressure
spikes coming from the mine’s water network. It also limits the maximum
water pressure before the mud separator assembly (31) to 15 bars.
When the water circuit shut-off valve (31.1) is opened water flows through
the mud separator (31.2) which removes the largest impurities coming from
the water network. A manually operated drain valve (31.3) is used for
cleaning the mud separator. An optional anti-freeze filling valve assembly
(38) is also connected to the mud separator. A 3-way ball valve on the anti-
freeze filling assembly is used when blowing air to the water circuit and
adding the anti-freeze agent (optional). From the mud separator (31) water
continues to pressure reducing valve (32). The valve is used for lowering
the feed pressure to 1-7 bars before the water booster pump (24) while the
pump is running and thus adjusting/defining the pump’s maximum output
pressure. The pressure can be checked from the mechanical pressure
gauge (32.1). The total flushing pressure equals the sum of the inlet
pressure and pump’s pressure. Turning the knob on the pressure reducing
valve (32) clockwise increases the pressure and turning counterclockwise
decreases the pressure.
From the pressure reducing valve (32) water continues to water booster
pump (24) which is used when the pressure level of the mine’s water
network is not sufficient to ensure proper flushing. The manually operated
bleeding valve (25) is used for bleeding the water pump.
The water flows next to the water line distributor block (26). Water circuit
pressure relief valve (27) limits the maximum pressure of the water circuit
to 25 bars. A pressure transducer (28) is connected to distributor block. The
pressure transducer measures the water pressure after the water booster
pump and sends the information to the control system. Also a water supply
line for an optional high pressure washer is branched from the distributor
block (26).
Water flows from the distributor block to the hydraulic oil-to-water cooler
(37) which is equipped with a manual drain valve (37.1). At water outlet port
of the cooler there is also a thermostat valve (39) connected in a branch.
The purpose of the thermostat valve (39) is to give additional water flow
through oil-to-water cooler (37) in situations where normal water flow is not
enough to cool down the hydraulic oil. Water flow through the thermostat

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valve is drained to the ground. Thermostat valve (39) measures

temperature of the hydraulic oil from outlet port of the oil-to-water cooler
(37). Operation of the valve is self-acting which means that it does not
require any external energy supply.

A F

Oil cooler (37)

A Drain valve (37.1) B Thermostat valve (39)

C Water in D Water out
E Oil in F Oil out

The water flows after the oil cooler (37) to water circuit distributor (40)
which distributes part of the water flow to water outlet (34), to optional boot
washer valves (35) and to optional cabin front window washer valve (33)
and to washing hose with reel (42). From the distributor water continues to
water flushing valve (36).
The water flushing valve (36) is a water piloted on/off type valve and it
controls the flow of the flushing water to the rock drill. After the water
flushing valve (36), the water flows through a water flow sensor (41) which
measures the flow rate of the water and sends the information to the control
system. The information is shown on GUI and control system also uses the
information for controlling the anti-jamming automatics.
From the water flushing valve (36), the water continues to the rock drill.
If the rig is equipped with optional air-mist flushing there is no oil-to-water
cooler (37) in the system and the flow path goes directly from the distributor
block (26) to distributor block (40).

5.2 Water circuit operation (OWA)

Water is supplied to the rig from the mine’s water network or from the
onboard water tank. Once the water is connected to the rig, water reaches

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the shut-off valve (31.1) of the water circuit’s mud separator assembly (31).
Water flows to shut-off valve directly via a water inlet line hose or via an
optional hydraulically controlled water hose reel (29). The water hose reel is
rotated by the hydraulic motor (29.1). The force, direction and speed of the
hydraulic motor is controlled with water hose reel control valve assembly.
For adjustment instructions of the water hose reel (29), please refer to
technical manual "Basic adjustment of the cable reel and water hose reel".
A 15 bar pressure relief valve (30) is always installed in the water inlet line.
Its purpose is to protect rig’s water system against the possible pressure
spikes coming from the mine’s water network. It also limits the maximum
water pressure before the mud separator assembly (31) to 15 bars.
When the water circuit shut-off valve (31.1) is opened water flows through
the mud separator (31.2) which removes the largest impurities coming from
the water network. A manually operated drain valve (31.3) is used for
cleaning the mud separator. An optional antifreeze blowing assembly (43)
is used when blowing air to the water circuit and adding the anti-freeze
agent. From the mud separator (31) water continues to pressure reducing
valve (32). The valve is used for lowering the feed pressure to 1-7 bars
before the water booster pump (24) while the pump is running and thus
adjusting/defining the pump’s maximum output pressure. The pressure can
be checked from the mechanical pressure gauge (32.1). The total flushing
pressure equals the sum of the inlet pressure and pump’s pressure.
Turning the knob on the pressure reducing valve (32) clockwise increases
the pressure and turning counterclockwise decreases the pressure.
From the pressure reducing valve (32) water continues to water booster
pump (24) which is used when the pressure level of the mine’s water
network is not sufficient to ensure proper flushing. The manually operated
bleeding valve (25) is used for bleeding the water pump. Bleeding valve
(44) bleeds the air from the upper part of the water booster pump (24)
always when the pump is started and at regular intervals during operation.
Mud separator (45) separates impurities from water after it flows from to the
water booster pump (24).
The water flows next to the water line distributor block (26). Water circuit
pressure relief valve (27) limits the maximum pressure of the water circuit
to 25 bars. A pressure transducer (28) is connected to distributor block. The
pressure transducer measures the water pressure after the water booster
pump and sends the information to the control system. Also a water supply
line for an optional high pressure washer is branched from the distributor
block (26).
Water flows from the distributor block to the hydraulic oil-to-water cooler
(37) which is equipped with a manual drain valve (37.1). At water outlet port
of the cooler there is also a thermostat valve (39) connected in a branch.
The purpose of the thermostat valve (39) is to give additional water flow
through oil-to-water cooler (37) in situations where normal water flow is not
enough to cool down the hydraulic oil. Thermostat valve (39) measures
temperature of the hydraulic oil from outlet port of the oil-to-water cooler
(37). Operation of the valve is self-acting which means that it does not
require any external energy supply.

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A F

Oil cooler (37)

A Drain valve (37.1) B Thermostat valve (39)

C Water in D Water out
E Oil in F Oil out

The water flows after the oil cooler (37) to water circuit distributor (40)
which distributes part of the water flow to water outlet (34), to optional boot
washer valves (35) and to optional cabin front window washer valve (33)
and to washing hose with reel (42). From the distributor water continues to
water flushing valve (36).
The water flushing valve (36) is a water piloted on/off type valve and it
controls the flow of the flushing water to the rock drill. After the water
flushing valve (36), the water flows through a water flow sensor (41) which
measures the flow rate of the water and sends the information to the control
system. The information is shown on GUI and control system also uses the
information for controlling the anti-jamming automatics.
From the water flushing valve (36), the water continues to the rock drill.
If the rig is equipped with optional air-mist flushing there is no oil-to-water
cooler (37) in the system and the flow path goes directly from the distributor
block (26) to distributor block (40).

5.3 Pressure reducing valve

The pressure reducing valve is used to adjust the feed pressure before the
water pump to 1-7 bar. Turning the knob clockwise increases the pressure
and turning counterclockwise decreases the pressure.
Water flows to the shut-off valve through a hose. When the shut-off valve is
opened, the water flows through the mud separator to the pressure
reducing valve and onward to the water pump.

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15 bar pressure relief valve is installed in case of high pressure peaks from
the working site's water supply system.

5.4 Water booster pump

The water booster pump is used when the direct water network does not
provide water at sufficiently high pressure to ensure proper flushing. The
arrows on the base of the pump indicate the direction of flow of the water.
5.4.1 Operation and maintenance
Before starting the pump, refer to technical manual: Water booster pump.

5.5 Oil cooler

The operating principle of the coolers is “oil to water”. The cooling cannot
be completely drained, e.g. by letting the liquid flow through the bottom
nipple; compressed air blowing through the flow route is required.

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6 AIR-MIST CIRCUIT OPERATION

6.1 Air-mist circuit operation
When the air-mist flushing is selected, the main operation principles of air
and water circuits are the same as described in sections Air circuit
operation, Air circuit operation (OWA), Water circuit operation and Water
circuit operation (OWA).
The capacity of rig’s own compressor alone is not sufficient for air-mist
flushing and the pressure from the mine network is also needed to produce
enough air to the system. OWA rig is equipped with a bigger compressor
(CT60 or CT80) which produces enough air to system. From the distributor
(13) the air flows to air line flow meter (54). The air line flow meter
measures the quantity of air flow and changes in air flow rate, based on the
calorimetric measuring principle. The information is send to the control
system and it is utilized by the drilling control system. In addition the air flow
rate is shown on GUI. For adjusting instructions of the air line flow meter
(54), please refer to section Adjusting the air line flow meter (optional).
After flowing through the air line flow meter (54), the air flows to air flushing
valve (12) and onward to drilling module connection plate.
Water for air-mist flushing is taken from the mine water network or from the
onboard water tank (OWA) and its pressure is boosted up with water
booster pump. From the distributor block (40) water flows to the air-mist
flushing water valves (52, 53).

B C

H
A

Air-mist flushing water valve (52, 53)

A Pilot valve B Oil in

C Oil out D Water in
E Water out F Spring
G Piston H Needle

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Air-mist flushing water valve (52, 53) is an electro-hydraulically operated

proportional valve. The valve is normally closed type and it is opened with
hydraulic pressure. The valve consists of a hydraulic pilot valve (A), piston
(G), needle type main spool (H) and main water part. The needle type main
spool (H) is connected to the piston (G). Once the hydraulic pilot pressure
is applied to the end of the piston, via electro-proportional pilot pressure
reducing valve, it starts to move against the spring simultaneously moving
the main spool and thus opening the flow path for water. The amount of the
air-mist flushing water flow is proportional to the hydraulic pressure applied
to the piston. If the control signal and thus the hydraulic pressure is
removed from the main spool, the spring force will close the valve.
After the valves (52, 53), water flows through air-mist water flow meters
(50, 51) onward to drilling module connection plate. Air and water are
combined and mixed in the rock drill carriage connection plate. The mixture
continues onward to the rock drill and to the hole.
Related information
Air Circuit Operation (Page 35)
Air Circuit Operation (OWA) (Page 36)
Water circuit operation (Page 39)
Water circuit operation (OWA) (Page 40)
Adjusting the air line flow meter (optional) (Page 85)

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7 OPERATOR'S MAINTENANCE PROCEDURES

7.1 Water circuit
7.1.1 Checking the water circuit for leaks
Visually check the circuit for possible leaks and repair them as soon as
possible.
7.1.2 Cleaning the mud separator
Note! The mud separator does not operate effectively if reusing water
already used for flushing.
Restricted water flow causes flushing and cooling problems. The most
common reason for the drop of pressure is a blocked mud separator. This
is why the separator must be cleaned every day. If the conditions change,
start by cleaning the separator more often and determine the correct
cleaning interval based on experience.

3 1 2

Clean the mud separator (1) as follows:

1. Open the shut-off valve (2).
2. Open the drain valve (3) enough to allow the dirt in the strainer (4) to
come out.
3. Close the drain valve (3).
4. If no water comes out, replace or clean the strainer (4).

7.1.3 Checking the operation of the pressure reducing valve

1. Check that the pressure reducing valve (1) operates properly.

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7.1.4 Bleeding the water booster pump

RISK OF WATER PUMP DAMAGE!

The water booster pump will be damaged if it gets to run dry.
NOTICE Every time the water booster pump is connected to the water line, it
must be bled.
Do not start the pump until it has been bled and filled with water.

1. Close the mine water supply valve.

2. Open the bleeding valve (1).

3. Gradually open the mine water supply valve until a steady stream of
water runs out of the bleeding valve.
4. Close the bleeding valve.

7.1.5 Checking the operation of the oil cooler(s) (oil-water)

1. Check visually that there are no

leaks in the connections. If the
cooling of the hydraulic oil do
not seem to work properly, clean
the cooler according to
instructions in Maintenance
Manual.

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7.1.6 Checking the oil cooler (oil-air)

WARNING! CUTTING HAZARD!

A rotating fan could cause severe injury.
Keep your fingers away from the rotating fan.
The cooler fan starts to rotate when the respective power pack is
started. The fan rotation is faster when the oil gets hot.

1. Check that the cooler element

(1) is clean.

2. If necessary, clean the cooler element according to instructions in

Maintenance Manual, section Cleaning the oil cooler (oil-air).

7.1.7 Adjusting the mine's inlet pressure

Water circuit flushing pressure consists of mine's inlet pressure and water
booster pump pressure. Pressure sensor (B230P) measures the flushing
pressure after the water booster pump and the measured value has to be
under 25 bars.

1
4

3 2

Mine's inlet pressure before the water booster pump is adjusted with the
pressure reducing valve (1) as follows:
1. Open the shut-off valve (2).
2. Turn the knob (3) fully open.
3. Start the water booster pump.

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4. Turn the knob (3) to adjust the pressure to 2-7 bars according to drilling
conditions.
Turning the knob clockwise increases the pressure and turning
counterclockwise decreases the pressure.
Check the pressure gauge (4) for the value.

5. Select → Troubleshooting → Compressor and Water Pump and

check that the pressure sensor (B230P) value is under 25 bars.

7.2 Air circuit

7.2.1 Draining the water separator (optional)
The separator (1) purifies the air from the external pressurized air line. The
impurities and water are collected at the bottom of the separator.
1. Open the drain valve (2) to remove impurities from the separator.

7.2.2 Draining the water separator

The water separator is automatically drained in every five minutes.
If manual draining is needed:
1. Open the drain valve (1).

