DD211L TECHNICAL

LEARNER GUIDE
 Learning material compiled by
Sandvik Academy
Version date : 5 November 2015
Version number: 1
Document number: SAND_TECH_DD211L_1.1.1

Copyright
The drawings, information and graphics contained in this document are and shall always remain the property
of Sandvik, and shell not be made public or used directly or indirectly in any way detrimental to our interests.
No person shall amend or alter the contents or format of this document in any way without written permission
from Sandvik. However, where permission is granted, Sandvik will not take responsibility for the accuracy of
any text, graphics or parts thereof extracted or cut from this document and inserted into any other form or
source.

Disclaimer
Sandvik expressly disclaim all and any liability to any person, whether a purchaser of this document or not, in
respect of anything and or the consequences of anything done or omitted to be done by any such person in
reliance, whether whole or partial upon the whole or any part of the contents of this document.
TABLE OF CONTENT
Module 1: GENERAL SAFETY INSTRUCTIONS ............................................................................................ 1
1. Preface ................................................................................................................................................................................................ 1
2. Modifications to equipment ..................................................................................................................................................... 1
3. Labels and warnings .................................................................................................................................................................... 2
4. Employer’s / principal’s responsibilities .............................................................................................................................. 3
5. Operator’s suitabilities ................................................................................................................................................................ 4
6. Operator’s responsibilities ......................................................................................................................................................... 4
7. Safety at work .................................................................................................................................................................................. 5
8. Drilling site surroundings ........................................................................................................................................................... 6
9. Electric power lines ...................................................................................................................................................................... 7
10. Ventilation and dust prevention .......................................................................................................................................... 8
11. Before use ...................................................................................................................................................................................... 9
12. Starting/stopping .......................................................................................................................................................................... 10
13. End of work shift .......................................................................................................................................................................... 12
14. Proper use ...................................................................................................................................................................................... 12
15. Replacements instructions ................................................................................................................................................... 12
16. Load lifting ...................................................................................................................................................................................... 14
17. Maintenance and service instructions ........................................................................................................................... 15
18. Consideration for the environment when servicing the equipment .............................................................. 20
19. Consideration for the environment when using the equipment ....................................................................... 21
Module 2: LUBRICATION AND COOLANT RECOMMENDATIONS .......................................................... 23
1. General ............................................................................................................................................................................................... 23
2. Oil viscosity ........................................................................................................................................................................................ 24
3. Tramming & drilling hydraulic system ................................................................................................................................... 24
4. Engine oils .......................................................................................................................................................................................... 25
5. Hydraulic oils .................................................................................................................................................................................... 26
6. Recommendations & quantities ............................................................................................................................................. 27
7. Shank lubrication of rock drill ................................................................................................................................................... 28
8. Diesel engine ................................................................................................................................................................................... 30
9. Deutz ..................................................................................................................................................................................................... 31
10. Recommendations & quantities ......................................................................................................................................... 31
11. Compressor ................................................................................................................................................................................... 32
12. Transmission and driveline oils ............................................................................................................................................ 34
13. Thread grease for drill rods ................................................................................................................................................... 35
14. Lubrication greases ................................................................................................................................................................. 35
15. Engine coolant ............................................................................................................................................................................. 36
16. Shell/ESSO lubricants table .................................................................................................................................................. 36
17. Sample extraction ...................................................................................................................................................................... 37
18. The diagnostic process ............................................................................................................................................................ 38
Module 3: ROCK DRILL HLX5 .......................................................................................................................... 41
1. Operation and maintenance .................................................................................................................................................... 41
2. Periodic maintenance .................................................................................................................................................................. 48
Module 4: CYLINDER FEED T5 500/TFX 500 .............................................................................................. 53
1. General ................................................................................................................................................................................................ 53
2. Safety ................................................................................................................................................................................................... 53
3. Technical data ................................................................................................................................................................................. 54
4. Lifting points ..................................................................................................................................................................................... 54
5. Main components ......................................................................................................................................................................... 54
6. Operating principle ........................................................................................................................................................................ 55
7. Beam and carriage slide ............................................................................................................................................................. 55
8. Hose reel ............................................................................................................................................................................................ 57
9. Hose support ................................................................................................................................................................................... 58
10. Adjusting hose tension ........................................................................................................................................................... 59
11. Adjusting wire tension ............................................................................................................................................................. 60
12. Impulse cylinders ........................................................................................................................................................................ 61
13. Front and intermediate centralizers .................................................................................................................................. 62
14. Return wheel .................................................................................................................................................................................. 63
15. Adjusting the side pieces ...................................................................................................................................................... 63
16. Periodic maintenance .............................................................................................................................................................. 64
MODULE 5: BOOM ............................................................................................................................................. 71
1. Description ....................................................................................................................................................................................... 71
2. Check welding condition using crack detector products ........................................................................................ 72
3. Control/adjustment of clearance between armature and extension tube ..................................................... 73
MODULE 6: DRILLING ....................................................................................................................................... 75
1. Safety .................................................................................................................................................................................................... 75
2. Controls of the THC 561 Drilling system ............................................................................................................................ 76
3. Hydraulic diagram ........................................................................................................................................................................ 79
4. Hydraulic components ............................................................................................................................................................... 84
5. Operation of the system ............................................................................................................................................................ 91
6. Special functions ............................................................................................................................................................................ 123
7. Adjustments of hydraulic components ............................................................................................................................. 129
8. Troubleshooting ............................................................................................................................................................................... 148
MODULE 7: TRAMMING .................................................................................................................................. 163
1. Main components ............................................................................................................................................................................ 163
2. Tightening torques ......................................................................................................................................................................... 167
3. Lubrication ......................................................................................................................................................................................... 168
4. Operating methods ...................................................................................................................................................................... 169
5. Periodic maintenance operations ........................................................................................................................................ 177
6. Periodic maintenance table ...................................................................................................................................................... 178
MODULE 8: EMR 2 .............................................................................................................................................. 179
1. Important notes ............................................................................................................................................................................. 179
2. System description ....................................................................................................................................................................... 180
3. System functions ............................................................................................................................................................................. 183
4. Interfaces ........................................................................................................................................................................................... 194
5. Configuration and parameter setting ................................................................................................................................ 194
6. Diagnostic button and fault indicator lamp ...................................................................................................................... 197
MODULE 9: AIR CIRCUIT .................................................................................................................................. 209
1. Explanation plan ............................................................................................................................................................................ 209
2. Air supply ........................................................................................................................................................................................... 210
3. Lubricated air circuit .................................................................................................................................................................... 211
MODULE 10: WATER CIRCUIT ....................................................................................................................... 213
1. Explanation diagram ..................................................................................................................................................................... 213
2. Repair diagnostics ........................................................................................................................................................................ 215
3. Check operations on main components ......................................................................................................................... 216
MODULE 11: ELECTRIC SYSTEM ................................................................................................................... 219
1. General ................................................................................................................................................................................................. 219
2. Main components of the MSE system ............................................................................................................................. 220
3. Operation ............................................................................................................................................................................................. 227
4. Maintenance ..................................................................................................................................................................................... 229
5. Troubleshooting ................................................................................................................................................................................ 229
MODULE 1 - GENERAL SAFETY INSTRUCTIONS
1. PREFACE

The purpose of these safety instructions is :

• To promote safe, proper, and economical use of SANDVIK equipment.
• To help the user to notice, avoid, and prevent dangerous situations.
• To minimize repair costs and downtime.
• To increase the reliability and life of the equipment.

