Original instructions

BG00528360 en-US B.001.1 2016-03-15

PANTERA DPi Compressor and air

circuit
PANTERA DPi Compressor and air circuit

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 instructions ............................................................................... 9

3 Main components ..........................................................11

3.1 Main components ................................................................................. 11

4 Operation ....................................................................... 13
4.1 Air end technical data .......................................................................... 13
4.2 Air end main components ....................................................................13
4.3 Compressing principle .........................................................................14
4.4 Compressor oil circulation .................................................................. 14
4.5 Compressor temperature sensor ........................................................ 17
4.6 Compressor control ............................................................................. 18
4.7 Air intake valve ..................................................................................... 21
4.8 The control valve of the air intake valve .............................................22
4.9 Air receiver pressure releasing ........................................................... 23
4.10 Air receiver ............................................................................................ 24
4.11 Compressor oil filter and water separator ......................................... 26
4.12 Regeneration line ..................................................................................27

5 Periodic maintenance ................................................... 29

5.1 Pneumatic system ................................................................................ 29
5.1.1 Checking the intake air line and connections .............................. 29
5.1.2 Replacing the air filter ..................................................................30
5.1.3 Replacing the safety filter ............................................................ 31
5.1.4 Checking the condition of the air filter maintenance indicator ..... 31
5.1.5 Changing the compressor oil .......................................................32
5.1.6 Replacing the compressor oil filter .............................................. 33
5.1.7 Replacing the oil separator ..........................................................34
5.1.8 Cleaning the compressor oil receiver .......................................... 34
5.1.9 Checking the operation of the compressor oil thermostat ........... 35
5.1.10 Cleaning the radiator core ........................................................... 36
5.1.11 Checking the safety valve ........................................................... 36

6 Troubleshooting ............................................................ 37
6.1 Compressor circuit troubleshooting .................................................. 37

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6.1.1 Air pressure is low or output is insufficient .................................. 41

6.1.2 Air pressure is too high ................................................................42
6.1.3 The compressor has overheated .................................................42
6.1.4 Oil consumption too high .............................................................43
6.2 External measurements ....................................................................... 44
6.3 Manual power pack control ................................................................. 45

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1 INTRODUCTION
1.1 The Purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
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 "2 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
This document describes the components, operating principle and
troubleshooting of the pneumatic system of the DPi drilling rigs.
The pneumatic circuit instruments and warning lights are described in the
‘Control instruments’ chapter of the operator's manual.
Compressor is used to generate air pressure and flow for the certain
functions in the drilling rig.
Pressure level created by the compressor depends on function which
needs pressurized air at the current moment.
To achieve and maintain desired (requested) pressure level is controlled by
the air intake valve of the compressor.
Air intake valve in turn is controlled by hydraulic pressure reducing relieving
valve (Y605).
Reducing relieving valve (Y605) in turn is controlled electrically by control
system.

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2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1 Safety instructions
High-pressure air injection hazard. Risk of serious injury. Relieve
pressure before removing filler plugs or fittings.

Note! Hazardous moving and rotating parts. Carry out maintenance and
repair work only when the rig is not running. Make sure that the rig
cannot be accidentally started when you are carrying out the
servicing.

Note! Always follow the safety instructions and perform your work with
care.

Note! Service, adjustment, and repair procedures are to be performed only

by persons who have been given specific service training. Read the
instructions before undertaking any servicing, adjustment, or repair
work.

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3 MAIN COMPONENTS
3.1 Main components

9 1 2

7 8

1 Thermostat 2 Cooler
3 Air filter 4 Control valve
5 Intake valve 6 Compressor
7 Oil filter 8 Flushing valve
9 Air receiver

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4 OPERATION
4.1 Air end technical data
Type Enduro 25
Max. ambient temperature 40...45 °C
Thermal switch 115 °C
Output 13.5 m3/min
Max. operating pressure 10 bar
Bearings Roller bearings
Male rotor diameter 171 mm
Gear ratio 1 : 2,846

4.2 Air end main components

The main components of the air end include:

5 1 2 2 3 4

1 Housing
2 Rotors
3 Outlet cover
4 Bearing housing cover
5 Gear

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4.3 Compressing principle

Together with the housing, the two meshing rotors form the compression
chamber. The rotating rotors take air into the housing through the intake
port as the grooves of the rotors pass the intake port.
As the rotors turn, the meshing point closes the passage to the intake port
and the air is trapped in the chamber.
As rotation continues, the volume of the chamber between the two rotors
becomes smaller and the pressure increases.
When the desired and most economical operational pressure is reached,
the compressed air flows through the outlet port into the receiver.