2. Close the valve after draining.

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7.2.3 Draining the air receiver (optional)

1. Open the drain valve (1) to drain the condensed water from the air
receiver.

7.3 Compressor
7.3.1 Checking the correct running temperature
Check the compressor oil temperature from the control system display. An
alarm is displayed on the control system display, if the compressor
temperature rises too high.
7.3.2 Checking the cooling air fan
Visually check the condition and fastening of the fan. Check that the fan
can rotate freely.
7.3.3 Checking the compressor oil level
Stop the compressor before checking the oil level (wait until the oil is
separated from the air, approx. 10 min). Make sure that the oil level
remains between the min. and max. levels of the sight glass. Only add
recommended oil types, when necessary.
7.3.4 Checking for oil leaks
Visually check for possible oil leaks, especially around the compressor unit,
oil cooler and oil hoses.

7.4 Compressor CT60/CT80/CT100

7.4.1 Checking the correct running temperature
Check the compressor oil temperature from the control system display. An
alarm is displayed on the control system display, if the compressor
temperature rises too high.

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7.4.2 Checking the compressor oil level

1. Stop the compressor before checking the oil level (wait until the oil is
separated from the air, approx. 10 min)
2. Make sure that the system is non-pressurized.
3. Check the oil level from the dipstick (1).

4. Add oil if necessary through the filling opening (2).

Use only recommended oil types.
7.4.3 Checking the compressor cooler

WARNING! CUTTING HAZARD!

A rotating fan could cause severe injury.
Keep your fingers away from the rotating fan.
The cooler fan starts to rotate when the respective power pack is
started. The fan rotation is faster when the oil gets hot.

1. Check that the cooler element (1) is clean.

2. If necessary, clean the cooler element according to instructions in

Maintenance Manual, section Cleaning the compressor cooler.

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7.4.4 Checking the oil leaks

Visually check the compressor for oil leaks. In particular check around the
compressor unit, the oil cooler and the hoses.
7.4.5 Checking the condition of the oil hoses

1. Visually check the condition of the oil hoses.

If visible damage is detected or the hose leaks, replace the hose with a
new one.
7.4.6 Cleaning the compressor air filter pre-cleaner

1. Squeeze the dust discharge

valve (1) until it opens and dust
comes from the dust collector.

2. If necessary, remove the cover (2) and clean by hand.

7.5 SLU
7.5.1 Checking the oil level
Note! To avoid problems caused by air bubbles in the oil, fill the tank after
drilling. DO NOT fill the tank during drilling.
1. Check the oil level from the
dipstick and fill the tank if
necessary.

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7.5.2 Emptying the shank lubrication return oil tank (DL422iE, DL432i)

1. Empty the tank always when the shank lubrication oil tank is filled:
a) Place a receptacle under the
drain valve (1).

b) Open the drain valve (1) to drain the oil into the receptacle.
c) Close the drain valve (1).
Note! Never reuse the used oil. Make sure that used oil is correctly
disposed.

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8 PERIODIC MAINTENANCE PROCEDURES

8.1 Water circuit
8.1.1 Replacing the mud separator strainer

1. Dismantle the mud separator (1) fittings.

2

2. Pull the old strainer (2) out and replace it with a new one.
8.1.2 Adjusting the thermostat valve
Purpose of the thermostat valve is to give additional water flow through oil-
to-water cooler in situations where normal water flow is not enough to cool
down the hydraulic oil. Thermostat valve adjusts the water flow
proportionally according to temperature setting and the setting can be
adjusted between 50-90 °C.
1. Rotate the adjusting screw of
the thermostat valve clockwise
to increase the water flow (more
cooling) and counterclockwise
to decrease the water flow (less
cooling).

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8.2 Air circuit

8.2.1 Cleaning the cooler for shank lubrication air (optional)

WARNING! BURN HAZARD!

Hot components could cause severe burns.
Let the cooler cool down before cleaning!

In a dirty environment clean the cooler more frequently because clogged

cooling element reduces the cooling capacity.

1. Shut down the engine.

2. Let the cooler cool down.
3. Check that the cooler has no damaged fins, corrosion, or dirt (grease,
oil, insects, leaves, etc).
4. Clean the cooler with compressed air.
Disconnect power if you use high pressure washer for cleaning. To avoid
damage to air fins, point the water jet parallel to fins.

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8.2.2 Checking the condition of the air receiver (optional)

1. Visually check the fastening and external condition of the receiver.

If there are cracks, dents, rust or other pollution in the receiver, replace
it.

8.3 Compressor
8.3.1 Procedures prior to compressor maintenance

WARNING! BURN HAZARD!

Hot surfaces of the equipment could cause burns.
Let the compressor cool down before starting any maintenance
work!

• Stop the compressor and check that the oil separator unit is not
pressurized. After the compressor is stopped, the oil separator unit is
drained by the out-blow unit – wait approximately 2 minutes.
• Turn the power off and make sure the compressor cannot be started.
• Ensure that the drill rig is detached from an external pneumatic network.
• Close the shut-off valve between the network and the compressor.
• Open the safety valve cap 4–5 turns.
Note! Make sure that the system is non-pressurized.

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8.3.2 Changing the compressor oil

1. Run the compressor until the oil temperature is approximately +40-50

°C.
2. Make the procedures mentioned in section Procedures prior to
compressor maintenance.
3. Open the oil filler plug (1) and drain valve (3) and let the oil drain into
the recovery tank.
4. Close the drain valve (3).
5. Replace the oil filter (refer to section Replacing the compressor oil
filter).
6. Fill with fresh oil up to the max. indicator.
7. Close the oil filler plug (1).
8. Close the safety valve (2).
9. Open the shut-off valve between the compressed air network and the
compressor.
10. Start the compressor.
Note! Follow the local regulations for oil disposal.
Related information
Procedures prior to compressor maintenance Procedures prior to
compressor maintenance (Page 57)
Replacing the compressor oil filter (Page 59)

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8.3.3 Replacing the compressor oil filter

1. Place a protective cloth under the filter. While the filter is being
replaced, oil runs from the filter housing.
2. Use a tightening belt and turn the filter counterclockwise to remove it.
3. Apply oil to the seal of the new filter.
4. Turn the filter manually clockwise to fasten it.
Note! Follow the local regulations for oil disposal.
8.3.4 Checking and retightening main motor cables
Check and retighten main motor cables in every 500h.
8.3.5 Replacing the compressor air filters
Note! The filters are disposable and cannot be cleaned.

1 2 3

1. Remove the air filter cover (3).

2. Remove the old primary and secondary filters (2).
3. Clean the air filter housing (1).

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4. Install new filters (2).

5. Reinstall the cover (3).
Note! Check that the particle remover hole (4) points downward.
8.3.6 Cleaning the cooler externally
Clean the cooler with pressurized air. For a more effective cleaning, brush
the cooler from underneath. Note! Do not use a metal wire brush.
Refer to the compressor manufacturer's instructions.
8.3.7 Cleaning the compressor externally with a cloth
Clean the compressor in every 500 h and in a dirty environment as needed.
8.3.8 Replacing the compressor belts

1. Untighten the screw (1) counterclockwise until the belts are loose
enough. (The screw pushes the motor up so that belts loosen.)
2. Change the belts.
3. Return the screw (1) to its original position.

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8.3.9 Replacing the compressor oil separator cartridge

CT

3 4 7

1. Make the procedures mentioned in section Procedures prior to

compressor maintenance.
2. Remove the output valve (1).
3. Remove the separator cartridge (2).
4. Clean the surfaces and output valve (1) of the oil separator unit.
5. Clean the orifices (3) at the ends of the hose.
6. Replace the strainer (4) and clean the oil separator unit.
7. Lubricate the separator O-ring and install the new separator cartridge by
hand.
8. Replace and lubricate the O-ring (5) between the oil separator unit and
the output valve.
9. Replace the output valve seals if needed. After the output valve
assembly, leave the nut (6) on the cover approximately 2 mm free of the
cover.
10. Install the output valve (1).
11. Tighten the screws alternately.

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12. Close the safety valve (7).

13. Open the shut-off valve between the network and the compressor.

CTN

8 5

1 3

1. Make the procedures mentioned in section Procedures prior to

compressor maintenance.
2. Remove the oil separator cartridge cover (1).
3. Remove the separator cartridge (2).
4. Clean the orifices (3) at the ends of the hose.
5. Replace the filter strainer (4) and clean the oil separator unit.
6. Lubricate the separator O-ring (5) and install the new separator
cartridge (2) by hand.
7. Install the cover (1).
8. Tighten the screws alternately.
9. Close the safety valve (6).
10. Open the shut-off valve between the network and the compressor.

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Note! Dispose of the used separator cartridge in accordance with local

regulations.
Related information
Procedures prior to compressor maintenance Procedures prior to
compressor maintenance (Page 57)

8.3.10 Cleaning the oil return line

Clean the return hose line and orifice plate.
8.3.11 Lubricating the electric motor bearings (CT compressor)
Lubricate the electric motor bearings once a year / in every 1000 h. See
separate motor manual.
8.3.12 Checking the operation of the compressor relief valve
The operation must be checked at least once a year, as recommended by
the manufacturer.

Note! All safety valve adjustment and repair tasks must be performed by
trained professionals (take into consideration local regulations).
The opening pressure of the safety valve must be tested in a separate
compressed air circuit.
The valve operation can be tested by turning the safety valve cap (1) 1–2
turns counterclockwise until you can hear the air bleeding out between the
cap and the body. Close the cap by hands to original position.

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8.3.13 Replacing the seal kit of the inlet valve

1. Remove the inlet valve housing by opening the nut.

2. Disassemble the valve cover by opening the bolt. A spring is released
when the cover is opened. Wear safety glasses.
3. Replace the seals (1-8).

4
3
5

7 2

4. Reassemble the valve in reverse order.

8.3.14 Checking the function of the thermometer safety limits

Thermometer´s functionality is tested by using a heater (operation range
0-120 °C) to heat the sensor to the temperature limits. Do not use fire.
1. Remove the sensor from the compressor's body.
2. Start the power packs, compressor and water pump.
3. Heat the sensor and monitor the temperature gauge.
When temperature reaches 105 ºC, check that the system gives a notice
pop-up.
When temperature reaches 115 ºC, check that the system gives an alarm
pop-up and the compressor stops.
8.3.15 Checking the condition of the compressor hoses
Visually check the hoses. If visible damage is detected or the hose leaks,
replace it with a new one.

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8.3.16 Replacing the blow-down valve

The blow-down valve is attached to a flange below the inlet valve.
1. Disassemble the hosing to the blow-down valve (1).

2. Replace the blow-down valve (1).

3. Reassemble the hosing.
8.3.17 Replacing the oil thermostat

1. Undo the lock ring (1) to open the cover.

2. Replace the thermostat (2) and the o-ring (3).
3. Reattach the cover with the lock ring.

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8.3.18 Replacing the motor bearings

Replace the motor bearings in every 5 years / 10 000h.
8.3.19 Replacing the shaft seal kit
Replace the shaft seal kit in every 5 years / 10 000h.
8.3.20 Replacing the air end
Replace the air end in every 10 years / 20 000h.

8.4 Compressor CT60/CT80/CT100

8.4.1 Procedures prior to compressor maintenance

WARNING! BURN HAZARD!

Hot surfaces of the equipment could cause burns.
Let the compressor cool down before starting any maintenance
work!

• Stop the compressor and check that the oil separator unit is not
pressurized. After the compressor is stopped, the oil separator unit is
drained by the out-blow unit – wait approximately 2 minutes.
• Turn the power off and make sure the compressor cannot be started.
• Ensure that the drill rig is detached from an external pneumatic network.
• Close the shut-off valve between the network and the compressor.
• Open the safety valve cap 4–5 turns.
Note! Make sure that the system is non-pressurized.
8.4.2 Changing the compressor oil
1. Run the compressor until the oil temperature is approximately +40– 50
°C.
2. Make the procedures mentioned in section Procedures prior to
compressor maintenance.

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3. Open the oil filling plug (2) and drain valve (3) and let the oil drain into
the recovery tank.

2
3

4. Close the drain valve (3).

5. Drain the oil cooler empty into the recovery tank. See instructions in the
following sections Draining and filling the compressor's OA/OW cooler.
6. Replace the oil filter (4).
7. Fill up the compressor through oil filling plug (1) to max-level. Use only
recommended new oil. Close the oil filling plug.
8. Fill up the cooler with fresh oil. See instructions in the following sections
Draining and filling the compressor's OA/OW cooler.
9. Close the safety valve (1) and open the shut-off valve of the compressor
air network.
When starting the compressor after the oil change:
1. Stop the compressor after the compressor has reached the normal
operating temperature (70-80 °C).
2. Make sure that the system is non-pressurized.
3. Check the correct oil level from the dipstick (5).
4. Add oil through oil filling plug (2), if necessary.
Note! Follow the local regulations for oil disposal.

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Draining and filling the compressor's OA cooler

First filling oil: Sandvik OC10-H, OA cooler capacity 10.8L
1. Open the ball valve (1) to drain the oil cooler into the recovery tank.

2. Close the ball valve (1).

3. Open the plug (2) and fill oil in the OA cooler.
4. Slightly open the ball valve (1), so that the OA cooler emptying hose
can be bled.
5. Add more oil to the OA cooler, if necessary.
6. Close the plug (2).

Draining and filling the compressor's OW cooler (optional)

First filling oil: Sandvik OC10-H, OW cooler capacity 3.6L
1. Open the ball valve (1) to drain the oil cooler into the recovery tank.

2. Close the ball valve (1).

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3. Open the connector (2) and use a funnel to fill up oil.