These safety instructions must be complemented with instructions given in local laws and regulations, and
with orders given by local authorities. The manufacturer provides a complete set of operator’s and service
manuals with the equipment. The operator’s manual must always be at hand where the equipment is used.
The manufacturer or their representative can also issue additional check-up and service instructions.

Every user of the equipment must read these general safety instructions and the operator’s manuals in order
to apply the information therein when, for instance:
• Using the equipment, preparing for work, troubleshooting, cleaning, handling raw materials and
other materials.
• Servicing, checking and repairing the equipment.
• Transporting the equipment.

Proper use, and following of operator’s and maintenance instructions, check-up and maintenance regulations
is very important for the safe use of the equipment. Using the equipment for other purposes than those it is
designed for, or exceeding the specified performance of the equipment, is not considered proper use. The
manufacturer or the supplier is not liable for damage caused by improper use.

Making any structural alterations on the equipment is strictly forbidden without a written permission from the
manufacturer. The manufacturer or the supplier is not liable for damage caused by the use of equipment on
which unauthorized structural alterations have been made.

2. MODIFICATIONS TO EQUIPMENT

Sandvik equipment is designed to be safe to operate and to comply with international and local standards
and legislation. Do not do anything that may hamper safety features on equipment.

It is strictly forbidden to make ANY modification to a Sandvik product without prior written approval of the
factory. If ANY modifications are made without written approval, Sandvik cannot be held responsible for any
accidents, incidents, or damage to persons or property that are related to use of the equipment after said
modifications, especially if modifications are made on any safety feature including, but not limited to, safety-
critical circuits or components.

In many cases, the affect of a modification to a machine’s total performance is unknown and there is a risk of
injury. Therefore, if a machine is modified for any reason, even if safety is not affected, Sandvik warranty shall
be void.

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3. LABELS AND WARNING INSTRUCTIONS

These instructions describe the manner in which SANDVIK Drills presents warnings in instructions. The
designing of warning texts aim at unifying the contents of the texts in different groups of equipment.

3.1 WARNING LABELS ON THE EQUIPMENT

All the warning labels on the device will be presented in the instructions chapter dealing with the warning
labels.

For instance :
Immediate danger related to a feature of the device, causing serious injury or death if the proper
safety precautions are not taken.

3.2 WARNING OF INJURY RISKS

A dangerous or unsafe manner of operation that may cause serious injury, health risks or death if the proper
safety precautions are not taken.

DANGER
For instance:
Dangerous boom movement. The boom movement can cause serious injury. Do not enter the
danger zone of the machine during drilling or tramming.

3.3 WARNING OF DAMAGE TO EQUIPMENT OR PROPERTY

These warnings are designed to instruct the operator how to use the equipment so that material damage can
be avoided.

NOTICE
For instance:
Risk of damage. Welding current can damage electric devices and circuit boards.
Disconnect the battery terminals and circuit boards before welding the equipment.

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3.4 WARNING “READ THE OPERATOR’S OR MAINTENANCE INSTRUCTIONS”

These instructions are used when it is forbidden to operate the equipment before receiving proper training or
reading the information in the manuals
WARNING
For instance :
Do not use the equipment unless you have been given proper training.
Read the operating instructions before using the equipment. The operator must know the
operating, maintenance, and safety instructions of the equipment, as well as the local safety
instructions of the mine, before using the equipment.

4. EMPLOYER’S / PRINCIPAL’S RESPONSIBILITIES

4.1 WORKING ENVIRONMENT

These instructions must be complemented as required by local laws and other regulations, and by requirements
issued by authorities, in order to prevent personal safety hazards and damage to property.
• Special attention must be paid to keep the equipment,machineries lifting devices, auxiliary
equipment, tools, safety devices, passages, and mining sites in proper condition.

4.2 MAINTENANCE

• To keep the equipment in safe working condition, original spare parts must be used when parts are
replaced in conjunction with service and repairs.
• Any alterations made on the equipment must be accepted by the manufacturer in writing.

4.3 PERSONNEL

• The operators must pass a medical examination when being employed, and we recommend that
regular medicals be conducted to all operators.
• The employer’s safety requirements include that one person in each working site is appointed
responsible formatters of safety. The employees must know who this person is, and they must know
the safety regulations of the working site.
• The employees must cooperate with the appointed safety person and follow the instructions he gives.
• Use and repair of the equipment is only allowed to persons trained for these tasks.
• Only authorized persons are allowed to operate the equipment.
• The employer / principal should clearly define the operator’s responsibilities and authorize him to not
obey instructions that contradict the safety regulations.
• New employees or persons in training are allowed to operate, service, or repair the equipment only
under the direct supervision of an experienced employee.
• The operators must be acquainted with the instruction manuals issued by the manufacturer.
• In addition, the operators must have a legal permits, if such are required.
• The principal must unambiguously define the qualifications required for operating, adjusting, servicing,
and repair work.
• Work on the electric equipment is only allowed to qualified electricians, or persons trained for the
tasks and working under the supervision and controlled by a qualified electrician as stated in electric
safety regulations.
• Work on the hydraulic equipment is only allowed to trained and experienced hydraulic equipment
mechanics.
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4.4 DISTRIBUTION OF RESPONSIBILITIES

The distribution of responsibilities must be agreed upon in writing.

• Organization
• Subcontractors
• Temporary employees
• Others
Any agreements, in which the manufacturer and the dealer restrict the right of a third party to compensation in
case of personal injury or material damage, are not valid. With all the concerned parties involved, agreements
can, however, be made on the distribution of and restrictions to responsibilities.

5. OPERATOR’S SUITABILITIES

5.1 SUITABILITY FOR THE WORK

• Physical suitability means that the person is able to act correctly and quickly to avoid accidents.
• Mental suitability means that the person is able to understand and apply the instructions and
regulations, to work safely and concentrate on the work, and to withstand mental stress and thus
avoid errors.

5.2 TRAINING AND EXPERIENCE

The operator must be given user and service training. He must acquaint himself with the instruction manuals
issued by the manufacturer, and know the specified performance and properties of the equipment he is using.