4.4 Compressor oil circulation

Oil circulation is based on pressure difference between the air receiver
(604) and compressor (607) suction side
Oil is flowing from the bottom of the air receiver through
• thermostat (613) if oil is cold (less than 65 °C)
• thermostat (613) and cooler (606) (oil temperature between 65 °C and
80 °C)
• cooler (606) if oil is hot (higher than 80 °C)
From the oil cooler the oil flows to the oil filter (612.03). The filter has a
built-in bypass valve (612.01) that allows the oil to flow past the filter if the
filter is clogged or if the oil is too thick when it is cold. The opening pressure
of the bypass valve is 3.5 bar. The filter unit also includes a pressure
difference switch (612.02) that indicates when the filter is dirty (pressure
difference above 2.5 bar).
From the filter the oil is led into the lubricating channels at the intake side of
the screw compressor (607). At the beginning of the single-phase
compression, oil is injected onto the rotors to cool down the air and to seal
the clearances between the rotors and the housing. Oil is also led through
other channels to lubricate the bearings and the shaft gasket.
After compression, the compressed oil/air mixture is led from the screw
compressor into the spiral duct of the oil/air receiver (607), where most of
the oil is separated from the air and falls to the bottom of the receiver. The
rest of the oil that is mixed with the air is separated out when the air flows
through the oil separator elements (607.08). The oil from the bottom of the
separator chamber is forced through the pipe to the intake side of the air

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end via the pressure difference. The pipe includes the strainer (604.04) and
orifice (604.05) (on top of the oil/air receiver), which must be cleaned
regularly.
All oil is going through the filter (612) and further to the suction side of the
compressor (607)
MAIN HYDRAULIC
DIAGRAM

604
.02
.06
.04 1bar

1,6 mm
.03 .05 11.7 bar
.04 AIR .03
B605P.2
.02 RECEIVER .08
64mbar

max.
.01
.01 M 257 min.
B240T
COMPRESSOR .07
.05
607 613
3.5 bar
.01
606
.03 THERMOSTAT
80 °C

.02 B606P

612 FILTER
COOLER

Compressor oil cooler (606) is in the right end of the cooler. Left end of the
cooler is for hydraulic oil.

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Thermostat (613) in the top of the cooler.

To ensure proper oil circulation when the rig is started in cold conditions, so
called warming function is used:
• If hydraulic oil temperature is below 25 degrees of celsius, compressor
pressure is set to 4 bar for 30 seconds.
• If hydraulic oil temperature is below -5 degrees of celsius, compressor
pressure is set to 4 bar for 5 minutes.

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4.5 Compressor temperature sensor

Compressor temperature monitoring (temperature sensor (607.05, B240T))

• 105°C Compressor overheating notification
• 110°C Compressor overheating alarm (control system reduces the diesel
engine to idle and decreases the compressor pressure)
• 115°C Compressor overheating stop level (control system shuts down
the diesel engine)

The temperature sensor Pt1000 measurement range

is -45...150 °C (823...1573 Ω)
In the figure, A = normal measurement range.
Output is resistive:
• 0 °C = 1000Ω
• 20 °C = 1078Ω
• 100 °C = 1385Ω
• Linear 1°C = 3.85Ω

Replacing
• No special action needed

Compressor temperature sensor is located on the air outlet flange

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4.6 Compressor control

Compressor pressure control is made by a hydraulically operated air intake
valve (607.02) and a pressure transducer (614.02 / B605P)
Air intake valve is controlled with a pressure reducing / relieving valve
(603 / Y605).
System pressure (actual pressure) is measured with the pressure
transducer (B605P) and this pressure is compared to the pressure request
coming from the software. If actual pressure is equal or higher than request
then the intake valve is closed by valve 603 and if actual pressure is lower
than request then the intake valve is kept open by valve (603).