4. Slightly open the ball valve (1), so that the OW cooler emptying hose
can be bled.
5. Add more oil to the OW cooler, if necessary.
6. Close the connector (2).
Related information
Procedures prior to compressor maintenance Procedures prior to
compressor maintenance (Page 57)

8.4.3 Replacing the compressor oil filter

Replace the oil filter after first 50 compressor hours and after that according
to maintenance program.
Let the compressor cool down before changing the oil filter.
1. Make the procedures mentioned in section Procedures prior to
compressor maintenance.
2. Place a protective cloth under the filter. While the filter is being
replaced, oil runs from the filter housing.
3. Turn the filter (1) counterclockwise to remove it.

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4. Apply oil to the seal of the new filter.

5. Turn the filter manually clockwise to fasten it.
Note! Dispose of the oil and the filter in accordance with local regulations.
Related information
Procedures prior to compressor maintenance Procedures prior to
compressor maintenance (Page 57)

8.4.4 Replacing the compressor air filter

Note! The filters are disposable and cannot be cleaned.
1. Make the procedures mentioned in section Procedures prior to
compressor maintenance.
2. Remove the air filter cover (3).
1 2 3

3. Remove the old primary and secondary filters (2).

4. Clean the air filter housing (1).
5. Install new filters (2).
6. Reinstall the cover (3).
Note! Check that the particle remover hole (4) points downward.
Related information
Procedures prior to compressor maintenance Procedures prior to
compressor maintenance (Page 57)

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8.4.5 Cleaning the compressor cooler

WARNING! CUTTING HAZARD!

A rotating fan could cause severe injury.
Keep your fingers away from rotating fins.

WARNING! FLYING MATERIAL HAZARD!

Flying debris and dirt could cause severe injury.
Wear appropriate eye and face protection when using compressed
air.

WARNING! BURN HAZARD!

Hot components could cause severe burns.
Let the cooler cool down before cleaning.

In a dirty environment clean the compressor cooler (1) more frequently

because clogged cooling element reduces the cooling capacity.

1. Make the procedures mentioned in section Procedures prior to

compressor maintenance.
2. Check that the cooler has no damaged fins, corrosion, or dirt (grease,
oil, insects, leaves, etc).
3. Clean the cooler with a high pressure washer. Keep the nozzle at a safe
distance and do not use too high pressure, to avoid damaging the
cooler. You can also use compressed air (maximum 4 bars) or soft
brush to clean the cooler.
Related information
Procedures prior to compressor maintenance Procedures prior to
compressor maintenance (Page 57)

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8.4.6 Cleaning the compressor externally

Clean the compressor in every 500 h and in a dirty environment as needed.
8.4.7 Adjusting the connectors and bolts
Tighten all connectors and bolts in every 500 h and first time after 100 h of
operation.
8.4.8 Checking the function of the thermometer safety limits
Thermometer´s functionality is tested by using a heater (operation range
0-120 °C) to heat the sensor to the temperature limits. Do not use fire.
1. Remove the sensor from the compressor's body.
2. Start the power packs, compressor and water pump.
3. Heat the sensor and monitor the temperature gauge.
When temperature reaches 105 ºC, check that the system gives a notice
pop-up.
When temperature reaches 115 ºC, check that the system gives an alarm
pop-up and the compressor stops.
8.4.9 Replacing the compressor belts

1. Make the procedures mentioned in section Procedures prior to

compressor maintenance.
2. Loosen the belts (1) by pumping the lifting jack handle (2).

3. Replace the belts (1).

4. Lower the lifting jack. When the motor mount plate goes down, the
compressor belts are tightened.
Related information
Procedures prior to compressor maintenance Procedures prior to
compressor maintenance (Page 57)

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8.4.10 Replacing the compressor oil separator cartridge

Note! Make sure that there is no extra pressure inside the receiver. There
remains pressure between the shut-off valve and the discharge valve.
Do not open the lock ring located on the upper end of the valve.
Note! DO NOT adjust the minimum pressure valve (factory setting for
minimum pressure is 4 bars).

1. Make the procedures mentioned in section Procedures prior to

compressor maintenance.
2. Open the bolts (1, 4 pcs) and remove the cover (2).
1
8
2
4
7
3
5

3. Remove the cartridge (3).

4. Clean the seal surfaces of the receiver and the discharge valve (4).
Make sure that there are no particles inside the receiver.
5. Clean the orifices (5).

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6. Clean the strainer (6).

If necessary, clean the oil separator.
7. Lubricate the O-rings of the separator element and install a new
separator cartridge (3) by hand.
8. Change and lubricate the O-ring (7).
9. Install the cover (2).
10. Tighten the bolts (1) alternately to torque 300 Nm.
11. Close the safety valve (8).
12. Open the shut-off valve between the network and the compressor.
Note! Dispose of the used separator element in accordance with local
regulations.
Related information
Procedures prior to compressor maintenance Procedures prior to
compressor maintenance (Page 57)

8.4.11 Checking the operation of the pressure relief valve

The operation must be checked at least once a year, as recommended by
the manufacturer.

Note! All safety valve adjustment and repair tasks must be performed by
trained professionals (take into consideration local regulations).
The opening pressure of the pressure relief valve must be tested in a
separate compressed air circuit.
The valve operation can be tested by turning the pressure relief valve cap
(1) 1–2 turns counterclockwise until you can hear the air bleeding out
between the cap and the body. Close the cap by hands to original position.

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8.4.12 Replacing the seal kits of the inlet and the discharge valve
Replace the seal kits of the inlet and the discharge valve at leats once a
year. Replace also repair kits of the inlet and the discharge valve when
necessery. Refer to the manufacturer's instructions.
8.4.13 Cleaning the strainer of the oil return line
Refer to the manufacturer's instructions.
8.4.14 Adjusting the compressor cooler fan
After replacing the compressor cooler electro-proportional pressure relief
valve or if the cooling capacity of the compressor cooler needs adjusting,
do as follows:
1. Attach pressure gauges to 1 2 3
measuring points MA (1) and
MB (2).

2. Open the locking nut of the pressure relief valve (3).

3. Loosen the adjusting screw of the pressure relief valve (3).
4. Remove the electrical connector from the pressure relief valve (3).
5. Tighten the adjusting screw until the pressure difference is 60 bars.
Factory set pressure difference is 60 bars and it equals approximately
2000 rpm.
6. Close the locking nut of the pressure relief valve (3).
7. Reinstall the cap to the pressure relief valve (3).
8. Remove the pressure gauges from measuring points MA (1) and MB
(2).
Note! The maximum rotation speed of the hydraulic motor and fan is 2700
rpm and it must not be exceeded.

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8.5 SLU
8.5.1 Draining the condensed water

1. Use the drain valve to drain the

condensation water from the oil
tank.

8.5.2 Checking the condition of the water separator

When mechanical service indicator (1) shows approximately all red, the
filter element (2) inside the water separator should be changed. Refer to
section Changing the water separator filter element.
Related information
Changing the water separator filter element (Page 77)

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8.5.3 Changing the water separator filter element

Disassembly
1. Water separator filter element (4) can be disassembled without removal
from air line.
2. Shut off inlet pressure. Reduce pressure in inlet and outlet lines to zero.
3. Remove bowl (8) - push into body and turn counterclockwise.
4. Disassemble in general accordance shown on the exploded view. Do
not remove the drains or the service indicator (1) unless replacement is
necessary. Remove and replace only if they malfunction.

9
1
1

2
6
3 8

11
4
7
5
10

Assembly
1. Lubricate o-rings, the portion of the manual drain body (6) that contacts
the bowl, and the hole in the manual drain body that accommodates the
stem of drain valve (7) with o-ring grease.
2. Assemble the filter as shown on the exploded view.
3. Arrows on the indicator (1) and the body (2) must point in the same
direction. Screw the baffle (5) onto the center-post (3) until contact is
made with the filter element (4), then tighten an additional 1/4 turn.
Push bowl (8), or bowl with guard, into body (2) and turn fully clockwise.
4. Torques in Nm:

3 2.0 - 2.7 Nm (center-post)

9 2.8 - 3.9 Nm (screw)
10 2.3 - 2.8 Nm (nut)
11 1.7 - 2.3 Nm (screw)

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8.5.4 Cleaning the tank

1. Use the drain valve to empty the

tank into a receptacle.

2. Clean the tank from the inside.

8.5.5 Replacing the breather

1. Replace the breather.

Replace the breather at the intervals specified in the maintenance

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

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9 MAINTENANCE AND REPAIR INSTRUCTIONS

9.1 Checking the operation of the air-mist flushing control valve
The valve needs attention only if water or oil comes out remarkably of the
breathing holes (arrow), or if the flushing water flow does not stop although
the valve is closed.

9.2 Changing the control needle of the air-mist flushing control

valve
1. Disconnect the hydraulic lines.
2. Remove the water lines and drain the valve properly.

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3. Open and remove the plug (1).

4. Remove the spring (2) and lift the control piston (3) out from the valve
body.
5. Open the screws (4) and remove the old needle (5).

6. Install a new needle and new shim washers (6).

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7. Tighten the screws (4) and check that the needle is moving radially free.

Axial clearance should be as small as possible. If necessary add or

remove shim washers (thickness 0.1 mm).
8. Secure the screws with Loctite 243 or 2701.
9. Center the needle in the middle.
10. Install control piston assembly (3) back into the valve housing.
11. Reinstall the spring (2) and plug (1).

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9.3 Changing the control needle seals of the air-mist flushing

control valve
1. Disconnect the hydraulic lines. Remove the water lines and drain the
valve properly.
2. Open and remove the plug (1). Remove spring (2) and lift the control
piston (3) out from the valve body.

3. Open M8 screws (7) and remove the valve housing (8).

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4. Remove bushing (9), centering socket (10), needle seals (11), and O-
rings (12). Insert new seals into their countersinks and reinstall parts
(10) and (9).
9

10

11

12

5. Install valve housing (8) and M8 screws (7). Center the needle in the
middle and reinstall control piston assembly (3) into the valve housing.
Reinstall spring (2) and plug (1).

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9.4 Adjusting the restrictor valve

1. Loosen the locking nut (1) of the restrictor valve (2).

1 3 2

2. Turn the adjusting screw (3) fully open.

3. Select → Troubleshooting → Shank Lubrication

4. Start the power pack.
5. Push the button (4) to activate
air flushing.

BG00939165
Version 02

6. Tighten the adjusting screw (3)

until Air pressure reading rises
to 4 bars.

7. Tighten the locking nut (1) of the restrictor valve.

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8. Check again Air pressure reading from the GUI.

If the reading has changed from the correct value (4 bars):
a) Loosen the locking nut (1).
b) Tighten/loosen the adjusting screw (3) until the value is 4
bars.
c) Tighten the locking nut (1).
9. Push the button (4) to deactivate air flushing.
10. Stop the power pack.

9.5 Adjusting the air line flow meter (optional)

Electrical connection

1 BN
2 L+
2 WH
3 1 4 BK
4 3 BU
L--
BN Brown
WH White
BU Blue
BK Black

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Operating and display elements

1 2

1 Controller
2 Display
3 Mode/Enter button
4 Set button

Important parameters

Suggested
Ref Parameter explanation
value
FCTR Pipe diameter 1.50
Scaling of the analogue value (current signal is
OU2 I
proportional to volumetric flow)

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Suggested
Ref Parameter explanation
value
Analogue start point (ASP) determines at which
ASP 0
measured value the output signal is 4 mA
Analogue end point (AEP) determines at which 213 (DD/DT)
AEP
measured value the output signal is 20 mA 589 (DL/DS)

I
20

ASP AEP MEW Q

Measuring range scaled

I Current (mA)
Q Controller readout
MEW Final value of the measuring range
ASP Analogue start point
AEP Analogue end point

Setting the important parameters

1. Open the cabin floor hatch to reach the flow meter controller (1).
2. Push Mode/Enter (3) so many times that FCTR is displayed.
3. Push Set (4) and keep it pushed down until FCTR starts flashing.
After five seconds the flashing stops and the parameter value can be
changed.
4. Push Set, keep it pushed down until value 1.50 is displayed and then
release the button.
5. Push Mode/Enter briefly and FCTR is displayed again.
6. Push Mode/Enter (3) so many times that OU2 is displayed.
7. Push Set and keep it pushed down until OU2 starts flashing.
After five seconds the flashing stops and the parameter value can be
changed.
8. Push Set, keep it pushed down until I is displayed and then release the
button.
9. Push Mode/Enter briefly and OU2 is displayed again.

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10. Push Mode/Enter briefly and ASP is displayed.

11. Push Set and keep it pushed down until ASP starts flashing.
After five seconds the flashing stops and the parameter value can be
changed.
12. Push Set, keep it pushed down until value 0 is displayed and then
release the button.
13. Push Mode/Enter briefly and ASP is displayed again.
14. Push Mode/Enter briefly and AEP is displayed.
15. Push Set and keep it pushed down until AEP starts flashing.
After five seconds the flashing stops and the parameter value can be
changed.
16. Push Set, keep it pushed down until value 213/589 (see the table
above) is displayed and then release the button.
17. Push Mode/Enter briefly and AEP is displayed again.
18. Push Mode/Enter so many times that the current measured value is
displayed or wait for 15 seconds.
The unit is back in operating mode.
19. If you want to lock the unit, push Mode/Enter and Set simultaneously
for ten seconds.
Loc is displayed.
20. If you want to unlock the unit, push Mode/Enter and Set simultaneously
for ten seconds.
uLoc is displayed.

9.6 Checking the water flow sensor settings

4 2
5

Electrical connections

1 + supply
2 Analogue out: 4...20 mA
3 GND

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4 Switch 1
5 Switch 2

I II

1 2 3 4

Sensor

1 Display
2 Up button
3 Enter button
4 Down button

1. Push and keep it pushed down.

• if display shows air or oil, release the button and continue from step
2.
• if display shows LPn and H2O, release the button and continue
working. If switch values need changing, continue from step 5.