6. OPERATOR’S RESPONSIBILITIES

Accidents at work often happen in unpredictable situations. Therefore, it is important to try to consider all
possible, even unlikely, situations that may occur in each phase of work.
• The operator must always bear safety in mind, and he must know the safety
regulations of the work site.
• The operator must be trustworthy and reliable.
• In addition, the operator is required willingness to observe instructions.
• The operator must always wear the safety devices, such as helmet, earmuffs,
eye protection, protective overalls, safety boots, gloves and other safety devices
required in the work or as stated in the regulations.
• All safety regulations must be observed.
• Always follow user and service instructions.
• Do not use any equipment, unless you are fully acquainted with its operation.
• The user must always know the operation of the equipment and all its controls.
• Safety systems are not to be bypassed or removed to make work easier. The
equipment must never be started or operated, if any safety devices or protective guards are removed.
• The user must always know the operation of the equipment and all its controls.
• Before starting or operating the equipment, the operator must make sure that it causes no risk of
personal or material damage.
• The equipment is not to be used for any other purpose than what it is designed for.
• The specified performance of the equipment must not be exceeded.
• It is forbidden to use the equipment when ill, or under the influence of alcohol or drugs.

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7. SAFETY AT WORK

7.1 BEFORE STARTING TO WORK

Acquaint yourself with the manuals issued by the manufacturer, and follow the instructions in them. Plan your
work in advance to avoid accidents, mistakes, and injuries.

If an accident takes place, or a fire breaks out, act quickly and use the available equipment. Learn how to use
first aid supply and fire extinguishers. Make always sure that you know where you can get help. Keep safety
device in good condition.

Work clothing should not be too loose. Loose jacket and sleeves, long hair, rings, bracelets, etc. can get caught
in rotating machine parts. Wipe off mud and grease from your shoes before getting on the rig and starting to
work. Always wear personal protective devices, such as helmet, eye protection, earmuffs, protective overalls,
and safety boots. Observe the safety instructions.

Before starting to work, check the equipment carefully for signs of wear or leakage, and check all functions.
When taking over from the previous shift, ask about the working conditions and the function of the equipment.

Before moving the rig, make sure that you know the height,width, length, and weight limits of the site, and that
the rig does not exceed these limits. You should know the site well before starting to work. The positions of
possible gas, water, and sewer lines, and overhead and underground electric lines, and other obstacles and
hazards on the site must be known. Any such points must be clearly marked by the responsible person in
order to avoid accidents.

Make sure that there is enough space for all movements. Cave-ins are dangerous when drilling. Observe the
condition of the rock, and use necessary supporting to prevent cave-ins.

Keep the equipment clean, especially all controls, windows, glasses, lights, etc. Remove possible oil and
grease stains, and ice. Wash the equipment regularly.

Keep the tools and other accessories in the tool box.

Simultaneous charging and drilling is strictly forbidden.

7.2 OILS, GREASES, AND FUELS

• Always use only the type of lubricants recommended by the manufacturer. Neglecting these
recommendations can lead to breakage or malfunction of the equipment, which can cause serious
personal or material damage.
• Check regularly that fuel, lubricant, coolant, and hydraulic fluid levels are correct.
• Do not mix different types of fluids and oils.
• Remember that all bearings are not alike. Each bearing has its specific properties and lubricant
requirements. Follow the manufacturer’s instructions.
• Starter fluid and other flammable materials must not be stored in the cabin.
• Flammable materials must be protected against heat, sparks, and open flames.
• Storage containers of flammable materials must not be punctured or destroyed by burning, they may
cause risk of explosion.
• Smoking is strictly forbidden when filling up the fuel tank.

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7.3 ELECTRIC EQUIPMENT

• To prevent personal injuries and material damage in conjunction with the use of electric equipment,
there are many regulations concerning the structure, installation, and use of electric equipment. The
regulations are always based on local laws and electric safety requirements - these must be strictly
observed.
• Work on electric equipment is only allowed to qualified electrician.
• Do not use other than original spare parts.
• Electric conductors should always be considered live, and thus dangerous. Damaged electric wires
and cables can start a fire or cause serious personal accidents.
• Current must always be cut off from the components to be checked, serviced, or repaired.
• If a component must be live when worked on, a fellow worker must stand by to immediately cut off
electricity at the emergency or main switch in case of emergency.
• If a fault is detected in the electric equipment, such as open main switchgear door, cable damage,
broken component, etc., current to the equipment must be cut off. The equipment must not be used
before the fault has been repaired, and the necessary measurements, tests, and trial runs have been
completed.
• Power must not be switched on until you have made sure that it will not cause any danger.

8. DRILLING SITE SURROUNDINGS

DANGER
NO UNAUTHORIZED PERSONNEL SHOULD BE ALLOWED NEAR
THE DRILLING SITE DURING DRILLING.

• Nobody should be allowed within the boom’s operating range.

• Explain the meaning of the rig’s warning signs and lights to everybody working on the site.
• The working area must be kept clear of drilling debris, hand tools, and other objects. All equipment,
such as straps, chains, hoses, etc. must be checked regularly for signs of wear, looseness, breakage,
or chafing, and any damaged equipment must be replaced immediately.
• The surroundings of the drilling rig must be kept clear of obstacles so that there is always free access to
the emergency stop buttons. Everybody working at the site must know the locations of the emergency
stop buttons.
• Under certain circumstances, work at the desired site can be dangerous. For instance, if the ground is
sloping, it may be necessary to level the site to avoid danger.
• If work is to be done near underground gas, telephone, oil, electric power, sewer, or water lines, the
owner of the network must be consulted before starting the work.
• In cooperation with the representatives of the owner you can determine what safety precautions are
necessary to avoid danger. The operator and the representatives are responsible for carrying out the
required safety precautions.
• The working environment should be arranged to promote safety, with regard to the methods, work, and
equipment involved, as well as the blasting techniques, opening of mine and preparatory work, loading
and transportation, crushing and lifting methods, supporting and reinforcing, possible construction
work, electric, water, and air systems, ventilation, occupational and fire safety, and other possible
measures promoting safety.
• The local environmental regulations must be observed.

6
9. ELECTRIC POWER LINES

To prevent the danger of injuries and material damage, the structure, installation, and use of electric equipment
involves a number of regulations. You should always make sure that you follow the current safety regulations
when working near electric power lines.

Electric current always flows to the ground when a suitable conductor is provided.
• Contact the local electricity board if you are going to drill near overhead power lines. Ask the electricity
board to have their experts on the site, if necessary.
• REMEMBER! ELECTRIC CURRENT DOES NOT ALWAYS NEED DIRECT CONTACT, WITH HIGH
VOLTAGES IT CAN “JUMP” OVER LONG GAPS, with high voltages up to 5 meters.
• ALWAYS KEEP A SAFE DISTANCE TO THE POWER LINES ! Refer to the local electric safety regulations
for safe working distances.
• If it is impossible to follow the safety regulations, the owner of the power lines should always be
contacted beforehand.
• The safety devices can become electrically charged if you are working near a high-frequency transmitter.
• Safety can be improved by earthing the drilling rig. Earthing is done with a thick copper cable connected
from the mast top to an earthing rod in the ground. THIS DOES NOT, HOWEVER, OFFER COMPLETE
PROTECTION!