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B605P
FLUSHING VALVE 614.04
614

P/I
F1 F2

MF1 MF2

MW2
.05
.01
1.5mm
Y10x y MW1

.06
MW

W1 P2 T2 W2
MAIN HYDRAULIC
DIAGRAM
Y605
Pilot for air intake
23
control valve
CARRIER HYDRAULIC
1
B CIRCUIT
603
L

604
.02
.06
.04 1bar

1,6 mm
.03 .05 11.7 bar
.04 AIR .03
B605P.2
607.02 RECEIVER .08
64mbar

max.
.01
.01 M 257 min.
B240T
COMPRESSOR .07
.05
607 613

603 / Y605

607.02

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B605P.1

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4.7 Air intake valve

MAIN HYDRAULIC
DIAGRAM

.03
.04
B605P.2
607.02
64mbar

.01 M 257
B240T
COMPRESSOR
.05
607

Air intake valve (607.02)

Light spring (1) on the disk valve works as a check valve.
Intake valve is closed with hydraulic pressure (2)
• About 23 bar is needed to close the valve
• Hydraulic return line (3)

2
2

3 1 3

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4.8 The control valve of the air intake valve

Air intake valve control valve (Y605) is proportional pressure reducing /

relieving valve
• Intake valve is controlled with proportional pressure reducing / relieving
valve
• Oil pressure to control valve comes from tramming valve port X
When there is no control current valve output pressure is low and intake
valve is open.
When there is control current valve output pressure is increasing and intake
valve is starting to close.

From tramming valve port X

Y605
23

1
B
603
L 1
3
2

Pressure Return

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4.9 Air receiver pressure releasing

The receiver pressure releases through the flushing line.

• There is small air flow from drill bit all the time when flushing valve is
closed
• The receiver pressure decreases to 0.5 bar when there is no need for
pressured air
• The air flows trough the 1.5 mm orifice (614.02) installed in the flushing
line

B605P
FLUSHING VALVE 614.04
614

P/I
F1 F2

MF1 MF2

MW2
.05
.01
1.5mm
Y10x y MW1

.06
MW

W1 P2 T2 W2

CARRIER HYDRAULIC
CIRCUIT

604
.02
.06
.04 1bar

1,6 mm
.05 11.7 bar
AIR .03
RECEIVER .08

max.
.01

min.

.07

613

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4.10 Air receiver

Air receiver (604) components

• Minimum pressure valve, 1,0 bar (604.02)
• Safety relief valve, 11,7 bar (604.03)
• Oil regeneration line strainer (604.04)
• Oil regeneration line orifice Ø 1,0 mm (604.05)
• Oil regeneration line check valve (604.06)
• Check valve, oil filling line (604.07)
• Oil separating elements, filters (604.08)

604
.02 Air out
.06
.04 1bar

1,6 mm
.05 11.7 bar 604.02
AIR .03
RECEIVER .08
604.08

max.
.01

min.
604.03
.07
604.04

604.05

604.06

Air / oil from

compressor

604.07

Visual level indicator

Oil drain

Oil coler

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Drain oil from the draining block

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4.11 Compressor oil filter and water separator

Compressor oil filter (612)

• Pressure difference switch (612.02, B606P , 2,5 bar)
• By-pass valve 3,5 bar
Water separator (702)

702 612.02

612

Water separator
drain valve

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4.12 Regeneration line

Regeneration line components

• Strainer (604.04)
• Orifice Ø 1,6 mm (604.05)
• Check valve (604.06)
Oil which is coming to the "dry side" of the receiver is transferred to the
suction side of the compressor screw unit with pressure difference between
receiver and suction side.

604.04

604.05

604.06

604
.02
.06
.04 1bar

1,6 mm
.05 11.7 bar
AIR .03
RECEIVER .08

max.
.01

min.

.07

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5 PERIODIC MAINTENANCE
5.1 Pneumatic system
5.1.1 Checking the intake air line and connections
1. Check the intake air line and connections.
2. Check the condition of the suction hoses, tightness of the connections,
and tightness of the air filter housing.
3. Check the fastening of the intake valve and the tightness of the
connections.

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5.1.2 Replacing the air filter

Note! The air filter element may not be cleaned.

Note! When replacing the air filter element (1), keep the safety filter
element (2) in place.

The air filter prevents dust and other impurities from entering the
compressor and other parts of the pneumatic system. Impurities in the
intake air cause the compressor to wear rapidly. It is therefore important to
check and perform maintenance of the pneumatic system regularly and
correctly.
1. Remove the used air filter element (1).

2. Clean the air filter housing and sealing surfaces.

3. Ensure that the safety filter element (2) is properly in place.
4. Install a new air filter element (1) in place.
5. Check the condition of the intake air lines and the tightness of the
connections.