2. Push and then , keep both buttons pushed down for two seconds
to enter the setup menu.

3. Insert the correct password with / buttons and then push .

Factory set password: 11

4. Scroll to FLui with / buttons.

a) Push to enter value screen.

b) Select H2O with / buttons.

c) Push to save and return to setup menu.

5. Change switch values, if needed.
S1d / S2d : switch delay time (in seconds)
S1L / S2L : switch operation switching levels (in liters per minute)
S1t / S2t : switch type (no = normally open or nc = normally closed)

a) Select switch which needs a change with / buttons.

b) Push to enter value screen.

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c) Select correct value with / buttons.

d) Push to save and return to setup menu.

e) Select next switch which needs a change with /

buttons and do steps from b to d.
f) Continue until desired changes are made.

g) Push to save and return to setup menu.

6. Push and then , keep both buttons pushed down to exit to main
menu.
If you want to exit setup menu / value screen without saving changes, do
not press any key for 10 seconds.

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www.sandvik.com
 Original instructions
en-US 7 2020-05-06

Shank lubrication unit

GUID-C99EBD0E-F246-451A-BABB-A0ED162D6D1E
Shank lubrication unit

WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and follow
operator's and maintenance manuals before installing, inspecting,
operating, servicing, testing, cleaning, transporting, storing,
dismantling or disposing of the product or a part or accessory of the
product. Keep this publication for future reference.

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Table of Contents
1 Introduction.......................................................................7
1.1 The purpose of these instructions............................................................ 7
1.1.1 Validity of the manuals...................................................................... 7
1.2 General.........................................................................................................7

2 Safety and environmental instructions.......................... 9

2.1 Safety precautions...................................................................................... 9

3 SLU main components...................................................11

3.1 Components.............................................................................................. 11
3.2 Technical data............................................................................................11
3.3 Shank Lubrication Controller (SLC)........................................................ 12
3.4 SLU level sensor....................................................................................... 16

4 SLU operation................................................................. 17
4.1 Operation of the SLCU..............................................................................17
4.2 Description of shank lubrication oil pump operation............................20
4.3 Heating circulation function.....................................................................21
4.3.1 Enabling/disabling the heating circulation function......................... 22
4.4 Adjusting the shank lubrication.............................................................. 23
4.5 Operation of the Boost button................................................................. 24
4.6 Editing parameters....................................................................................24

5 Operator's maintenance procedures............................ 25

5.1 SLU............................................................................................................. 25
5.1.1 Checking the oil level...................................................................... 25
5.1.2 Emptying the shank lubrication return oil tank (DL422iE, DL432i).. 25

6 Periodic maintenance procedures................................27

6.1 SLU............................................................................................................. 27
6.1.1 Draining the condensed water.........................................................27
6.1.2 Checking the condition of the water separator................................ 28
6.1.3 Changing the water separator filter element................................... 29
6.1.4 Cleaning the tank............................................................................ 30
6.1.5 Replacing the breather.................................................................... 31

7 SLU repair instructions..................................................33

7.1 Replacing the shank lubrication hose.................................................... 33
7.2 Bleeding the shank lubrication oil tank.................................................. 33
7.3 Bleeding the shank lubrication oil pump................................................34
7.4 Replacing the seals...................................................................................35
7.5 Removing the shank lubrication unit...................................................... 37
7.6 Replacing the SLU control unit................................................................39
7.7 Replacing the SLU pump unit.................................................................. 41

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Shank lubrication unit

8 SLU troubleshooting...................................................... 43
8.1 Troubleshooting........................................................................................ 43
8.1.1 CAN troubleshooting....................................................................... 45

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Shank lubrication unit

1 INTRODUCTION
1.1 The purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
These instructions must be followed along with other manuals of the rig,
any instructions given in local laws and regulations, any orders given by
local authorities, and all protective measures specific for the site.
Before operating, or performing maintenance or repair procedures for the
component or system described in this manual, read and understand the
information in operator´s and maintenance manuals supplied with the
machine. Pay special attention to the safety information in chapter Safety
and environmental instructions of those manuals.
1.1.1 Validity of the manuals
This manual, and especially the safety information, is valid only if no
unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include information
on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.

1.2 General
The purpose of shank lubrication is to lubricate the rock drill’s rotation
mechanism and shank. Lubrication is carried out using a mixture of shank
lubrication oil and compressed air. Proper shank lubrication is essential.
Inadequate lubrication rapidly causes serious damage to the rock drill.
Following these instructions will significantly increase the safety, reliability
and operating life of the rig. Sandvik Service is always willing to provide
advice and help with any problems related to the rig.

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2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1 Safety precautions
Take all safety factors into consideration and perform your work with care.
Follow all drilling site safety regulations.

WARNING
PERSONAL INJURY HAZARD!
Moving machine could cause death or severe injury.
Maintenance and repairwork 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 repairwork.
Unauthorized persons are not allowed near the rig during the repair
work.

WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and obey
following instructions before operating the equipment.
Service and adjustment procedures must be carried out by
personnel with specialized operation and service training.
Carefully plan your work beforehand to minimize risk of damage or
injury.

WARNING! HIGH PRESSURE INJECTION HAZARD!

Compressed air jets could cause death or severe injury.
Allow the pressure to be released before opening the filling cap or
the compressed air connector.

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Shank lubrication unit

3 SLU MAIN COMPONENTS

3.1 Components
4
3
5
11
15 16 18 14

2
17
6
1

7
10
8
12

9 13

1 Water separator 2 SLU air valve(s)

3 Level guard 4 Oil dipstick
5 Breather / filling cap 6 SLU oil receiver
7 SLU control unit 8 Pump unit(s)
9 Manual drain valve of the 10 SLU air line pressure sen-
shank lubrication oil sor
11 Automatic drain valve of the 12 Manual drain valve of the
water separator water separator
13 Check valve (CT1) 14 Check valve (CT2)
15 Piston assembly (CT3) 16 Hydraulics bleeding screw
(CT4)
17 Control valve (CT5.1) 18 Bleeding screw (CT7)

3.2 Technical data

Oil tank SLU 14
Total amount of oil (L) 14
Effective amount of oil without heater 12

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Oil tank SLU 14

Breather (µm) 10
Oil strain (mm) 1

Stroke volume with standard percussion (7.5 mm) / maxi-

0.85/1.25 cm 3
mum percussion (11 mm)
Output range with standard percussion (7.5 mm) 50–1200 g/h
Max. operating pressure 210 bar
Min. operating pressure 25 bar
Max. lubrication oil pressure 25 bar
Pump unit

Control switch 7
Pump unit fastening screws 20
Tightening torques (Nm)

3.3 Shank Lubrication Controller (SLC)

Component
The shank lubrication control unit is used for controlling the rig's shank
lubrication.

1 2 3

5 4

1 Power indicator light

2 CAN-RUN indicator light
3 CAN-ERR indicator light

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4 Status indicator light

5 Boost mode button

Specifications:
• Connections: Hummel (power), 2 x M12 SLU air flow, 4 x M12 SLU oil
flow valve, 2 x M12 air pressure sensor, 2 x M12 level sensor
• Operating temperature: -40...+70 °C
• Operating voltage range: 9...30 VDC
• Protection class: IP65 (water and dust protected)
Led indicators:
1. POWER
Status Description
(green)
ON On SLCU 5 V operating voltage OK
No operating voltage, internal automatic fuse tripped or fault in the
OFF Off
internal voltage controller

2. CAN-RUN
Status Description
(green)
Single flash Stopped SLCU has stopped sue to internal fault
SLCU is on standby. Awaiting a command from the CAN bus control
unit.
Flashes Standby
CAN bus connection is broken.
Control unit (CAC) does not send a start command.
On On SLCU is on
Off Reset SLCU is resetting or the unit is down

3. CAN-ERR
Status Description
(red)
Off No errors SLCU is operating normally
At least on CAN control error counter has reached or exceeded the
Alarm lim-
Single flash alarm limit (too many errors). Reset automatically when data trans-
it reached
fer is OK.
On Bus off CAN control bus is off

4. STATUS
Description
(yellow)
Off Lubrication off, Boost mode off
Lubrication allowed. The user may start the Boost function by pressing the
Single flash
Boost button.
Continuously
Boost function is on
on

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Shank lubrication unit

4. STATUS
Description
(yellow)
On for a mo-
ment, then Lubrication on
flashes
Two flashes Malfunction in lubrication oil flow. Signal from flow sensor not detected.
Malfunction indicated by the air pressure sensor.
Three flashes Air pressure sensor broken or disconnected.
Current signal from sensor lower than 2 mA (normal value: 4...20 mA).
Malfunction indicated by the lubrication oil level switch.
Four flashes Level switch sensor broken or disconnected.
Current signal from sensor lower than 1.7 mA (normal value: 4...20 mA)

Functions
The purpose of the shank lubrication controller is to dispense shank
lubrication oil to the rock drill(s). The rock drill’s shank lubrication request
comes from the BDM node via the backbone.

Initialization when replaced

Not needed.

Calibration when replaced

Not needed.

Connections

2
SLCU
1 3
6
POWER
4 CAN-RUN / ERR 4 1 2 3
5
5 5
STATUS 1

STATUS 2 3 2 1 4
BOOST
ON/OFF STATUS 3

STATUS 4
4 1 1 4
Blinking codes
5 5 OFF
BOOST allowed
3 2 2 3 BOOST selected
Lubrication
Lubr. failure
P sens. failure 4 1 2 3
L sens. failure
5 5

3 2 1 4

4 1 2 3
5 5

3 2 1 4

4 1 2 3
5 5

3 2 1 4

4 1 2 3
5 5

3 2 1 4

Connector Description Connection

POWER SLC power supply Connected to the power supply
CAN CAN connection Connected to the backbone
CAN CAN connection Connected to the backbone

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Connector Description Connection

Connected to the air valve(s) of boom 1 (and 2
1-2XY127 Air flow control connection
shank) lubrication
3XY127/
Air flow control connection Connected to the water separation drain valve
XY129
1XY277- Shank lubrication oil flow con- Connected to the boom 1 flushing flow sensor
B277 trol connection B277 and lubrication pump valve Y277
Connected to the boom 2 flushing flow sensor
2XY277- Shank lubrication oil flow con-
B277 and lubrication pump valve Y277 (if equipped
B277 trol connection
with two booms)
3XY277-
Not in use Not in use
B277
Connected to the boom 1 air pressure sensor
B127. The sensor is used to measure the pressure
1XB127P Air pressure sensor connection
level of the air produced by both the SLU and the
compressor.
Connected to the boom 2 air pressure sensor B127
XB127/ (if equipped with two booms). The sensor is used
Air pressure sensor connection
2XB127P to measure the pressure level of the air produced
by both the SLU and the compressor.
XB923L Level sensor connection Connected to the SLU oil level sensor
3X127P Level sensor connection Not in use

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3.4 SLU level sensor

+SLCU

B923L SUPPLY

SLU OIL LEVEL SENSOR

00

00
00

00
00

00
00

24V 00AI
0-20mA
. .

1 2 3 4

1 2
XB923 1 XB923 2
WB923L GR WB923L BN

B923L

GN GN YE RD

4.7 kOHM
YE :DO NOT CONNECT

S1 WH : DO NOT CONNECT

S2
S3

Ref State Oil amount in the 14 L receiver (L)

1 Four lights turned on 12.5-14
2 Three lights turned on 6.5-12.5
3 Two lights turned on 1.7-6.5
4 One light turned on 0-1.7

Note! Do not connect wires YE and WH.

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Shank lubrication unit

4 SLU OPERATION
4.1 Operation of the SLCU
5
1 6 16

8
14

4 P/I 7

3 10 11 13
15

CT5.1 T P
CT1 12
2

Operating principle of the SLU

1 Level switch 2 Pump unit

3 SLCU control unit 4 Boost toggle button
5 Control system 6 Air line water separator
7 SLU air line pressure sen- 8 SLU air valve
sor
9 Rock drill 10 Mixing piece
11 Feed hose 12 Shank lubrication oil hose
13 Mixing hose 14 Drain valve
15 SLU air line restrictor (3 16 Cooler for shank lubrication
mm) air (optional)

The hydraulics-operated piston pump (2) pumps lubrication oil along the
hydraulic hose (12) to the mixing piece (10). From the mixing piece (10),
the oil is directed along the feed hose (11) to the air and oil mixing hose
(13) and from there the oil mist continues onward to the rock drill (9).
The compressed air from the compressed air system is directed through
the water separator (6) to the air valve (8) controlled by the SLCU (3). If the

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rig is equipped with air-air cooler (16), the air flows through it before the
water separator (6). SLU air line pressure sensor (7) monitors the air
pressure in SLU air line and the SLU air line restrictor (15) restricts the air
flow before the mixing piece (10). The drain valve (14) opens automatically
every five minutes and drains water out of the separator (6). If necessary,
manual drain valve can also be used.
When the rock drill percussion and/or rotation is switched on, the control
system sends the SLCU (3) a command to start rock drill lubrication with
the set lubrication dosage. The SLU air valve (8) opens and the lubricant
pump unit (2) starts. The pressure sensor (7) measures the air pressure. If
the pressure is too low, the SLCU sends an error message to the control
system.
Lubrication cycle

Pump valve LED on Pump valve LED off

(Pump suction phase) (Pumping phase)

Lubrication Pulse Time (Defau lt=1.00 s)

20 ms delay 20 ms delay

Defined by Lubrication Demand, 1...30 sec

In the boo st mode pause is always 1.00 s

OIL FLOW CONTROL

VALVE OUTPUT

OIL FLOW MONITORING INPUT

Ball valve Monitoring: Ball valve Monitoring:
INPUT has be en INPUT has bee n ope n continuously
closed continu ously minimum 50 ms.
minimum 50 ms.