9.1 CONTACT WITH ELECTRIC POWER LINE

If the rig touches an electric power line, the following instructions may prevent injuries or death:
• If you are standing outside the rig, do not touch any part of the rig or try to get onto the rig. Keep
everybody away from the rig.
• If you are on the rig, do not try to get off it (the rig is insulating by the tyres). Leave the rig as soon as the
tyres start smoking. JUMP OUT ! Do not make yourself a conductor for the electric current to flow from
the rig to the ground. Move away from the rig by jumping, or by leaping so that only one foot at a time
touches the ground. The electric field in the ground can cause a dangerously high voltage between
your legs. You will not be in safety until you are about 20 meters away from the rig.
• If the boom, or some other component of the rig touches an electric power line, the whole rig becomes
live. Although the insulating rubber tyres may make the situation seem safe (not concerning track
models), a person standing on the ground and touching the rig can get a fatal electric shock.
• Call for help without delay.

9.2 IF PERSONAL INJURIES OCCUR

• If you come to a place where an electric accident has taken place, do not risk your own life by acting
incautiously!
• Try to find out whether a high or a low voltage is involved.
• Where high voltage is involved, do not start any rescuing attempts until the power company has cut
off the voltage. It can be dangerous even to approach a person in contact with the electric conductor,
or with the rig that touches the conductor. Remember that high voltage power lines have no fuses that
blow, the conductors are always dangerous, until a qualified electrician has made them dead.
• If a person is in contact with a low voltage line or with a rig that is touching a low voltage line, rescuing
can be attempted by using a dry and clean rope, or a dry and unpainted piece of wood. Anyone who
is attempting the rescue must keep as far away from the victim as possible. The victim must not be
touched until he is completely disconnected from the live components.
• If the victim is unconscious, resuscitation and artificial respiration must be started immediately.
7
10. VENTILATION AND DUST PREVENTION

In mining and other quarrying work, ventilation and dust prevention are an important part of the technique.
Mining regulations and safety requirements demand careful ventilation plans and air quality monitoring.
Adequate ventilation must always be provided. Exhaust fumes can be lethal. If the engine has to be started in
an enclosed space, make sure that ventilation is sufficient.

One of the purposes of ventilation is prevention of dust accumulation. Any or several of the following methods
can be used:
• Prevention
Correctly applied working methods
Correct equipment
• Extraction
Cleaning Filtrating
• Binding
Water spray or vapour, foam
Water flushing
Chemical treatment of settled dust
• Isolation
Enclosing Local extraction ducts
• Attenuation
Local auxiliary ventilation General ventilation If the rig is equipped with a dust separator, make sure that it is
working properly.

10.1 DUST PREVENTION

DANGER
BREATHING OR INHALING DUST PARTICLES WILL CAUSE DEATH
OR SEVERE INJURY.

Always work with a respirator approved by the respirator manufacturer for the job you are doing. It is
essential that the respirator that you use protects you from the tiny dust particles which cause silicosis
and which may cause other serious lung diseases. You should not use the equipment until you are sure your
respirator is working properly. This means the respirator must be checked to make sure that it is clean, that
its filter has been changed, and to otherwise make sure the respirator will protect you in the way it is meant
to.

Make sure the dust suppression system in your equipment is working properly. If the dust suppression
system is not working properly, stop working immediately.

Always make sure dust has been cleaned off your boots and clothes when you leave your shift. The smallest
particles of dust are the most harmful. They may be so fine that you can not see them. Remember, you
must protect yourself from the danger of breathing or inhaling dust.

8
11. BEFORE USE

• Before starting, make sure that it will not cause any danger.
• Make sure that the equipment is used only when it is in safe and proper working condition.
• Starting an automatic drilling rig is forbidden if there are people within the operating range. Do not
start the power packs when the automatic mode is on.
• The equipment should only be used when all the necessary protective and safety devices, such as
detachable guards, emergency stop devices, sound insulations, dust separator, etc. are in place and in
safe and proper working condition.
• When stepping in and out of the rig, move cautiously and use the rails and grips provided - beware of
slippery surfaces.
• Before starting the engine and starting off, check the interior, surroundings, and underside of the
vehicle.
• Make sure that all controls are in the correct position before starting the engine. Test the function of
the controls.
• If warning signs are placed on the engine starting switch or controls, these must not be touched until
the person who placed the signs, or some other person who knows the situation, has removed them.
• The engine should never be started otherwise than with the proper starting controls.
• Always follow the starting and stopping instructions given by the control and indicator devices as
described in the manuals.
• Drain condensate water out of the system as instructed by the manufacturer.
• Check all safety devices.
• Check all gauge readings and indicator lights, and replace all faulty devices.
• At least once during every shift, the equipment should be visually checked for faults or defects.
Report all possible faults (also functional disturbances) immediately to the person or department
responsible for the equipment. If necessary, the equipment must be stopped at once, and possible
safety precautions must be taken.
• Stop the equipment at once, and take necessary safety precautions if functional disturbances occur.
Repair the fault or have it repaired without delay.
• Never leave the immediate vicinity of the equipment if the engine is running.
• Everybody who is working near the rig when it is in operation must wear earmuffs, a safety helmet,
and eye protection.

11.1 HYDRAULIC SYSTEM

• Check the hydraulic system for possible leaks. Repair all leaks before use. Check all hydraulic hoses,
especially those that bend in use, and replace hoses as necessary. Check that all cover plugs and
caps, and filling caps are properly in place.
• Check that all safety devices, such as pressure relief valves, pressure gauges, etc. are in place and
working properly. Make sure that you know their functions. Any of the safety systems must not be
bypassed.
• Check that the oil accumulators are in proper working condition before working on hydraulic circuit.

9
11.2 WATER AND AIR CIRCUITS

• Check the pipes, valves, drain valves, and other components of the pneumatic and water systems.
Make sure that their pressures are correct, and that no leaks occur.
• Drain the air and water systems and valves completely if the ambient temperature drops below freezing
point.
• Check that the air tanks are unpressurised before working on the air circuit.

11.3 ELECTRIC SYSTEM

• Check the operation of the safety devices. Test the instrument panel indicator lights by depressing the
test button, see manual for location of the button. NOTE! This test does not reveal the condition of the
indicator light sensors, and therefore they must be checked separately at regular intervals. Check the
operation of the stopping solenoid as well.
• Check the electric cables visually, and make sure that the electric boxes and cabinets are properly
closed. Before starting, make also sure that the power supply cable offers sufficient range of movement.
• A high deviation of supply voltage damages the equipment. Over voltage damages components and
starting with under voltage damages the starting circuit components of the engine.

11.4 FRAME STRUCTURES

• Check all sheet metal plates and welds visually for possible damage, such as cracks, bending, and
deformations. Cracks in the surface paint or paint peeling may indicate a point of dangerous breakage
in the structure. The equipment must not be used until the necessary repairs are made.