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5.1.3 Replacing the safety filter

When replacing the safety filter, make sure that no dirt can enter the inlet
duct.
1. Change the compressor's safety filter (2).

2. Check the condition of the seals and sealing surfaces.

The safety filter element must be replaced if the air filter (1) has been
removed three times.
5.1.4 Checking the condition of the air filter maintenance indicator
1. Visually check the condition and operation of the air filter maintenance
indicator.
The control system display shows a message if the filter is clogged.
2. Check the condition and mounting of the connector and the condition of
the cable.
3. Replace a faulty maintenance indicator as necessary.

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5.1.5 Changing the compressor oil

The compressor's oil-change interval depends on the oil type used and on
the operating conditions. For more information, refer to the compressor's oil
recommendation.
Before changing the oil, ensure that there is no pressure in the pneumatic
system.
1. Drain the oil from the tank into a receptacle by opening the drain valve.
2. Close the valve. Add the amount of oil specified under ‘Filling capacities’
with a hand pump.
The hydraulic oil tank (3) and the compressor oil tank (4) are filled with a
manual pump (1). The tank to be filled is chosen with a 3-way valve (2).

3 1

3. Check the sight glass on the tank to ensure that the oil level is correct.
The oil level must be between the Min and Max marks.

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5.1.6 Replacing the compressor oil filter

The control system display shows a message when the oil filter is clogged.
1. Ensure that there is no pressure in the pneumatic system.
2. Open the filter housing, and remove the old filter cartridge and seal.
3. Install the new filter cartridge and seal.
4. Close the filter housing by twisting. Ensure the tightness of the filter
housing upon the next start-up.

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5.1.7 Replacing the oil separator

1. Ensure that there is no pressure in the pneumatic system.
2. Open the tank cover and pull out the old filter cartridges. Ensure that the
cartridge O rings do not remain in place.
3. Press the O rings and filter cartridges into place and reinstall the tank
cover.

5.1.8 Cleaning the compressor oil receiver

1. Ensure that there is no pressure in the pneumatic system.
2. Empty the oil tank to the receptacle using the drain valve (1).

3. Clean, rinse, and dry the tank thoroughly.

4. Before adding oil, ensure that the tank is free of impurities.

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5.1.9 Checking the operation of the compressor oil thermostat

If the compressor oil temperature increases too much or is too low, clean
the thermostat and verify its correct operation.
1. Replace the thermostat (1) if necessary.

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5.1.10 Cleaning the radiator core

1. Turn off the engine.
2. Check that the radiator (1) has no damaged fins, corrosion, or dirt
(grease, oil, insects, leaves, etc.).

3. The radiator can be cleaned with a high-pressure washer or with

compressed air:
• When cleaning the radiator with a high-pressure washer, keep the
nozzle at a safe distance and do not use too high pressure to avoid
damaging the radiator.
• When cleaning the radiator with compressed air, do not use a
pressure of above 4 bar.
4. Check the cleanliness of the radiator core by using a flashlight to point
light through the opposite side of the core.
If you cannot see any light through the core, there is still dirt in the core
and it must be cleaned more thoroughly.
5.1.11 Checking the safety valve
1. Check the safety valve function at least once a year according to the
local regulations.

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6 TROUBLESHOOTING
6.1 Compressor circuit troubleshooting
Compressor is used to generate air pressure and flow for the certain
functions in the drilling rig.
Pressure level created by the compressor depends on function which
needs pressurized air at the current moment.
To achieve and maintain desired (requested) pressure level is controlled by
the air intake valve of the compressor.
Air intake valve in turn is controlled by hydraulic pressure reducing relieving
valve (Y605).
Reducing relieving valve (Y605) in turn is controlled electrically by control
system.

In machine view is shown com-

pressor air pressure (1) and com- 2
pressor temperature (2).

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Diagnostic view
Function of compressor circuit can be monitored on the display.

In the user interface select → Troubleshooting → Compressor.

You can see structure and functioning of compressor diagnostics.
If the signal next to the actuator is blue, it indicates active signal (actuator is
controlled or information is read).

16
10
3
4
17
5
6
7
8
11

In Compressor pressure requests (11) view can be seen those functions

which require certain pressure from the compressor when they are
activated.
In Compressor (10) view can be seen measured values and the state of
compressor.