The lubrication oil dosage is adjusted by changing the operation frequency

of the pump (2). The frequency is changed with an electrically controlled
valve (CT5.1), which is controlled with the SLCU (3). The required amount
of lubrication oil depends on the rock drill and the drilling conditions.
The shut-off ball of the lubrication pump output port check valve (CT1)
operates as a control valve against the valve seat. The oil flow through the
check valve removes the ball from the seat surface and shuts off the circuit.
The ball is electrically connected to the pump (and rock drill) frame. The
voltage is directed to the ball via a spring isolated from the pump frame.
The SLCU (3) measures the signal of the control valve (CT1) and sends a
message to the control system if the oil flow ceases. The control system
transmits an error message to the user interface and stops the drilling after
a delay.
Note! If the control valve shut-off ball is left open or closed for four
operational cycles, in deviation from normal operation, an alarm is
switched on. The user receives an error message and the drilling
stops. The alarm is reset when pumping returns to normal.
The output of the pump can be maximized with the Boost button (4), please
refer to section Operation of the boost button.

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Oil mist that has traveled through the rock drill’s lubrication circulation
system is removed through the middle section of the rock drill.
Related information
Operation of the Boost button (Page 24)

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Shank lubrication unit

4.2 Description of shank lubrication oil pump operation

S 3 S 3

TG TC TG TC
1 2

Pump operation (as many blocks as booms in the machine)

The lubrication pump is a hydraulic, electrically controlled piston pump. The

lubricant dosage is determined electrically by changing the operating
frequency of the pump.
The lubrication pump has a block structure. The pump consists of a main
block (1), to which an auxiliary block (2) is attached. If equipped with two
booms, both blocks have their own lubrication control switches. The control
is always operational when the operating voltage is switched on.
The directional valve (CT5.1) guides the hydraulic oil to the piston side or
from the piston side to the tank.
When valve (CT5.1) coil receives the control voltage, the spool changes its
position and the oil from the piston side is directed into the tank line T. At
the same time, the lubrication oil is sucked from the SLU oil receiver
through port S into the operating piston chamber (3).
When the control voltage is cut off from the valve (CT5.1) coil, the spool
changes its position back to original and the hydraulic oil is directed to the
piston side. At the same time, the lubrication oil from the piston chamber (3)
is pumped through the check valve (CT1) into the rock drill through port L.

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4.3 Heating circulation function

TC

The performance of the SLU pump decreases in cold conditions. This is

due to the increased viscosity of both the shank lubrication oil and the
hydraulic oil that drives the pump. The increase in viscosity causes
problems in, for example, the control valve (CT5.1) and check valve (CT2).
The heating circulation function is based on circulating the hydraulic oil
through the pump. The oil circulates through an 0.6 mm orifice and flow
control valve (CT8) directly into the tank. The volume flowing through the
orifice is about 1–2.5 L/min. The heating circulation function can be enabled
and disabled (factory setting is enabled).

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4.3.1 Enabling/disabling the heating circulation function

3
1

1 Locking nut
2 Heating circulation orifice, 0.6 mm
3 Plug screw
4 Seal
5 Cap

Enabling the heating circulation Disabling the heating circulation

1. Unscrew the cap (5) 1. Unscrew the cap (5)

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

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4.4 Adjusting the shank lubrication

Note! Inadequate operation of the shank lubrication quickly causes severe
damage on the rock drill and difficulties during drill steel uncoupling.
The shank lubrication amount is adjusted according to rock drill type and
drilling conditions (drilling direction and hole size). Drilling upward and/or a
large hole size requires more lubrication than small holes drilled downward.
More lubrication is recommended if the rock drill (shank) temperature is
high.
If necessary, the shank lubrication amount can be adjusted from the GUI:
→ Troubleshooting → Shank lubrication

Shank lubrication
Rock drill type
amount (g/h)
HEX1, HLX1 50-100
RD106 50-200
H200, HL300 100-150
RD314 100–200
RD414 150-250
HLX5, RD520, RD525 180-250
HL510 200-300
HL650, HL710, HF820T, HL820T, HL1010 400-850
RD921S 500-700
RD925M 600-800
HL1060T, HL1560T 600-1200
RD927L 700-900
HF1560T 800-1200

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4.5 Operation of the Boost button

2XY277-B277
1XY277-B277
1
SLCU

POWER
POWER 2
CAN-RUN / ERR

3XY277-B277
3
CAN STATUS 1

CAN
STATUS 2
BOOST

XB127P/2XB127P
5 4
ON/OFF STATUS 3
3XY127/XY129
1-2XY127

1XB127B
STATUS 4
Blinking codes
OFF
BOOST allowed
BOOST selected

3XB127P
XB923L
Lubrication
Lubr. failure
P sens. failure
L sens. failure

The Boost function is used:

• during filling the shank lubrication hose
• when higher oil output is required momentarily.
When the Boost button (5) is pressed, the output of all pumps is 1200 g/h,
and the pumping frequency is 30 strokes per minute. The Boost function
remains active until the button is pressed again.

4.6 Editing parameters

If your user level is maintenance/factory, you can edit SLU parameters by
selecting: → Maintenance → Parameters / Parameter Management
→ Drilling control
Note! Parameters take effect immediately after editing. Parameters are boom
related in two boom machines.

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5 OPERATOR'S MAINTENANCE PROCEDURES

5.1 SLU
5.1.1 Checking the oil level
Note! To avoid problems caused by air bubbles in the oil, fill the tank after
drilling. DO NOT fill the tank during drilling.
1. Check the oil level from the
dipstick and fill the tank if
necessary.

5.1.2 Emptying the shank lubrication return oil tank (DL422iE, DL432i)

1. Empty the tank always when the shank lubrication oil tank is filled:
a) Place a receptacle
under the drain
valve (1).

b) Open the drain valve (1) to drain the oil into the receptacle.
c) Close the drain valve (1).
Note! Never reuse the used oil. Make sure that used oil is correctly
disposed.

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6 PERIODIC MAINTENANCE PROCEDURES

6.1 SLU
6.1.1 Draining the condensed water

1. Use the drain valve to drain the

condensation water from the oil
tank.

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6.1.2 Checking the condition of the water separator

When mechanical service indicator (1) shows approximately all red, the
filter element (2) inside the water separator should be changed. Refer to
section Changing the water separator filter element.
Related information
Changing the water separator filter element (Page 29)

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6.1.3 Changing the water separator filter element

Disassembly
1. Water separator filter element (4) can be disassembled without removal
from air line.
2. Shut off inlet pressure. Reduce pressure in inlet and outlet lines to zero.
3. Remove bowl (8) - push into body and turn counterclockwise.
4. Disassemble in general accordance shown on the exploded view. Do
not remove the drains or the service indicator (1) unless replacement is
necessary. Remove and replace only if they malfunction.

1 1

2
6
3 8

11
4
7
5

10

Assembly
1. Lubricate o-rings, the portion of the manual drain body (6) that contacts
the bowl, and the hole in the manual drain body that accommodates the
stem of drain valve (7) with o-ring grease.
2. Assemble the filter as shown on the exploded view.
3. Arrows on the indicator (1) and the body (2) must point in the same
direction. Screw the baffle (5) onto the center-post (3) until contact is
made with the filter element (4), then tighten an additional 1/4 turn.
Push bowl (8), or bowl with guard, into body (2) and turn fully clockwise.
4. Torques in Nm:

3 2.0 - 2.7 Nm (center-post)

9 2.8 - 3.9 Nm (screw)
10 2.3 - 2.8 Nm (nut)
11 1.7 - 2.3 Nm (screw)

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6.1.4 Cleaning the tank

1. Use the drain valve to empty the

tank into a receptacle.

2. Remove the tank cover.

3. Clean the tank from the inside.
4. Reinstall the tank cover.

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6.1.5 Replacing the breather

1. Replace the breather.

Replace the breather at the intervals specified in the maintenance

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

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7 SLU REPAIR INSTRUCTIONS

7.1 Replacing the shank lubrication hose
Change a faulty shank lubrication hose as follows:
1. Disconnect and replace the faulty shank lubrication hose from the rock
drill.
2. Start the diesel engine or the power pack and the compressor.
If using diesel engine, pressurize the carrier hydraulics as follows:
a) Push the carrier hydraulics pressurizing stud and turn it
clockwise to release the stud to up position.
3. Start the Boost function.
4. Keep the Boost function on until oil flows from the hose (collect the oil in
a receptacle).
5. After bleeding the hose, stop the Boost function.
6. Stop the diesel engine or the power pack and the compressor.
7. Connect the shank lubrication hose to the rock drill.

7.2 Bleeding the shank lubrication oil tank

1. Stop the diesel engine or the power pack.
2. Open the bleeding screw (CT7) 1–2 rounds.
CT4 CT7

3. When the bled oil no longer contains bubbles, close the bleeding screw
(CT7).
Note! Bleed all pump blocks at the same time.

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7.3 Bleeding the shank lubrication oil pump

1. Connect the separate bleeding hose to port (L) and direct it to the
receptacle.
CT4 CT7

2. Start the diesel engine or the power pack.

3. Open the bleeding screw (CT7) 1/2 rounds and the bleeding screw
(CT4) one round.
4. Leave the screws open for about one minute. Close the bleeding screw
(CT7).
5. Wait until the oil bleeding out no longer contains air bubbles. Close the
bleeding screw (CT4).
6. Stop the diesel engine / power pack.
7. Disconnect the bleeding hose and connect the original hose to port (L).
8. Start the diesel engine or the power pack and the compressor.
9. Start the Boost function with the Boost button on the control unit for
approximately 10 minutes to ensure that the hose contains lubrication
oil all the way to the rock drill.
10. Stop the Boost function.
Note! Bleed all pump blocks at the same time.

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7.4 Replacing the seals

Replace the seals as follows:
1. Depressurize the system.
2. Open the plug (2).

2 3

3. Pull the piston (3) out.

4. Remove the old seals from the piston.
5. Clean the parts thoroughly.
6. Install the new seals (4) 3
carefully.
After the seals are installed on the
piston, the seals at both ends of the
4
piston must be calibrated using a
calibration tool (5). Lubrication (with
oil or grease) is recommended in
order to avoid seal damage during
calibration.

7. Push the piston (3) in place in the pump unit.

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8. Close the plug (2).

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7.5 Removing the shank lubrication unit

1. Shut down the diesel engine and power packs.
2. Isolate the electrical system as instructed in operator's and maintenance
manuals.
3. Place a waste oil receptacle under the oil tank (1).
3 11

2
8

10

4. Empty the oil tank (1) into the receptacle via the drain valve (2).
Dispose of the waste oil in accordance with local regulations.
5. Close the drain valve (2).
6. Open the cover (4) by loosening the wing screw(s) (5).
7. Disconnect the level switch (3) cable.
8. Disconnect the oil heater cable (optional).
9. Check the markings on the control unit (6) cables.
Mark the cables so that they can be connected correctly during
assembly.
10. Disconnect the control unit (6) cables.
11. Check the markings on the hoses and cables of the pump(s) (7).
Mark the cables and hoses so that they can be connected correctly
during assembly.
12. Open the mounting clamp (8) bolts (9) and nuts (10).

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13. Lift the tank assembly from the carriage.

14. Install the serviced/new tank assembly on the carriage.
15. Install the mounting clamp (8) in place.
16. Tighten the mounting bolts (9) and nuts (10).
17. Connect the hoses and connectors to the pump(s) (7).
18. Connect the cables to the control unit (6).
19. Connect the oil heater cable (optional).
20. Connect the level switch (3) cable.
21. Open the breather (11).
22. Fill the tank to the maximum limit.
23. Tighten the breather (11).
24. Close the cover (4) after bleeding.
25. Start the system and check the operation of the module in the
troubleshooting view.
For instructions on bleeding the tank and pump(s), see the separate
SLU maintenance instructions.

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7.6 Replacing the SLU control unit

1. Shut down the diesel engine and power packs.
2. Isolate the electrical system as instructed in operator's and maintenance
manuals.
3. Open the cover (1) by loosening the wing screw(s) (2).

5 2

4. Check the marking on the control unit (3) cables.

Mark the cables so that they can be connected correctly to the new
component.
5. Disconnect the control unit (3) cables.
6. Replace the control unit.
If the new control unit comes with the mounting plate, proceed as
follows:
a) Open the 4 mounting screws (5) of the mounting plate (4) for
the control unit (3) on the oil tank mounting plate.
b) Install the new control unit on the oil tank with the mounting
plate and mounting screws (5).
If the new control unit comes without the mounting plate, proceed as
follows:
a) Open the control unit (3) cover mounting screws (6, 4 pcs).
b) Open the control unit mounting screws (4 pcs) from inside
the control unit (3).
c) Remove the control unit (3).
d) Open the cover of the new control unit.
e) Install the new control unit on the mounting plate (4) with the
mounting screws.

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f) Install the control unit cover.

7. Connect the cables to the control unit.
8. Close the cover (1).
9. Start the system and check the operation of the module in the
troubleshooting view.

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7.7 Replacing the SLU pump unit

1. Shut down the diesel engine and power packs.
2. Isolate the electrical system as instructed in operator's and maintenance
manuals.
3. Place a waste oil receptacle under the oil tank (1).

4
6

4. Open the tank drain valve (2).

5. When the tank is empty, close the drain valve (2).
Dispose of the waste oil in accordance with local regulations.
6. Open the cover (3) by loosening the wing screw(s) (4).
7. Check the markings on the hoses and cables of the pump(s) (5).
Mark the cables and hoses so that they can be connected correctly
during assembly.
8. Disconnect the cables and hoses of the pump(s) (5).
9. Open the protective cover mounting screws (6, 3 pcs).
10. Replace the faulty pump unit with the new one.
11. Before installing, carefully clean the joint surfaces of the pumps.
12. Replace the seals on the tank and intake lines of the pumps.
13. Clean the joint surface of the oil tank pump(s) .
14. Install the pump(s) (5) on the oil tank (1) using the mounting screws (6).
15. Connect the hoses and cables to the pump(s) (5).
16. Open the breather (7).
17. Fill the oil tank (1) to the maximum limit.