12. STARTING/STOPPING

• Before starting, make sure that it will not cause any danger.
• Starting an automatic drilling rig is forbidden if there are people within the operating range. Do not
start the power packs when the automatic mode is on.
• Many SANDVIK equipment are provided with an alarm and monitoring system that prevents serious
damages caused by incorrect function. The automatic monitoring devices do not only prevent
damages, but also indicate which component has caused the disturbance.
• The safety systems must never be bypassed or removed in order to make some work easier.
• Check all safety devices.
• Test the function of the controls.
• Check all gauge readings and indicator lights, and replace all faulty devices.
• At least once during every shift, the equipment should be visually checked for faults or defects.
Report all possible faults (also functional disturbances) immediately to the person or department
responsible for the equipment. If necessary, the equipment must be stopped at once, and possible
safety precautions must be taken.
• Stop the equipment at once, and take necessary safety precautions if functional disturbances occur.
Repair the fault or have it repaired without delay.
• Never leave the equipment if the engine is running.
• Everybody who is working near the rig when it is in operation must wear earmuffs, a safety helmet, and
eye protection.

10
12.1 BE ALERT

• When the machine is running :

• Do not read anything.
• Do not drink or eat.
• Concentrate on your work. If you must divert your attention elsewhere, stop the equipment.

12.2 USE IN COLD WEATHER

• See user manuals for cold starting instructions.
• Operate the controls softly until the hydraulic oil has warmed up to normal working temperature.
Hydraulic oil can be warmed up by following the manufacturer’s instructions.
• Sudden, abrupt loading should especially be avoided.
• Oils for cold weather should be chosen according to the lubricant recommendations.
• The air and water circuits must always be drained if the temperature drops below freezing point.
• Use anti-freeze mixture in the engine cooling system (only water cooling engine models). Check the
freezing point of the coolant.

12.3 MONITORING AND SAFETY DEVICES

Many SANDVIK equipment are provided with an alarm and monitoring system that prevents serious damage
caused by improper function. The automatic monitoring devices do not only prevent damage, but also
indicate the component that has caused the disturbance. This feature shortens the time required for repairs,
and promotes safer working.

• The phase sequence control relay monitors phase sequence and drop out of a phase.
• The return oil filter monitoring employs a pressure switch. If the pressure difference between the intake
and discharge pressures is too great, a warning indicator light goes on.
Automatic safety devices cut off current in the event of a serious disturbance. Simultaneously they usually
indicate the component that has caused the disturbance.

• The emergency stop button stops all electric motors, and an indicator light goes on. Before restarting,
the button must be turned in the direction indicated by the arrow in order to return the button up. The
powerpack cannot be restarted until the pressure control reset button has been pushed.
• Electric motor overheating is prevented with an automatic switch that cuts off current to the motor if
the load rises above the set limit.
• Hydraulic oil level control switch stops all drilling functions if the oil level is too low. Simultaneously, a
warning light goes on.
• Oil temperature control switch stops drilling functions if the oil temperature rises above the set value
(e.g. +65°C; different values are used). Simultaneously, the oil temperature warning light goes on.
• The safety systems must never be bypassed or removed in order to make some work easier.

11
13. END OF WORK SHIFT

Stop the equipment and finish work according to instructions.

• Move the equipment away from high walls or steep slopes before ending the day’s work.
• Carefully choose the place where you park the equipment. Do not leave it in a place where rocks may
fall down on it, or in a place where heavy rain may form a pool.
• Do not leave the equipment in a slope or ramp, unless you can make sure that it will not start moving.
• To ensure that the rig remains stationary, refer to the instructions given in the manuals.
• Make sure that the pressurized systems are in the state given in the manuals.
• Move all control levers to middle or parking position.
• Engage parking brake and lock it to prevent the equipment from moving.
• If a clutch is provided, disengage it before stopping the diesel engine.
• Lock the ignition switch or the starting circuit, and take the key away, if locking is possible.
• Lock up the cabin, and install protective devices, if provide.

14. PROPER USE

The use of the equipment for other purposes than what it is designed for, or exceeding the specified
performance ratings is not considered proper use. The manufacturer / supplier is not liable for damage caused
by such use. Proper use also includes observing the information in the user and service instructions and
following the control and service regulations.

Acquaint yourself with the user and service manuals issued by the manufacturer, and keep them always with
the equipment.

15. REPLACEMENTS INSTRUCTIONS

15.1 BRAKES

Do not operate the vehicle with faulty brakes. The operation and holding capacity of the brakes must always
be ensured before driving is started. Damage to vehicle or serious personal injury or death may result.

15.2 TRAMMING

Tramming requires some special procedures depending on the equipment of your SANDVIK drilling rig. Read
the manuals of your rig carefully.
Do not release the parking brake until you have checked that
• Steering works
• Booms are in transport position
• Correct speed range is selected
• Tramming direction is selected
• All equipment and functions are in working order
• Moving the rig will not cause personal or material damage

In passages with limited space, it may be necessary to use the boom control levers in addition to the actual
controls of the carrier. If the rig is equipped with a cable or hose reel, remember their use when tramming.
• You should never move or operate the rig unless you have made sure that it does not cause any danger.

12
Do not try to steer the rig from anywhere else than the actual steering position.
• The rig must not be operated by anybody but trained persons.
• Stepping aboard or hopping out of a moving rig is forbidden.
• Transporting people with the rig is forbidden.
• Avoid narrow and low passages.
• Move the boom into the transport position. In this position, the centre of gravity is as low as possible
and stability increases. Stresses on the boom will also be greatly decreased.
• In rough terrain, it may be necessary to move the boom during tramming. However, the boom should
be kept as short as possible (extension cylinder fully retracted) and the feed in vertical position. The
boom should always be moved very cautiously to maintain stability in slopes and difficult terrain.
• If you have to move the rig in dangerous places, for instance along the brink of a steep slope, use the
control platform rather than the cabin (Track models). Try to drive the rig so that the operator is not on
the brink side.
• If the rig is equipped with track oscillation, acquaint yourself with the instructions. Incorrect use of
oscillation may cause the rig to turn over, resulting in serious damage.

15.3 TOWING

Great caution and the manufacturer’s instructions should always be observed when towing. Neglecting the
instructions will cause severe damage on the rig, and the damaged rig can cause serious accidents.
• Do not try to start the engine by towing.
• If the engine is running, the rig’s normal tramming speed can be used for towing.
• If the engine cannot be started, towing requires special preparations depending on the rig type; see
towing instructions in the rig’s manuals.
• A rig without brakes must always be towed using a rigid towing bar. Power steering works thanks to the
engine. If the engine is not running, steering works but it is heavy and slow.
• Make sure that the towing vehicle’s brakes are in good condition, and powerful enough to stop both
vehicles in all circumstances.