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Pressure control = Measured control current of the air intake valve's

control valve (Y605)
• Blue arrow means that RCC module is sending signal to the con-
trol valve (Y605)
3 • 880 mA = Air intake valve is totally closed
• 450 mA = Air intake valve totally open
• Values in between 880 mA - 450 mA = Air intake valve partly
open (opening depends on current)
Temperature = Measured oil and air mix temperature, sensor
(B240T)
4
• Blue arrow means that RCC module is reading signal from the
sensor (B240T)
Air filter blocked = If grey arrow next to text turns to blue, air filter is
5 blocked (switch (B605P.2) contact normally open), or module input
Xex:22 is short circuited to supply voltage.
Oil filter blocked = If blue arrow next to text turns grey, oil filter is
6 blocked (switch (B606P) contact normally closed), or module input
XSt:24 has lost the signal (e.g. wire cut).
7 Pressure = Pressure measured in the air receiver sensor (B605P.1)
Unloading = Compressor state at the moment
Compressor states can be:
• Unloading = No pressure request from the control system
• Pressurizing = Pressure is increased to achieve the pressure re-
quest
• Pressurizing error = Requested pressure can not be reached in a
reasonable time
8 • Pressurized = Requested pressure has been achieved
• Derate = Pressure is requested and the pressure sensor has
been bypassed
• Warming = When engine is started and temperature is under cer-
tain limit, compressor is warmed to decrease the humidity in the
system
• Off = Engine is not running or air intake valve has been control-
led to be closed due to monitoring
16 Compressor pressure request in per cent from maximum
17 Compressor presuure request

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14 15

13

For example compressor pressure request for filter cleaning (13) is 7.0 bar.
Compressor pressure (14) is 7.0 bar (15).

Monitoring of the components in compressor circuit

Control valve (Y605) of the air intake valve → if electrical signal is out of
range (short circuit, wire is cut or coil of the valve is faulty) > operator is
informed with pop-up, alarm is generated to log.
Pressure sensor (B605P.1) → if electrical signal is out of range (wire is cut,
short circuit or faulty sensor), operator is informed with pop-up, alarm is
generated to log.
Temperature sensor (B240T) → if electrical signal is out of range (wire is
cut, short circuit or faulty sensor), operator is informed with pop-up, alarm is
generated to log.

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Bypass possibilities

Bypasses can be done when selecting → Troubleshooting → Bypass,

and then selects the sensor to be bypassed.
Pressure sensor (B605P.1)
• In case that pressure sensor is noticed to be broken, compressor is
controlled to be in off state.
• Bypassing the sensor air intake valve can be controlled to be partly open
when flushing is used.
• Normal drilling is not possible because pressure in the air receiver is not
known.
• Idea is to be able to get the drilling tools out of the hole and be able to
move the rig.
Temperature sensor (B240T)
• In case that temperature sensor is noticed to be broken, engine will be
shut down.
• Bypassing the sensor engine can be started. hydraulic oil and
compressor oil cooling fan control is set to max cooling.
• Normal drilling is not possible because temperature in the compressor
circuit is not known.
• Idea is to be able to get the drilling tools out of the hole and be able to
move the rig.
6.1.1 Air pressure is low or output is insufficient
1. Start the diesel engine.
2. Check the pressure under Compressor pressure (B605P.1) The
pressure should be 0.5 bar when no compressed air is used. If it is not
• The valve (603) leads the pressure behind the intake valve (607.02)
and the intake valve does not open.
• The intake valve is defective.
- The valve is stuck in the closed position
- Clogged breather hole of the connection flange
• The proportional valve (603) adjusts the pressure incorrectly or the
valve is faulty. Note: The spool of the valve can be moved
manually with 3 mm allen key.
- Check under Pressure control (Y605)
- Also check the valve coil and wiring

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6.1.2 Air pressure is too high