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18. Close the breather (7).

19. Close the cover (3) after bleeding.
20. Start the system and check the operation of the module in the
troubleshooting view.
For instructions on bleeding the tank and pump(s), see the separate
SLU maintenance instructions.

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8 SLU TROUBLESHOOTING
8.1 Troubleshooting
The use of self-diagnostics is the primary troubleshooting method for the
rig.

Select → Troubleshooting → Shank lubrication

Display text Function Information

Oil request Lubrication amount (g/h) The amount is set in the field.
When the light is turned on, the air
Air valve Indicator light (On/Off)
valve Y127 is open.
The air pressure produced by the com-
Air pressure Air pressure (bar)
pressor.
When the light is turned on, there is a
Lubrication failure Indicator light (On/Off)
malfunction in the oil flow.
When the light is turned on, air pres-
Pressure low Indicator light (On/Off)
sure level is too low.
When the light is turned on, current
Pressure sensor failure Indicator light (On/Off) signal from the pressure sensor is un-
der 2 mA.
When the light is turned on, the Boost
Boost Indicator light (On/Off) mode is active and SLU pumps the
maximum amount of oil.

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Display text Function Information

When the light is turned on, the drain
Water separator valve Indicator light (On/Off)
valve Y129 is open.
When the light is turned on, current
Level sensor failure Indicator light (On/Off) signal from the level sensor is under 2
mA.
Amount of lubrication oil in the tank
Oil level Indicator lights (On/Off) (full, up, half and low). Information from
sensor B923L.

Possible cause Solution

Oil level too low Add oil and bleed the pump.
Pump intake opening clogged Check and clean the tank.
Remove the inner tube and clean
Inner tube clogged
or replace it.
Oil viscosity too high Use correct oil type.
Pump control valve (CT5.1) broken Check/replace the valve.
Pump timer faulty Check/replace the timer.
Control valve (CT5.1) wire broken Check and replace the wire.
Shank lubrication pressure hose
Replace or repair the hose.
damaged
No oil flow

Possible cause Solution

Timer frequency incorrectly adjusted Check the adjustment.
Check the oil tank level and
Air in the pump
bleed the pump.
Foreign object in the suction side of the
Clean the check valve ball.
check valve (CT1)
Foreign object in the control plug non-return Clean the control plug /
valve tank.
Filler cap clogged (formation of underpres-
Clean the breather.
sure)
Return hose to oil collecting tank clogged Remove the blockage.
Oil flow too low

Possible cause Solution

Hydraulics bleeding screw (CT4) open Tighten the screw.
Timer frequency incorrectly adjusted Check the adjustment.

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Possible cause Solution

Check the piston and replace the
Piston (CT3) seals broken
seals.
Check and turn off the boost func-
Boost function activated
tion.
Oil flow too high

Possible cause Solution

Hydraulics bleeding screw (CT4) open Tighten the screw.
Check the piston and replace the
Piston (CT3) seals broken
seals.
Internal air leak in the pump

Possible cause Solution

Control plug wire broken Check and replace the wire.
Change oil in the shank lubrication oil
Oil dirty and conductive
receiver.
Flow control rig worn (ball surface
Check/replace flow switch assembly.
corroded)
Oil flow normal but control alarm on

8.1.1 CAN troubleshooting

Problem Solution
Check whether the control unit has supply voltage.
Power indicator off Check the condition of the automatic fuse.
Check the condition of the internal voltage regulator.
No supply voltage to the control unit.
CAN-RUN indicator off The control unit is being reset. Wait a few seconds. If the light does not
switch on, the control unit is not functioning properly.
If the light is flashing, the error counter has reached or exceeded the
alarm limit. The fault condition is reset automatically when data transfer is
CAN-ERR indicator OK.
If the light is lit continuously, the CAN control bus is off.

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Problem Solution
If the status indicator flashes twice, there is a malfunction in the lubrica-
tion oil flow.
See the troubleshooting section for other causes of flow malfunction.
If the status indicator flashes three times, there is a problem with the air
pressure or a malfunction in the air pressure sensor.
Status indicator Measure the sensor current signal; the value should be 4–20 mA.
Check the SLU air pressure.
If the status indicator flashes four times, the lubrication oil level in the
tank is below the minimum limit or the level sensor is broken.
Measure the sensor current signal; the value should be 4–20 mA.
Check the lubrication oil level in the tank.
Control unit LED indicators

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www.sandvik.com
 V64102-5en0318

OPERATING INSTRUCTIONS
CT60-100
Screw compressor

Version 1.0

EN © 2018 Gardner Denver Oy

1. Introduction ............................................................................................................................ 1
1.1 Storing the books ......................................................................................................... 1
1.2 Warranty terms............................................................................................................. 1
1.3 Log book....................................................................................................................... 1
1.4 Inquiries........................................................................................................................ 1

2. Safety ...................................................................................................................................... 2
2.1 Safety during installation and preparations for use ...................................................... 2
2.2 Safety during operation ................................................................................................ 2
2.3 Safety during maintenance........................................................................................... 3
2.4 Safety signs.................................................................................................................. 4

3. Main components .................................................................................................................. 5

3.1 Main components ......................................................................................................... 6

4. Operating principles .............................................................................................................. 7

4.1 Air end .......................................................................................................................... 7
4.2 Air compressing process .............................................................................................. 7
4.3 Oil circulation and the compressed air circuit............................................................... 8
4.3.1 Oil circulation........................................................................................................ 8
4.3.2 Compressed air circuit.......................................................................................... 9
4.4 Compressor control system........................................................................................ 10

5. Handling instructions .......................................................................................................... 13

5.1 Storing the compressor .............................................................................................. 13
5.2 Lifting instructions (diagram) ...................................................................................... 14
5.3 Decommissioning ....................................................................................................... 14
5.3.1 WEEE (Waste Electrical and Electronic Equipment Directive) label .................. 15

6. Operating instructions ........................................................................................................ 17

6.1 First start-up of the compressor ................................................................................ 17
6.2 Adjusting the capacity control and unloading pressure limits..................................... 17
6.2.1 PS3 valve ........................................................................................................... 17
6.2.2 PS2 valve ........................................................................................................... 18

7. Maintenance instructions ................................................................................................... 19

7.1 Before maintenance work........................................................................................... 19
7.2 After maintenance work.............................................................................................. 19
7.3 Maintenance schedule ............................................................................................... 20
7.4 Adjusting the minimum pressure valve....................................................................... 21
7.5 Adding and changing oil ............................................................................................ 22
7.5.1 Oil top-up............................................................................................................ 22
7.5.2 Oil change .......................................................................................................... 23
7.6 Replacing the oil filter ................................................................................................. 24
7.6.1 Removing the oil filter......................................................................................... 24
7.6.2 Installing the oil filter........................................................................................... 24
7.7 Replacing the air filter................................................................................................. 25
7.8 Replacing the oil separator element........................................................................... 26
7.8.1 Removing the oil separator elements................................................................. 26
7.8.2 Installing the oil separator elements................................................................... 27
7.9 Replacing the belts..................................................................................................... 28
7.10 Removing the belt pulley and the cone sleeve......................................................... 29
7.11 Attaching the belt pulley and the cone sleeve .......................................................... 30
7.12 Testing the safety valve............................................................................................ 31
7.13 Testing the overheating protection switch ................................................................ 31
 7.14 Decommissioning ..................................................................................................... 32
7.15 Oil recommendations ............................................................................................... 32
7.15.1 Recommended lubricants................................................................................. 32
7.15.2 Oil specifications .............................................................................................. 32
7.15.3 General guidelines for oil change intervals for mobile use............................... 33

8. Troubleshooting instructions ............................................................................................. 35

9. Technical Appendixes ......................................................................................................... 39

Declaration of Incorporation of CT and CTN

Declaration of Incorporation
(Machinery Directive 2006/42/EC, part B, Annex II) of CT- and CTN-compressors
Type: Oil-Flooded Screw Compressor (called “CT” in the following text)

This CT-compressor was Gardner Denver Oy

manufactured from: P.O.Box 516
FIN-33101 Tampere
Finland

The CT concerned is an air compression unit without an electric starter, type: CT3, CT6, CT12, CT25,
CTN2, CTN3 or CTN25. The CT name plate shows the model, the part number and the serial number
of the CT. This compressor is allowed to compress air and separately specified gases. The maximum
allowed operational temperature is 120°C.

The relevant technical documentation is compiled in accordance with part B of Annex VII of the
Machinery Directive. All the relevant information of the CT will be transmitted, in writing, in response to
a reasoned request by the national authorities. This shall be done without prejudice to the intellectual
property rights of the manufacturer of the CT.

Documenting unit: Gardner Denver Oy, Tampere

Engineering Manager, sustaining: Harri Väänänen

The following essential health and safety requirements of Directive 2006/42/EC, Annex I, are applied
and fulfilled:

• Principles of safety integration:

The incorporation of the CT in the pressurized air system shall be carried out only by qualified
personnel. Qualified personnel is, as a general rule, The Gardner Denver Service personnel or the
Service personnel authorized by Gardner Denver. The Service personnel should wear appropriate
clothing and eye protection during the assembly of the CT and the air system. Safety footwear and
safety glasses should be compulsory in all workshops. Safety helmets must be worn if there is any
risk of falling objects. Gloves are recommended.

• Materials and product:

The CT is essentially made of cast iron. Remainder of mineral compressor oil (used in test run)
could be inside the CT.

• Handling:
The packaging of the CT is done for safe transportation with a minimized risk of damaging during
transportation. The installation and commissioning of the CT should be done within 3 months after
delivery. If the CT should be stored over a long time period, please contact authorized distributor
of Gardner Denver for appropriate preservation.

Gardner Denver Oy
P.O.Box 516
FIN-33101 Tampere
Finland
Declaration of Incorporation of CT and CTN

The CT can only be moved and lifted by using of standard lifting gear. Eye bolts for attaching of
lifting tackle have already been installed or are enclosed. Install a minimum of two eye bolts to lift
the CT.

All openings and holes of the CT are covered and plugged during shipping. After removing covers
do not grasp into the CT! Be careful that no foreign particles or pollution could fall into the CT
during the assembly job or could end into the oil circuit.

• Protection against mechanical hazards

During the installation of the CT into the pressurized air network normally it’s required to
disassemble specific protective devices like coupling guard or V-belt guard. These specific
protective devices must be reassembled before commissioning of the compressor. Oil must be
filled in again according to the user manual. Follow the instructions of the compressor user
manual when commissioning the compressor.

• Risk of uncontrolled movements:

During the assembly job the compressor unit must be isolated from the main power supply.

• Risk of other hazards:

The essential health and safety requirements, mentioned in the user manual of the compressor
(machinery), must be fulfilled when the CT is incorporated into the pressurized air network and
first and foremost when the pressurized air network is commissioned or re-commissioned.

In particular the compressor discharge temperature and the discharge pressure must be
monitored with sensors, connected to the pressurized air control system, tripping ALARM or
SHUTDOWN when critical limits are reached.

The CT must not be put into service until the pressurized air network (final machinery) into which it is
to be incorporated has been declared in conformity with the provisions of Directive 2006/42/EC.

Tampere 22.3.2018
(Place) (Date)

(Signature)

Jussi Nurminen, Managing director

(Name, position in company)

Gardner Denver Oy
P.O.Box 516
FIN-33101 Tampere
Finland
1. Introduction

1. Introduction

Gardner Denver wishes you welcome among the users of Gardner Denver screw compressors!

This manual gives you instructions on correct and safe operation and maintenance of your screw
compressor.

Read these and other instructions with the compressor carefully before using your screw
compressor. This ensures correct preparations and use from the very beginning.

1.1 Storing the books

All the instructions in this manual have been provided to guarantee a long life and reliable operation of your
screw compressor.

Always keep the manual available near the compressor. Make sure that the compressor is operated and
serviced according to the instructions.

1.2 Warranty terms

Get acquainted with the Gardner Denver warranty terms, which are enclosed with the manuals for the
compressor. Fill in the warranty registration card with care and return it to the seller as instructed.

The warranty becomes void if the terms are not observed or if other than original Gardner Denver spare
parts are used. Use only the recommended AEON oil types in order to ensure undisturbed operation.

All the service and maintenance duties, which are not covered in this manual should be made only by
trained and qualified service personnel authorized by Gardner Denver or its representative.

1.3 Log book

There is a log book enclosed with the manuals for the compressor. Always fill it in after any maintenance or
repair work.

1.4 Inquiries

When making inquiries concerning your screw compressor, always quote the complete type specification
and the serial number as they are given on the data plate of the compressor.

Gardner Denver reserves the right to change the construction and manuals of the compressors without
prior notice.

1
2. Safety

2. Safety

The general safety instructions concerning the compressor are presented in this chapter.

Read also the safety instructions for transportation, installation, operation and maintenance
presented separately in each section of the manual.

Always read the safety instructions before starting to work.

The instructions concerning safety are marked with this symbol.

In addition to these instructions, the local regulations in your country may impose additional requirements
that must be observed.

2.1 Safety during installation and preparations for use

The noise level of the compressor, which is presented in the "Technical data", is determined according to
ISO2151 and ISO3744. The noise level may rise higher if the walls surrounding the installing location
reflect sound. Take this into consideration, when choosing the best location for the compressor.

Observe the local regulations concerning the use of ear protectors.

The intake air for the compressor must be clean and cool. Prevent the used and hot cooling air
circulating back to the cooling air intake. Make sure that foreign objects cannot get into the compressor
with the intake air. The intake air must not contain any explosive or inflammable gases or harmful
substances.