15.4 TRANSPORTING

Always plan transportation in advance to be able to ensure safety. Choose the safest method of transport,
and make sure that the capacity of the transporting vehicle is sufficient.
• Use access ramps when moving the rig onto the platform and down from it. Driving on or off the
platform must be done on level ground.
• Always use low tramming speed, and be very careful when coming from the ramps onto the platform.
• When coming onto the access ramps, the rig must be balanced with boom movements and oscillation
(if provided).
• Before transportation, the parking brake must be engaged and the boom lowered down and properly
supported against the platform. Secure the rig with straps or chains to prevent it from moving during
transportation. In addition, observe all other special requirements for transport of your rig, as given in
the user manual.
• When planning the transporting route, keep the rig’s dimensions in mind (especially cabin models).
Always measure the maximum height and width of the transport.
• The lifting points of the drilling rigs are marked with hook symbols.(Note that some rigs have no lifting
eye on the boom). When you lift a drilling rig make sure that the lifting equipment is in good condition.
• Make sure that you know the actual weight of the rig before starting to lift it.

13
16. LOAD LIFTING

Most countries have regulations concerning lifting, lifting wires, and lifting devices. These local safety
regulations must always be followed.
• Only the right type of lifting device with sufficient lifting capacity should be used. No other devices
than specified lifting devices should be used for lifting the equipment or their components. Do not use,
for instance, a loader for lifting.
• The weight of the load must be known, and the rated lifting capacity must not be exceeded.
• Lifting should be planned so that the load need not be moved over people or places where people may
be present.
• Make sure that the lifting device is in good condition.
• Lifting wires and chains should be checked regularly. Discarded wires must be marked clearly and
disposed of without delay.
• The lifting points of SANDVIK drilling equipment are marked with hook symbols. Lift the
equipment at the marked points only.
• Check proper fastening and balance of the load by at first lifting it up only a few centimetres.
Continue lifting when you are sure that the load is properly fixed and in balance.
• Lifting wires with several ropes must not be twisted. Lifting ropes must be fixed according to
the manufacturer’s instructions.

• The lifting wire must not make a loop round the load in place of a lifting strap or chain.

• The load should never be lowered so far down that less than two turns of wire is left on the wire reel.
This way you can make sure that the weight of the load is evenly distributed between the wire and its
fixing point on the reel.
• Check the capacity and length of the wire whenever the wire or mast length is altered.
• Never stand or work under a hanging load.
• Do not estimate lifting capacity on the basis of stability.
• Do not move a load over persons.
• Take care that the load does not bump into anything.
• Do not use any other lifting devices for lifting persons than those designed for that purpose. Drilling
rig booms are not designed for lifting persons, and it is absolutely forbidden to climb on them!
• It is ABSOLUTELY FORBIDDEN to carry persons on the load.

14
17. MAINTENANCE AND SERVICE INSTRUCTIONS

17.1 SAFETY AND QUALITY

17.1.1. BEFORE SERVICING

• Be extremely careful to prevent personal injury and avoid damage to material. Comply with all safety
regulations.
• Apply the parking brake and prevent the machine from rolling with tire blocks.
• Stop the hydraulic system power source (engine) and disconnect the battery.
• If necessary, block off the safety area.
• Wash dirt and grease from exterior of the components.
• Await the complete cooling down and de-pressurisation of the hydraulic system (accumulators must
be purged).

WARNING
Hot or pressurized hydraulic fluid may cause serious burns & infections to the
human body. Consult a physician in case of accident.

17.1.2 DURING SERVICING

• Some hydraulic components are very heavy. Secure them with a lifting device of adequate capacity
when removing from the machine frame.
• Cleanliness is essential to functioning of the hydraulic components. Most of the parts may be cleaned
with a clean solvent.
• During handling, protect all sensitive surfaces from shocks (piloting and interface surfaces, thrust &
bearings surfaces, seal races, etc...)
• Clean up these surfaces before reassembling.
• Always install new O-rings, seals & gaskets discarding the old ones. We recommend lubricating all
seals prior to assembly.
• Lubricate all surfaces which have relative motion between parts by coating them with a film of clean
hydraulic fluid.
• Never heat hydraulic fluid, as it may flame at high temperature. Some solvents are also
flammable. Do not smoke during servicing.

WARNING
Do not replace relief valve.

15
17.2 GENERAL

We recommend that records be kept on services and wearing part replacements. Regular maintenance at
correct intervals increases reliability, economy, and safety of the equipment. Even maintenance work can
be dangerous, unless caution is observed. Everybody involved in maintenance work should understand the
possible hazards, and use safe working methods. Before starting any maintenance or repair work, read the
manufacturer’s instructions and follow them.

The person responsible for maintenance and repairs should be clearly defined.
• Do not do any work that you are not authorized to do.
• Inform the users of the equipment of the start of special and maintenance work.
• Reserve a sufficient safety area around the rig for maintenance work.
• If the equipment or a part of it has been stopped for maintenance or repair, make sure that it cannot
be started accidentally.
-- Turn main switch off.
-- Remove ignition key.
-- Put a warning sign on the main switch. The sign can be removed only by a person who is fully
aware of the situation, and who can be sure that the sign can be removed without causing danger.
• Clean and wash the equipment regularly, and always before maintenance and repair work.
• Before starting to clean the equipment with water, high-pressure washer, steam, or other cleaning
methods, protect all such openings and other points that can cause danger or become broken.
Especially electric motors, switchgear cabinets, and electric boxes need to be protected.
• Do not use parts of the equipment as steps. If maintenance work must be done high up, or in an
otherwise dangerous place or position, use necessary safety devices to prevent falling.
• All platforms, steps, grips, rails, ladders, and other similar parts must be kept clean of oil, dirt, snow, and
ice to prevent accidents caused by slipping.
• Always use proper working equipment.
• If you are doing maintenance or repair work under the vehicle, engage safety and parking brake. Make
also sure that accidental starting or moving is prevented.
• When changing tyres or wheels, make sure that the equipment is in balance and properly supported.
Refer to the specifications for maximum tyre pressure. Do not exceed maximum tyre pressures.
• Do not stand in front of the wheel when the tyre is being inflated. DANGER OF SERIOUS INJURY!
• Pay special attention to the exhaust piping and the exhaust gas cleaning system. Ensure sufficient
ventilation.
• Overheating indicates a fault. Stop the engine and repair the fault before more serious damage is
caused. Make sure that the engine radiator is not covered, and that it is not clogged.
• When checking engine coolant level, stop the engine and allow it and the radiator to cool down for a
while. Use thick gloves and protective clothing when opening the radiator filling cap. Stand to the side,
turn your face away, and open the cap a little. Wait until the pressure is released and coolant stops
running out, then open the cap slowly.
• When replacing heavy parts or units, fasten them properly to the lifting device and
make sure that the moving does not cause any danger. Use only suitable and technically
faultless lifting devices, and lower the load on a surface that can carry the weight.