1. The pressure increases to the set value for the pressure-relief valve
(604.03)
• The proportional valve (603) adjusts the pressure incorrectly or the
valve is faulty. Note: The spool of the valve can be moved
manually with 3 mm allen key.
- Check under Pressure control (Y605)
- Check the log for the possible alerts regarding compressor
suction clapper coil resistance. This can be caused by cut wire,
short circuit or faulty coil.
- Also check the valve coil and wiring
• Leaking intake valve (607.02) piston seal or intake valve is faulty
(Intake valve will not close)
- If air escapes through the breather hole above the piston while
the compressor is running and the intake valve is closed, replace
the piston seals.
6.1.3 The compressor has overheated
1. There is too little oil in the compressor circuit.
• Check oil level and top up if necessary. Avoid overfilling (about 1/3 of
the height of the sight glass is sufficient).
2. Thermostat (613) is faulty. (Oil circulation through the cooler core is
partially or completely obstructed.)
• Check the operation and condition of the thermostat (613).
3. Dirty oil cooler core (606).
• Clean the core.
4. The oil filter (612.03) is clogged. (Poor oil circulation, poor cooling
efficiency)
• Replace the oil filter (612.03). Also check the condition of the intake
air filters (607.03) and the tightness of the inlet duct!
5. Output air pressure is too low. (Poor oil circulation with low receiver air
pressure)
• Check the setting pressure from the diagnostics screen, pressure
has to be 0.5 bar when there is no need for pressured air.
6. Oil viscosity is too high (oil is too thick). (Poor oil circulation, poor cooling
efficiency)
• Check the oil grade – refer to the oil recommendations.
7. Air in the oil cooler core (606). (Poor oil circulation)
• Bleed the oil cooler core and switch to a different type of oil if
foaming occurs.
8. Oil cooler fan rotates slowly and cooling efficiency is insufficient.
• On the diagnostics screen, check the log for the possible alerts
regarding the control valve Y920 coil resistance (Compressor and oil
cooling pump electrical circuit failure). This can be caused by cut
wire, short circuit or faulty coil.

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6.1.4 Oil consumption too high

1. Clogged oil return line. (Too much oil in the separator chamber of the
oil/air receiver – oil is mixing with the output air)
• Clean the orifice (604.05) (Ø 1.6 mm) on top of the oil/air receiver
(604.01), and the strainer (604.04) and the non-return valve (604.06)
located in the same line.
2. Faulty oil separator element (604.08) or O-ring.
• Check the condition of the oil separator elements (604.08) and their
O-rings (e.g. there may be holes in the oil separator element itself).
3. There is too much oil in the compressor circuit.
• Check the oil level, and decrease to the correct level.
4. Foaming oil.
• Check the oil grade – refer to the oil recommendations. Check the oil
level.

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6.2 External measurements

External measurements make possible to get desired pressure

measurements visible on the display in the cabin.
There are two connectors (Xex:23 and Xex:24) available for pressure
measurements in the I/O board connected to the FCC-module.
Performing external measurement require an extra pressure transducer,
cable, adapter and measurement hose.

In the user interface select → Troubleshooting → External

measurements.

3 4 1 2
5

Depending on the used pressure transducer (25 or 400 bars), correct

pressure value must be selected from the display by clicking the desired
value: 25 bar (1) or 400 bar (2). The selected pressure value is shown on
the dispaly (3). Default value is 400 bar.
Measured values are ahown on the display (4) and (5). Signal (6), shown
on the display, represents the measured values at it can be select to be
visible/invisible by clicking the measured values (5). Signal is always in 400
bar scale regardless of the selected pressure transducer.

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6.3 Manual power pack control

1. Select → Support Functions → Manual powerpack control → On.
Confirmation pop-up appears on the display.

2. Select OK to start the manual power pack control.

Following adjustments can be done when the manual power pack control is
started:
• Engine speed with water injection adjustment knob
• Percussion pump with rotation speed adjustment knob
• Rotation pump with drilling power adjustmetn knob
• Compressor pressure with feed pressure adjustment knob
By changing temporarily the following parameters, safety pressure relief
valve in the air receiver can be tested.

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Note! Restore original parameter values after testing.

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 Original instructions
BG00418026 en-US B.001.1 2017-02-03

DPi Shank lubrication system

DPi Shank lubrication system

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 Main components ..........................................................11

3.1 Main components ................................................................................. 11
3.2 SLU components .................................................................................. 12
3.3 Technical data ....................................................................................... 12

4 Operation ....................................................................... 15
4.1 Operation diagram of the shank lubrication oil pump ...................... 15
4.2 Heating circulation function ................................................................ 16

5 Periodic maintenance ................................................... 19

5.1 SLU Shank lubrication unit ..................................................................19
5.1.1 Draining condensation water from the oil tank ............................ 19
5.1.2 Changing the oil receiver breather .............................................. 19
5.1.3 Cleaning the oil receiver ..............................................................20
5.1.4 Emptying the shank lubrication return tank ................................. 20
5.1.5 Checking the operation of the monitoring unit .............................21

6 Repair instructions ....................................................... 23

6.1 Monitoring unit ......................................................................................23
6.2 Bleeding the shank lubrication oil line ............................................... 23
6.3 Bleeding the shank lubrication oil pump ........................................... 24
6.4 Replacing seals .....................................................................................25

7 Troubleshooting ............................................................ 27
7.1 Shank lubrication troubleshooting table ............................................27

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1 INTRODUCTION
1.1 The Purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
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 "2 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.