Do not exceed compressor's rated maximum pressure, capacity or rotation speed. For more details see
"Technical data".

Use pneumatic hoses that can hold the working pressure. Pay special attention to the hose mountings.
The pressure in the hoses must be removed before disconnecting. A whipping hose may cause
unpredictable damage.

The pressure vessels in the pressurized air network must be in accordance with the pressure vessel
regulations.

Only authorized and qualified personnel should make the electrical connections. For more information on
electrical connections, see "Electrical drawings".

The condensate water contains oil. It should be disposed of according to the local regulations on waste oil.

2.2 Safety during operation

Do not blow pressurized air against the skin.

Do not use the compressor with its doors open.

2
2. Safety

Use only the recommended AEON oil types. Do not mix different types of oil.

Compressors with remote start-up should be provided with a warning sign that indicates the method of
starting.

Do not use the compressor in explosive environment.

2.3 Safety during maintenance

While doing maintenance, the compressor must always be stopped and disconnected from the electrical
mains connection. The shut-off valve of the pressurized air network must also be closed. Make sure that
there is no pressure in the air/oil receiver before starting maintenance.

Starting of the compressor or compressors with remote control or in multi-compressor installation must be
prevented while maintenance work is in progress.

Use only original Gardner Denver spare parts.

Do not repair the receiver by welding.

All alterations must comply with the pressure vessel regulations PED 2014/68/EU.

Do the regular checkups and maintenance of the compressor in order to ensure undisturbed operation.

Maintenance and service operations other than described in this manual must be left to service personnel
authorized by Gardner Denver.

In the frequency converter compressors, the high voltage can cause serious or fatal injury. Frequency
converter and motor connections can remain under high voltage after the main power is switched off.
Service is permitted only by trained and authorized personnel.

Only one safety function is allowed to be disabled at a time for any maintenance or troubleshooting
purposes.

3
2. Safety

2.4 Safety signs

Read User Manual before starting the compressor Wear ear protectors

Warning: hot surface Warning: risk of electric shock

Warning: compressor is remotely controlled and

Warning: moving parts
may start without warning

Warning: risk of hot exhaust fumes/hot air

General meaning of geometric shapes, safety colors and contrast colors for the safety signs

Graphical symbol
Geometric shape Meaning Safety color Contrast color
color

Mandatory action Blue White White

Circle

Warning Yellow Black Black

Equilateral triangle

4
3. Main components

3. Main components

The Gardner Denver screw compressor is an oil-cooled, single-phase screw compressor that produces
compressed air using a screw compressor unit driven by an electric motor. Oil is separated from
compressed air in an oil separation tank. Compressed air and the oil are cooled in separate cooling
circuits.

5
 3. Main components

3.1 Main components

1 2 3 4 5 7 8 6

Item Part Purpose

1 Motor Drives the screw unit

2 Belt Power transmission

3 Air end Produces compressed air

4 Inlet valve Regulates the production of compressed air

5 Intake air filter Cleans the intake air

6 Receiver Separates oil from air

7 A back-pressure valve that maintains minimum pressure in

Discharge valve
the receiver

8 Safety valve Protects the receiver from over pressure

6
4. Operating principles

4. Operating principles

4.1 Air end

Main components of the air end

1. Housing

2. Female rotor

3. Male rotor

4. Discharge flange

5. Shaft seal

6. Bearing cover

Screw unit

4.2 Air compressing process

Rotors

In a screw compressor the air is compressed in the air end driven by a motor.

The meshing rotors take air in between the ridges as they pass the inlet opening. When the rotors turn, the
connection to the inlet opening closes and the space between the ridges starts to decrease. At the end of
the compression phase, the desired pressure has been reached and the connection to the receiver opens.

The air in the air end is cooled by oil that is injected into it. The oil cools also the air end. In addition, the oil
lubricates the bearings and seals the clearances between the rotors and the rotor housing.

7
 4. Operating principles

4.3 Oil circulation and the compressed air circuit

Oil circulation and the compressed air circuit , parts 7 and 8 are not included in GD delivery.

4.3.1 Oil circulation

From the compressor air end the mixture of pressurized air and oil mist is ducted into the oil separating
receiver, where oil is separated from the pressurized air. The separating process has two phases.

Main part of the oil is separated in the cyclone (10) in the receiver, where the centrifugal effect is utilized.
The separated oil flows to the bottom of the receiver (11). The remainder of the oil is separated from the air
by means of oil separator (1). The oil separated in the oil separator is led back into circulation through the
oil return pipe (2). The return pipe is provided with an orifice plate (3) that prevents excess air recirculation
back into the compressor air end.

The internal pressure forces the oil back to the circulation through the oil cooler (8) and the oil filter (4).The
oil circulation is controlled by an oil thermostat valve (5). The oil thermostat valve controls the oil flow to the
oil cooler and to the oil cooler by-pass.

The forced oil circulation is maintained by the pressure difference between the receiver and the
compressor air end. To guarantee oil circulation whenever the compressor produces pressurized air, the
discharge valve (6) together with minimum pressure valve prevents the receiver pressure from dropping
below the set minimum pressure level (4bar(g)).

8
4. Operating principles

4.3.2 Compressed air circuit

The compressed air is led out through the discharge valve (6). Alternatively (option) the compressed air is
led from the discharge valve to the after-cooler (7), where its temperature drops.

The pressure relief valve (9) protects the receiver against overpressure. It opens at a certain pressure,
preventing the receiver pressure from rising dangerously high.

9
 4. Operating principles

4.4 Compressor control system



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P&I diagram

Item Description Item Description

Pressure regulator for controlling off-load

1 Intake air filter 11
pressure PS3

2 Intake valve assembly 12 Oil cooler

3 Compressor air end 13 Oil filter with bypass

4 Oil receiver 14 Strainer in oil return line

5 Oil separator 15 Orifice

6 Minimum pressure valve 16 Thermometer

7 Minimum pressure regulator PS1 17 Shut-off valve for oil drainage

Pressure regulator for throttling control

8 18 Pressure relief valve
PS2

9 Solenoid valve to control intake valve Y1 19 Oil thermostat valve

10 Blow down valve BDV 20 Pressure gauge

10
4. Operating principles

The control system adjusts compressor output in accordance with the current air consumption and
maintains uniform pressure. It also cuts the power consumption for each cubic meter of pressurized air as
low as possible.

The output control range is continuous, and ranges from zero to full output capacity. Output is adjusted by
opening and closing the intake valve. The intake valve is controlled automatically by a control valve that
measures compressor pressure and regulates it so that it remains within a set fluctuation range (normally 1
bar). The fluctuation range limits the allowed output pressure, which may vary because of changing air
consumption.

When the consumption of the pressurized air stops, the compressor unloads. In this stage the inlet valve
closes and the compressor stays pressurized. The raising of unloading pressure caused by leakages is
prevented by PS3 valve. Unloading pressure limit (8bar) is set by adjusting the PS3 valve. If the PS3 valve
adjustment is correct the internal pressure should not rise higher than 10bar(g).

When the motor is stopped, the blow-down valve depressurises the receiver.

11
 4. Operating principles

12
5. Handling instructions

5. Handling instructions

5.1 Storing the compressor

If the compressor is stored for a long period of time, the stockroom must be dry and warm. Check the
functioning of the belt tightening before starting the compressor first time after the storing.

If the compressor is stored unused for over 12 months, please contact an authorised Gardner Denver
retailer before using the equipment again.

13
 5. Handling instructions

5.2 Lifting instructions (diagram)

Lifting and transporting the compressor requires caution. Check the compressor’s centre of gravity from
Dimensional drawings.

The water separator (if available) must be removed before lifting the compressor.

Do not go under the equipment when lifting the compressor.

Lifting the compressor with forklift

Lifting the compressor with lifting wire or lines

5.3 Decommissioning

When the compressor is decommissioned, the compressor oil, the oil filter and the oil separator elements
must be disposed of in accordance with local hazardous waste regulations.

14
5. Handling instructions

5.3.1 WEEE (Waste Electrical and Electronic Equipment Directive) label

The WEEE label means the product must be disposed of separately from other waste.
Appropriate recycling of the product helps to maintain a cleaner environment. For
more information about recycling the product, please contact your local authorised
Gardner Denver retailer.

15
 5. Handling instructions

16
6. Operating instructions

6. Operating instructions

6.1 First start-up of the compressor

Temperature sensor/gauge must be installed before first start -up !

The first start-up must be performed by qualified personnel.

1. Check for sufficient oil level in the receiver. For more information, see "Adding and changing
oil" on page 22 and "Oil recommendations" on page 32.

2. Open the shut-off valve of the compressed air network.

3. Turn the power on with the main switch

4. Make sure the screw elements rotate in the correct direction before starting the compressor .

Wrong rotation direction will damage the screw unit.

Correct rotation direction must always be ensured after the power supply or motor cables have been
disconnected and reconnected. Please look from the air end the arrow indicating the correct rotation
direction.

Do not control the air flow in the compressed air network using the shutter valve. Misuse of the shutter valve
may cause a rapid deflation of the system and increases oil consumption.

6.2 Adjusting the capacity control and unloading pressure limits

The capacity adjustment that is described in the following section must only be carried out by maintenance
staff who have been authorized by Gardner Denver.

Capacity control valve PS2 closes the inlet valve at set pressure. Unloading pressure limit valve PS3 is
adjusted to prevent the pressure rising over pressure limit set by PS2.

PS2 and PS3 valve are pre-adjusted in the factory. Follow these instructions when adjusting valves in the
field. See the P&I diagram in section "Compressor control system" on page 10 to identify control parts in
the compressor.

6.2.1 PS3 valve

1. Before making any adjustments to the valves connect a separate pressure gauge to the side
of the Tempest unit.

17
 6. Operating instructions

2. Make sure the minimum pressure valve is adjusted to min 4bar(g) before making these
adjustments. See "Adjusting the minimum pressure valve" on page 21.

3. Start the compressor with solenoid valve Y363 de-energized and network shut-off valve
closed. The compressor will now run off-loaded with inlet valve closed.

4. Loosen the locking nut (B) using a 10 mm spanner.

5. Adjust the unloading pressure limit by turning the adjusting screw (A) on the PS3 control valve
using a 3 mm hexagonal key. Turning the screw (A) clockwise increases pressure and turning
it counterclockwise lowers the pressure.

6. Adjust the PS3 valve to open at 8bar(g). By disconnecting tube 10 it is possible to detect by
hand the that line is not open below 8bar(g). If the adjustment is correct the internal pressure
should not rise higher than 10bar(g).

7. If needed the pressure can be lowered by opening the safety valve cap. Caution! Hot air will be
discharged from safety valve!

6.2.2 PS2 valve

1. Before making any adjustments to the valves connect a separate pressure gauge to the side
of Tempest unit.

2. Adjust PS3 first and run the compressor to on-load before adjusting PS2 valve.

3. Keep network shut-off valve closed. Keep solenoid valve Y363 energized.

4. Open the shut-off valve so that the internal pressure stays in 5bar(g). Make sure the pressure
stays over min pressure 4bar(g) at all times.

5. Adjust PS2 so that inlet valve starts to open at 7,5bar(g).

18
7. Maintenance instructions

7. Maintenance instructions

All maintenance and repair work that is not described in this instruction manual must only be carried out by
maintenance staff who have been authorised by Gardner Denver.

Always wear protective clothing and protective gloves when performing maintenance work.

Only use original Gardner Denver spare parts. Using other spare parts could damage the compressor.

7.1 Before maintenance work

The surfaces are hot immediately after stopping the compressor.

1. Stop the compressor and ensure that there is no pressure in the pressure vessel. The
emptying function will empty the pressure vessel after the compressor has been stopped. Wait
for two minutes.

2. Switch off power using the main switch and ensure that the compressor cannot start
unintentionally.

3. Close the shut-off valve located between the compressed air network and the compressor.

4. Open the safety valve by turning it 4-5 rounds.

When the compressor is stopped and the safety valve closed, pressure will remain between the discharge
valve and the equipment shut-off valve. Release the pressure from the water outlet, for example.

7.2 After maintenance work

1. Close the safety valve.

2. Open the shut-off valve located between the compressed air network and the compressor.

3. Start the compressor.

19
 7. Maintenance instructions

7.3 Maintenance schedule

Always fill in the maintenance log.

If the operating conditions are extremely demanding, it is recommended to shorten the maintenance
intervals by half. For more information, please contact an authorised Gardner Denver dealer.

The maintenance schedule can be found on the following page.

Action 1 2 3 4 5 6 7 8 9

Check the operating temperature*** x

Check the oil level* x
Check for oil leaks x x x
Replace the oil filter x x
Check and retighten the main motor cables and contactors x x
Change the oil x
Replace the air filter x x
Replace the belts x
Clean the compressor outer surface with a cloth x x x
Replace the oil separator elements x x
Clean the oil return line and replace the filter x x
Test the safety valve x
Replace the discharge and intake valve seal assembly x
Replace the oil hoses x x
Replace the motor bearings x
Test the overheating protection** x

1) Daily 6) As needed
2) After 50 h 7) Every 3 years/5,000 h
3) Every 500 h 8) Every 5 years/10,000 h
4) Every 1,000 h 9) Every 10 years/20,000 h
5) Once a year
* Stop the compressor before checking the oil level. Wait for 10 minutes.
** The overheating protection is tested by using a heater (0-120°C ). Do not use fire.
***A standard thermostat adjusts the operating temperature to the minimum setting of 70°C However, the temperature must be 50...55 °C
higher than the ambient temperature, so that there will be no water condensation in the system.

If the operating conditions are extremely demanding, it is recommended to shorten the maintenance
intervals by half. The compressor going quick transition between unloading and discharge stages shortens
the maintenance intervals. For more information, please contact an authorised Gardner Denver dealer.