16
17.3 REFILLING FUEL

The following precautions must be observed when replenishing fuel:

• Do not fill fuel tank when the engine is running.
• Take care not to spill fuel on hot surfaces.
• Fuel filling should be done in a well ventilated space.
• Smoking, open flame, and sparks are dangerous when the fuel tank is being filled.
• Wipe off spilled fuel before starting the engine.
• Keep the fuel replenishing pipe in contact with the fuel tank, or arrange earthing to prevent sparking
caused by static electricity.
• Cabin heater must be switched off.
• 17.4. Pneumatics maintenance
• The pneumatic circuit must be completely pressure-less before any repairs are made.
• Make sure that the pneumatic system completely pressureless before starting maintenance or
repair work on the compressor.
• The system pressure must not be adjusted higher than specified by the manufacturer. Increasing
the pressure does not increase the performance of the equipment.

17.5 ROCK DRILLS PRESSURE ACCUMULATORS MAINTENANCE

The pressure accumulators of the rock drills are pressurized with nitrogen gas N². Before
removing the accumulators , release the pressure by opening the filling valve. Do not
pressurize the accumulators over the specified filling pressure. Follow the instructions
for pressure accumulator maintenance and repair.

17.6 HYDRAULICS MAINTENANCE

Maintenance, repair, and installation of hydraulic equipment is only allowed to experienced hydraulics experts,
observing the hydraulics regulations.
• Do not attempt any such repairs that you do not fully understand.
• Never do any repair work on the hydraulic circuit if the system is pressurized.
• Do not use the drilling equipment if the system has a hose leakage.
• Do not tighten or repair a leaking hose connection before stopping the engine and the power pack.
• Do not try to locate a leak from a hose or a connection by feeling with your hand. The high-pressure
oil spray from the leak can penetrate the skin and cause a serious condition. A high-pressure oil spray
can also start a fire.
• Avoid direct skin contact with oil. Prevent oil from getting into your eyes; use gloves and eye protection.
• Do not work under a device or component that is held up only by the hydraulics. Use separate supports
in conjunction with maintenance and repair.
• Do not remove boom cylinders or their non-return valves before the boom, the feed, and the rock drill
are properly supported.
• Pipe connections, hose lengths, and hose types must correspond with the specifications. When
replacing or repairing hoses, use original SANDVIK spare parts or hoses and fittings recommended by
the manufacturer. Ensure that the pressure ratings of the hoses and connecting fittings correspond
with the working pressures.
• Any alterations require a written authorization from the manufacturer.

17
17.7 ELECTRIC SYSTEM MAINTENANCE - SAFETY INSTRUCTIONS

DANGER
ELECTRICAL HAZARD! Work on electrical equipment or devices is to be per-
formed only by persons with the expertise and qualifications required by the au-
thorities, or under the supervision of a person meeting these requirements. Make
sure that the instructions set forth below are read and understood before any
electric system maintenance. Failure to strictly follow instructions will lead to se-
vere injury and/or death and/or property damage.

Performing maintenance on electrical components

The work must be carried out according to local electric safety regulations.
Always use approved, correct and certified electrical testing equipment and personal protective equipment.
When performing electrical work, always ensure that the machine is disconnected from the supply network
before any service, repair or maintenance. Ensure that the components in question are not live, and then lock
the main switch or arrange appropriate grounding.

When the electrical cabinet main switch is switched off, always be aware that this does not normally isolate
the electrical supply going into the machine’s electrical cabinet. Hence, the trailing cable, cable reel and cable
going to the live side of the main switch remain live! (This is the case unless a separate Pilot core electrical
system has been adopted at the work site and the pilot core is wired through the machine’s main switch!).

Do not open live junctions or terminal boxes on electric motors, cable reel, electrical cabinets, light fittings,
HID gas discharge lamp fittings or the like. Check the condition of the drill rig’s electrical devices regularly.

Check the operation of the earth leakage control system from the gate end panel weekly. If the control does
not switch the power off, the control system must be repaired or replaced before any device connected to it
is started.
DANGER
ELECTRICAL HAZARD! Isolate the machine by turning off the main switch and
removing the power plug from the electrical network before any work on elec-
trical components. Ensure that nobody connects the power on during the main-
tenance or repair work! Electrical safety tests and measurements must be done
before operating the machine.
Failure to follow these instructions could lead to death or serious injury.

Fuses and the circuit breakers are protecting the wires and electrical components against overheat and fire in
case of overload and short circuit.

Breaker tripping or fuse burn is a sign of failure. Before resetting the breaker or replacing the fuse the failure
must be repaired. The original fuse size and type must be used. Never replace the fuse with a fuse having
higher ampere value than the original.

18
Modifications to electrical systems

WARNING
Electrical modifications to the drill rig require written permission from Sandvik Mining and
Construction’s electrical design department to ensure the correct operation of the modi-
fied device.

When replacing any electrical components or wiring, always use original parts of original equipment
manufacturer and use the correct installation and testing procedure before operating the machine. All
replacements and tests should be documented for future reference.

Current settings of circuit devices such as overloads, circuit breakers and other protective devices shall only
be set to the specifications of original equipment manufacturer.

Replacing the light bulbs

WARNING
WARNING! Electric shock hazard. Cut the supply voltage to the light using the
main switches before replacing the bulbs of the working and driving lights. Ex-
ercise extreme caution when performing work on HID gas discharge lamps. The
light components include high voltage parts. Failure to follow these procedures
could result in serious injury!

Note that parts of the light may be hot after use, so allow it to cool before commencing repair work. The bulbs
of gas-discharge lamps are gas-filled, so handle with care. Use gloves and safety glasses. Do not touch the
lamp holder or the glass part of the bulb when carrying out the replacement.

17.8 BATTERY MAINTENANCE

• Always wear eye protection, protective overalls, and protective gloves when servicing batteries.
• Always disconnect the negative (-) pole first, and then the positive (+) pole.
• Always connect the positive pole (+) first, and then the negative (-) pole.
• To prevent sparking when connecting a battery charger, pull the charger supply cord or switch the
charger off before connecting the charging wires to the battery terminals. Open the battery cell caps
slightly during charging to allow the generating gases to escape.
• The acid in the battery burns the skin, eats holes in clothing, and can cause blindness if it gets in
the eyes. If you get battery acid on your skin, flush the spot at once with plenty of water. Use sodium
bicarbonate to neutralize the acid if it gets in the eyes. Flush the eyes with plenty of water, and call a
doctor.
• When servicing batteries, remember that lead-acid batteries generate (during charging and
discharging) oxygen and hydrogen which form a highly explosive mixture. A spark or an open flame can
cause an explosion. If necessary, ventilate the battery compartment properly before disconnecting or
connecting the cables.
• To prevent explosion, the electrolyte level must be kept correct and checked regularly. Add distilled
water, if required, before starting, never immediately after use. With the electrolyte level high enough,
the cells have less space for gases.
• Use an flashlight when checking electrolyte levels, never an open flame.
• The battery terminals should never be shorted. The sparks can cause the battery to explode.
• Do not test electric devices by making the contact directly to the battery terminal.

19
17.9 WELDING

Before starting to weld, determine the material to be welded, and the welding method and fillers. Contact
SANDVIK Service, if necessary.
• Do not repair steering equipment by welding.
• Welding must be left to qualified personnel.
• Disconnect both cables from the battery before starting to weld. The welding voltage can damage
electric devices.
• Use a protective mask when welding.
• Arrange adequate ventilation.
• Arrange protection against fire.