Operating, service and adjustment procedures must be carried out

only by personnel with specialized operation and service training.
Read and ensure that you understand the operating, maintenance,
and safety instructions before using or servicing the rig.

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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3 MAIN COMPONENTS
3.1 Main components

3 2

1 Sight glass 2 Level sensor

3 The breather 4 Filler opening
5 Tank 6 Pump
7 Air valve

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3.2 SLU components

1 2 3

1 Oil tank
2 Level switch
3 Breather / filler cap
4 Pump unit
5 Sight glass

The tank is equipped with level switches that no-

tify the control system if the oil level in the tank
drops to a level that causes an alarm. The con-
trol system issues a notification.

3.3 Technical data

The oil tank
Total amount of oil (l) 30
Breather (µm) 10
Oil strain (mm) 1
Level switch Yes

Pump unit
Stroke volume at pump 55174643 0.85 cm³
Stroke volume on pump 55174640 2.0 cm³
Output range at pump 55174643 80–1200 g/h
Output range on pump 55174640 188–2800 g/h

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Pump unit
Max. operating pressure 210 bar
Min. operating pressure 25 bar
Max. lubrication oil pressure 25 bar

Tightening torques Nm
Control switch 7
Pump unit fastening screws 20

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4 OPERATION
4.1 Operation diagram of the shank lubrication oil pump

CT1 Control switch CT2 Suction side non-return valve

CT3 Operating piston CT4 Hydraulics bleeding screw
CT5. Directional valve CT6. Non-return valve
1 1
CT7 Bleeding screw CT8 Heating circuit

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

lubricant dosage is determined electrically by changing the operating
frequency of the pump.
The main block has its own lubrication control switch CT1. The control is
always operational when the operating voltage is switched on.
The directional valve (CT5.1) guides the hydraulic oil pressure to the piston
side and the piston rod side alternately. When valve (CT5.1) receives the
control voltage, it prevents the pressure from entering at the piston side,
whereupon the pressure on the piston rod side forces the oil on the piston
side into the tank line. At the same time, the lubrication oil is sucked from
the tank through port S into the operating piston chamber. When the control

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voltage is cut off from the valve (CT5.1), the higher pressure is directed to
the piston side, and the oil on the piston rod side re-enters circulation. The
lubrication oil is pumped to the rock drill through port L.

4.2 Heating circulation function

Pump performance 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 ON/OFF valve (CT5) controlling the pump and pump intake
valve (CT2).
The heating circulation function is based on circulating the hydraulic oil
driving the pump through the pump. The oil circulates through an 0.6-mm
orifice (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.

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Heating circulation components

3
1

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

Enabling/disabling the heating circulation function

Enabling the heating circulation Disabling the heating circulation
1.Unscrew the cap (5).
2.Loosen the locking nut (1) but do not re- 1.Unscrew the cap (5).
move the nut. 2.Loosen the locking nut (1) but do not re-
3.Tighten the plug screw to ensure correct po- move the nut.
sition of the adjustment. 3.Screw the plug screw (3) in place.
4.Turn the plug screw (3) 2.5 turns counter- 4.Tighten the locking nut (1).
clockwise.
5.Reinstall the cap (5).
5.Tighten the locking nut (1).
6.Reinstall the cap (5).

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5 PERIODIC MAINTENANCE
5.1 SLU Shank lubrication unit
5.1.1 Draining condensation water from the oil tank
1. Drain the condensation water from the oil tank to the receptacle using the
drain hose.

5.1.2 Changing the oil receiver breather

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

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5.1.3 Cleaning the oil receiver

1. Empty the oil tank into the receptacle. Remove the receiver cover (1) and
clean the receiver from the inside. Replace the cover seal if necessary.

5.1.4 Emptying the shank lubrication return tank

1. Empty the shank lubrication return tank into the receptacle.

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5.1.5 Checking the operation of the monitoring unit

1. Disconnect the directional valve (CT5) plug: the alarm must activate after
four operational cycles.
2. Disconnect the flow monitoring cable from the monitoring unit (CT1): the
alarm must activate after four operational cycles.
3. Short-circuit the flow monitoring cable to the pump body: the alarm must
activate after four operational cycles.