These maintenance intervals are recommended for rolling stock, for example, to correspond to a propulsion
engine´s maintenance intervals.

20
7. Maintenance instructions

7.4 Adjusting the minimum pressure valve

The minimum pressure valve maintains the internal pressure of the compressor at the set level. This
ensures sufficient oil circulation inside the compressor.

The minimum pressure can be adjusted to the desired level by connecting the machine to an empty
compressed air network and measuring the internal pressure of the CT compressor, which can then be
adjusted. The data sheet states the lowest allowable minimum pressure value (the machine´s factory
setting is at this level, 4bar(g)). It is recommended to adjust it by turning the adjusting screw to the
maximum pressure and decreasing it from there to the desired level, however without going below the
lowest allowable minimum pressure value.

Minimum pressure regulator

Valve adjustment:

1. Lift the regulating knob to adjust the valve.

2. Turn the knob clockwise to increase the minimum pressure and anti-clockwise to decrease it.

3. Press the regulating knob down to its locking position.

21
 7. Maintenance instructions

7.5 Adding and changing oil

Only use the recommended AEON oil types. Do not mix different oil types together.

The oil is hot right after the compressor has stopped.

Do not open the oil filler plug or the oil cooler drain plug when there is pressure inside the equipment.

Dispose of the used oil in accordance with the waste oil handling regulations.

7.5.1 Oil top-up

1. Please see the safety procedures under "Before maintenance work" on page 19.

2. Open the oil filler plug (1) and add new oil up to the dipstick maximum mark. Do not exceed
the maximum limit!

3. Close the oil filler plug (1).

4. Close the safety valve (2) and open the compressed air shut-off valve.

2 1

Oil top-up

22
7. Maintenance instructions

7.5.2 Oil change

1. Operate the compressor until the oil temperature reaches 40...50 °C

2. Please see the safety procedures under "Before maintenance work" on page 19 before
starting work.

3. Open the oil filler (1) and oil drain plugs (3). Drain the oil into a suitable container. Close the oil
drain plug (3).

2 1

Oil change

4. Drain the oil cooler until empty. See the cooler manufacturer’s instructions! The cooler is not
included in GD´s delivery.

5. Replace the oil filter; see "Replacing the oil filter" on page 24.

6. Add new oil up to the dipstick maximum mark. Close the oil filler plug (1).

7. Close the safety valve (2) and open the compressed air shut-off valve.

23
 7. Maintenance instructions

7.6 Replacing the oil filter

Let the compressor cool down before replacing the oil separator.

Dispose of the old oil filter in accordance with the regulations on hazardous waste.

Only use original Gardner Denver spare parts. Using other spare parts could damage the compressor.

7.6.1 Removing the oil filter

1. Please see the safety procedures under "Before maintenance work" on page 19.

2. The oil filter is attached to the screw unit. Wear protective clothing, as some oil will leak out
when the filter is being removed.

3. Remove the oil filter by turning it anti-clockwise.

Replacing the oil filter

7.6.2 Installing the oil filter

1. Lubricate the oil filter´s annular seal with pure oil.

2. Install the filter by turning it clockwise by hand.

24
7. Maintenance instructions

7.7 Replacing the air filter

The air filter cannot be cleaned or reused.

Remove the filter with caution. Make sure that particles do not get into the inlet air channel.

Use only original Gardner Denver spare parts. The use of other spare parts may compressor damage.

1. Please see the safety procedures under "Before maintenance work" on page 19.

2. Remove the air filter cover (3) and the old filters(2)

3. Clean the air filter housing (1).

4. Install the new air filters (2) and its cover (3) back to their places

1 2 3 4

Replacing the air filter

25
 7. Maintenance instructions

7.8 Replacing the oil separator element

Dispose of the old oil separator element in accordance with the regulations on hazardous waste. Let the
compressor cool down before replacing the oil separator.

Only use original Gardner Denver spare parts. Using other spare parts could damage the compressor.

7.8.1 Removing the oil separator elements

1. See the safety procedures to be carried out before replacing the element under "Before
maintenance work" on page 19. Ensure that there is no pressure in the tank. Please note!
There is remaining pressure between the discharge valve and the shut-off valve.Do not
open the lock ring located at the upper end of the valve.

2. Remove the discharge valve body and the tank lid (1) by unscrewing the bolts (7).

3. Remove the oil separator elements (2).

7
1

2
5

Removing the oil separator element

26
7. Maintenance instructions

7.8.2 Installing the oil separator elements

1. Clean the seal surfaces of the tank and the discharge valve (1). Ensure that there are no
particles inside the pressure vessel.

2. Clean orifices (3) in the hose ends.

3. Clean strainer (4) and, if necessary, the oil separator.

4. Lubricate the separator element O-rings and install new separator elements (2) by hand.

5. Replace and lubricate the O-ring (5) located between the tank and the discharge valve.

6. Tighten the bolts (7) alternately to ensure that they are evenly tightened to 300 Nm.

7
1

2
5

Installing the oil separator element

Please note! The gap between the nut (6) and the upper end of the discharge valve should be
approximately 2 mm when the tank or network is pressureless. Do not tighten the nut.

27
 7. Maintenance instructions

7.9 Replacing the belts

Only use original Gardner Denver spare parts. Using other spare parts could damage the compressor.

1. Please see the safety procedures under "Before maintenance work" on page 19.

2. Install the lifting jack (1) by turning the screw (2) and using the handle.

3. Loosen the belts (3) by pumping the lifting jack handle.

4. Replace the belts (3).

5. When the lifting jack is lowered, the motor mount plate goes down and the belts tighten.

Lift and lower the motor carefully to avoid personal injuries.

28
7. Maintenance instructions

7.10 Removing the belt pulley and the cone sleeve

1. Please see the safety procedures under "Before maintenance work" on page 19.

2. Remove the two screws from the belt pulley and insert one screw into the discharge outlet.

3. Tighten the screw evenly until the sleeve comes off the hub.

4. Remove the loose belt pulley from the shaft by hand. Handle the shaft carefully; do not hit it
with a hammer.

Removing the belt pulley and the cone sleeve

29
 7. Maintenance instructions

7.11 Attaching the belt pulley and the cone sleeve

1. Please see the safety procedures under "Before maintenance work" on page 19.

2. Remove the protective grease from the sleeve and the belt pulley hub. Attach the sleeve to the
belt pulley and align the holes.

3. Lubricate the two fastening screws (1), insert them into the holes and tighten loosely. The
threads are located on the belt pulley.

Attaching the cone sleeve Attaching the belt pulley

4. Clean the shaft and attach the belt pulley and sleeve to it. Please note that the sleeve is
attached first, after which the belt pulley can still be moved with respect to the sleeve. Take this
into account when you align the belt pulleys.

5. Tighten the screws evenly using a wrench.

6. Tap the sleeve lightly with a blunt mandrel and tighten the screws again. Repeat this a few
times to ensure that the sleeve is securely in place.

7. Check the tightness of the screws periodically.

8. Protect the vent holes against dirt by filling them, for example, with grease.

9. Carefully check the alignment of the belt pulleys.

Sleeve torque

Sleeve Torque Nm

2517 49

3020 92

3535 115

30
7. Maintenance instructions

7.12 Testing the safety valve

Any adjustment and repair work concerning the safety valve must be carried out by a professional
mechanic. Follow the local regulations.

The safety valve opening pressure must be tested in a separate compressed air network. The safety valve
has been tested at the factory before the delivery of the compressor. If the valve has been replaced, its
functionality must be checked. This can only be carried out by a professional mechanic.

The functionality of the valve can be tested by turning the valve knob (1) 1-2 rounds anti-clockwise. Always
tighten the safety valve knob properly to prevent any damage that could be caused by vibration.

Testing the safety valve

7.13 Testing the overheating protection switch

Test the overheating protection switch by shutting off the compressor´s cooling air flow on the intake or
discharge side. This will lead to a discharge temperature rise in the compressor.

The temperature alarm indicator light must light up at the set alarm temperature (default value is 105°C),
and the compressor must stop when the temperature is +115°C.

Please note! The alarms have a short delay time. The default delay is 30 seconds. The compressor will stop immediately
if the temperature rises to 115 °C.

31
 7. Maintenance instructions

7.14 Decommissioning

When the compressor is decommissioned, the compressor oil, oil filter and oil separator elements must be
disposed of in accordance with the local regulations on the handling of hazardous waste.

Decommissioning

7.15 Oil recommendations

These oil recommendations are for Gardner Denver screw compressors in mobile use.

7.15.1 Recommended lubricants

The oil tanks of the Gardner Denver compressor have been filled with AEON lubricants at the factory.
These lubricants have been developed according to the highest quality standards, and the factory has
tested and approved them for use in screw compressors. AEON lubricants are available at authorised
Gardner Denver compressor dealers.

7.15.2 Oil specifications

Recommended lubricants for the compressor:

• Gardner Denver AEON 3000 SP (mineral oil) factory first fill.

• Gardner Denver AEON 9000 SP (synthetic oil) by request.

Recommended lubricants for the compressor

Package size AEON 3000 SP* order no. AEON 9000 SP order no.

3 X 5 litres pack -

20 litres VP1149836 897 560 89

209 litres VP1149837 897 676 89

* first fill

32
7. Maintenance instructions

7.15.3 General guidelines for oil change intervals for mobile use

We recommend AEON 9000SP oil to cold conditions where the environment temperature is <-10°C or to
warm conditions where the compressors running temperature is > 90°C.

For recommended oil change intervals, please see the table below.

Recommended oil change intervals

Running temperature of AEON 9000 SP oil change

AEON 3000 SP oil change interval
the compressor interval

70–87°C 500 hours 500 hours

88–92°C 500 hours 500 hours

 93°C 300 hours 300 hours

Operating temperature of the compressor can be seen in temperature gauge. .

Specific AEON lubricants are recommended for use in this equipment. Other lubricants will cause:

• shortened life time of oil filter, oil separating cartridges and oil
• varnishing and blockage of oil circuit
• increased oil consumption
• excessive oil carryover and compressor damage

Do not mix different types of oil

Note! If wrong oil type has been used or oil circuit is varnished, please contact an authorized distributor of Gardner
Denver for oil circuit cleaning instructions.

33
 7. Maintenance instructions

34
 8. Troubleshooting instructions

8. Troubleshooting instructions

Troubleshooting table

Problem Possible cause and remedy

Find out the cause of overheating:

The thermostat or sensor is faulty.

Hot cooling air has been mixed with the

intake air.

There is not enough cooling air.

The compressor stopped
The ambient temperature is too high.
due to overheating.
The cooler has become blocked.

The oil type is incorrect or there is not

enough oil.

The oil separator has become blocked.

The oil filter is blocked.

Check the condition of the protective

THE COMPRESSOR HAS The compressor does not relays and their suitability for voltage
STOPPED AND WILL NO get power. supply. Please contact a dealer
LONGER START. authorised by Gardner Denver.

Check whether the maximum pressure

has been exceeded.

Check the supply voltage.

Check the oil level.

Check the oil separator elements,

The motor is overloaded. whose pressure must not exceed the
network pressure by more than 0.7 bar
when loaded.

Check the discharge valve; minimum

pressure 4 bar.

Check the temperature and volume of

the cooling air; clean the motor.

Check the main switch.

Electric fault.
Check the motor wires and the
tightness of the connectors.

35
 8. Troubleshooting instructions

Troubleshooting table

Problem Possible cause and remedy

The air filter is blocked. Replace the filter.

The oil separator is

Replace the oil separator.
blocked.

The intake valve is faulty. Repair or replace the valve.

The discharge valve or

Repair or replace the discharge valve or
condensation water drain
drain pipe.
pipe is faulty.
THE COMPRESSED AIR
DISCHARGE IS There are leaks in the
Find and repair the leaks.
INSUFFICIENT. compressed air system.

The safety valve is open. Close the safety valve manually.

The pressure limits have

Adjust the pressure limit settings.
been set incorrectly.

Ensure sufficient cooling air circulation.

The ambient temperature is
too high. Ensure that the intake air is taken from
the coolest possible place.

The return oil pipe is

Clean the pipe.
blocked.

The oil separator is faulty. Replace the oil separator.

The oil separator is

Replace the oil separator.
blocked.
THE OIL CONSUMPTION IS
TOO HIGH. The oil type is incorrect. See the oil recommendations.

The discharge air

Find out the reason and fix it.
temperature is too high.

The shaft seal is leaking. Replace the seal.

There is too much oil. Decrease the amount of oil.

Replace the seal.

The intake valve seal is
leaking. Check the functionality of the intake
OIL IS LEAKING FROM THE valve‚ check valve.
INTAKE VALVE AFTER
STOPPING. The emptying circuit’s
Clean or replace the valve.
check valve is faulty.

Check the oil separator. Replace the oil separator.

36
8. Troubleshooting instructions

Troubleshooting table

Problem Possible cause and remedy

The cooler is blocked. Clean the outside of the cooler.

The ambient temperature is

Check the cooling air circulation.
too high.

There is too little oil. Add oil.

The oil type is incorrect. See the oil recommendations.

THE COMPRESSOR IS
OVERHEATED. The oil filter/separator is
Replace the filter/separator.
blocked.

The thermostat is faulty. Replace the thermostat.

The discharge air

temperature sensor is Replace the thermostat.
damaged.

There is pressure in the

Wait until the vessel pressure drops.
vessel.
THE COMPRESSOR
The supply voltage is too
STARTS TOO SLOWLY. Check the supply voltage.
low.

The oil type is incorrect. See the oil recommendations.

37
 8. Troubleshooting instructions

38
9. Technical Appendixes

9. Technical Appendixes

Technical data

Dimensional drawings

39
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