CT5

CT1

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6 REPAIR INSTRUCTIONS
6.1 Monitoring unit
The shut-off ball of the lubrication pump output port non-return valve
operates as a control switch (CT1) against the valve seat. The oil flow
through the non-return valve removes the ball from the seat surface and
shuts off the circuit. The control switch non-return valve 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.
Note! If the ball remains against the seat or remains open for four
operational cycles, an alarm is switched on and drilling functions
stop.

6.2 Bleeding the shank lubrication oil line

CT4 CT7

1. Turn off the engine.

2. Open the bleeding screw (CT7) 1–2 revolutions.
3. Close the bleeding screw (CT7) when the oil bleeding out no longer
contains air bubbles.

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6.3 Bleeding the shank lubrication oil pump

CT4 CT7

1. Disconnect the hose from port L.

2. Connect a separate hose to port L and place the other end of the hose in
a receptacle.
3. Start the diesel engine.
4. Open the bleeding screw (CT7) half a turn and the bleeding screw (CT4)
one turn.
Leave the screws open for about one minute.
5. Close the bleeding screw (CT7).
6. Close the bleeding screw (CT4) when the oil bleeding out no longer
contains air bubbles.
7. Turn off the engine.
8. Disconnect the bleeding hose from port L and reconnect the original
hose.
9. Start the diesel engine.
10. Start the forced shank lubrication from the display by selecting →
Support Functions and changing the Shank lubrication booster field
state from Off to On.
Leave the forced operation on for about 10 minutes.
11. Ensure that the rock drill receives shank lubrication oil.
12. Stop the forced shank lubrication from the display by selecting →
Support Functions and changing the Shank lubrication booster field
state from On to Off.

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6.4 Replacing seals

2 3 1

1 Pump unit
2 Plug
3 Piston
4 Piston seals

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1. Remove the old seals from the piston grooves.

A B C D E F G H A

B D E

2. Clean the grooves.

3. Install the guide sleeve C on to piston E as shown in the picture.
4. Lubricate the o-ring D and slide it over the guide sleeve into the groove in
the piston.
5. Lubricate the piston seal B and slide it over the guide sleeve into the
groove on top of the o-ring D.
Use the mounting sleeve A if needed.
6. Repeat the procedure with the o-ring F and the piston seal H using
corresponding tools (G and A).
7. Press the seals lightly with oily fingers to better fit them into the grooves.
8. Calibrate the seals from both ends of the piston (B, D, F and H) using
mounting sleeve A.
Calibration is performed by sliding the mounting sleeve carefully over the
piston and the piston seal, and then carefully rotating the sleeve so that
the seal is set to its groove evenly.
9. Install the piston back into the pump unit.

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7 TROUBLESHOOTING
7.1 Shank lubrication troubleshooting table
No oil flow, error message displayed
Possible cause Solution
Oil tank level too low Add oil and bleed the pump using the bleeding screw.
Pump intake opening clogged Check and clean the tank.
Inner tube clogged Remove and clean the inner tube, or replace it.
Viscosity too high Choose suitable oil type.
No pump operating pressure Fault in the hydraulic system.
Pump solenoid valve broken Check the valve / replace the valve.
Solenoid valve wire broken Check and replace the wire.
Shank lubrication pressure hose dam-
Replace or repair the hose.
aged

Oil flow too low

Possible cause Solution
Air in the pump Check the oil tank level and bleed the pump.
Foreign object in the suction side non-
Clean the non-return valve ball.
return valve
Foreign object in the control plug non-
Clean the control plug / tank.
return valve
Filler cap clogged (formation of under-
Clean the breather.
pressure)
Return hose to oil collecting tank clog-
Remove the blockage.
ged

Oil flow too high

Possible cause Solution
Hydraulics bleeding screw open Fasten the screw.
Piston seals broken Check the piston and change the seals.
Boost function activated Check and turn off the boost function.

Internal air leak in the pump

Possible cause Solution
Hydraulics bleeding screw open Fasten the screw.
Piston seals broken Check the piston and change the seals.

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Oil flow normal but control alarm on

Possible cause Solution
Control plug wire broken Check and replace the wire.
Oil dirty and conductive Change oil in the shank lubrication tank.
Flow control rig worn (ball surface cor-
Check/replace flow-switch assembly.
roded)

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