18. CONSIDERATION FOR THE ENVIRONMENT WHEN SERVICING THE

EQUIPMENT

When servicing the equipment, you handle many substances that are regarded as hazardous waste. When
dealing with these, be very careful and follow the applicable local regulations. The following instructions
should provide useful guidance - for more location-specific instructions, contact the local garbage disposal
company or the appropriate authority.

Service area
The facilities used for servicing must be designed for this purpose. The floor material must be oil-resistant
- preferably cast concrete. For washing the equipment and to prevent damage from oil, the sewage system
must be equipped with an oil trap.

According to regulations, those in possession of hazardous waste must know the amount, quality, and origin
of the waste; i.e., companies must keep a record of this information. Always follow the regulations for storage
of hazardous waste. It is a good idea for the company to appoint a person who is responsible for the storage
and further processing of hazardous waste.

Appropriate handling of oil waste

Any oil that is spilled onto the ground, including biodegradable oil, must be collected as carefully as possible.
Oil waste must not be disposed of by burning, and under no circumstances must oil be poured down the
drain or into water systems. One litre of oil is enough to pollute a million litres of ground water intended for
household consumption.

Used lubrication oil is hazardous waste that must always be processed by an authorized waste treatment
plant. During its use, metal particles and other impurities have entered the oil. These increase the risks to the
user’s health.

If the company produces a larger amount of oil waste, it is worth separating. For treatment, oil waste is divided
into three categories:
• Clear oils, which include hydraulic and transmission oils.
• Black oils, which are motor oils. Synthetic and mineral oils are collected in the same container.
• Vegetable oils, which are collected in a separate container. Greases, fuels, solvents, and other
substances must not be mixed with oil waste.

20
Solid waste containing oil
Oil filters, oil rags, fuel filters, and oil absorbents must be collected in a separate container.

Radiator, brake, and clutch fluids

Used radiator, brake, and clutch fluids contain traces of heavy metals, zinc, and copper, for which reason they
must not be poured down the drain or mixed with oil waste. They are to be collected in a separate, labelled
container and delivered to the same plants as the oil waste.

Solvents and oil trap sludge

Solvents and sludge that has collected on the surface of the oil traps are collected in the same container. The
surface layer in the oil traps must be removed regularly, and the entire trap must be drained at least once a
year, including the sludge at the bottom. Do not mix the oil trap sludge with oil waste.

Fuel oil
Fuel oil is hazardous waste that must in all cases be processed by an authorized waste treatment plant.

Oil waste storage

The best containers for collecting oil waste are the original containers for the oils. Naturally, new containers
become available whenever new oil is purchased. They already have the necessary warning labels, are easy to
close, and can be moved around fairly easily. Always strike out the product name on the label and clearly label
the container “oil waste”.

This ensures that everyone knows the container contains oil waste. Store the waste in an appropriate manner.
A suitable storage room for hazardous waste has a roof, a leak--proof floor, and preferably a lockable door.
When storing flammable fluids, always ensure that the room has a separate ventilation system or is otherwise
well ventilated. The path to the storage room must be free of obstacles.

Empty oil containers

Empty oil containers must not be dumped in landfills without having been cleaned. Cleaned plastic containers
can be disposed of as regular waste. Most countries have arranged a recycling system for metal barrels.

19. CONSIDERATION FOR THE ENVIRONMENT WHEN USING THE EQUIPMENT

SANDVIK actively considers environmental concerns when designing and manufacturing its products. The
equipment are designed to burden the environment as little as possible; i.e., the vibration, noise, exhaust,
and lubrication/additive emissions of the machine have been minimized. The manufacturing process for the
equipment has been designed so that recycled materials are used as much as possible, and the process
quality and emissions are considered carefully in selection of the subcontractors. There is an ongoing aim
of continually lowering the emissions from the machining of metal, and from painting and assembling the
equipment, and these processes fulfil the very strict requirements of the Finnish environmental legislation.

19.1 ECONOMICAL OPERATION OF THE EQUIPMENT

The costs incurred by using the equipment go hand in hand with the amount and type of emissions it lets
into the environment. Through systematic training of the operator and service personnel, one can reduce the
operating costs of the equipment significantly, and at the same time reduce the environmental burden caused
by the equipment. See the graph below.

21
An economical driving method and correct operation are another key factor in reducing operating costs and
the effect on the environment:

• Avoid idling. Warm up the machine by performing light tasks, not by idling.
• When you are working, try to keep the engine speed close to the maximum torque or just above it, as
this will ensure optimal engine fuel economy and keep the noise and exhaust emissions low. There are
still some power reserves in the engine for momentary load peaks.
• Avoid unnecessary carrying and use of auxiliary devices (e.g., air-conditioning unit or extra electrical
and other work equipment) that will not be needed for the work at hand.
• Avoid overloading

Factors affecting the service life of the equipment

19.2 DECOMMISSIONING

The end user of the equipment is responsible for its decommissioning. If the end user does not have the
ability or the resources to disassemble the equipment, the work must be performed by someone who does
possess the necessary knowledge and skills. In disposing of the waste material from disassembly of the
equipment, the following matters should be considered:
• The equipment body, all the steel constructions, and the copper and aluminium in the electrical wiring
are recyclable. The metals can be melted and used as raw material for new products, except for parts
that have been in contact with substances that are regarded as hazardous waste. The contaminated
parts can usually be simply cleaned or rinsed, after which they can be recycled.
• Most plastic parts are recyclable, similarly to the metals. Each plastic part carries information on the
material used and a manufacturing date, which can be used for determining whether the part can be
recycled.
• Rubber parts are not regarded as hazardous, and they can be disposed of according to normal
procedures. Tubes (hydraulics etc.) Must be cleaned before they are disposed of. Worn-out tires can
be returned to the dealer from whom they were originally bought.
• Windshields and other cabin windows are not accepted for conventional glass recycling, but they can
be disposed of via normal waste disposal methods.
• Electrical components that are classified as hazardous waste (accumulators, batteries, circuit boards)
and other hazardous waste must be delivered to a licensed waste treatment location or be disposed
of according to local regulations.
• Air conditioning units, which contain CFC and HCFC compounds, must always be delivered for
treatment to a licensed waste disposal facility. For disposal instructions for fluids and lubricants, refer
to the service manual.

These instructions are not binding, but they offer suggestions for appropriate waste disposal procedures.
Local authorities always have more detailed instructions and recommendations on the disposal of different
materials.
When removing equipment from use, you must always follow the relevant authorities’ regulations on
waste disposal that are in force at the time and location of disassembly.

22
MODULE 2 - LUBRICANT AND COOLANT RECOMMENDATIONS

1. GENERAL

Choosing the oil

Oil is chosen according to the properties of the oil and application.

Choosing the oil according to the properties of the oil

• Stability of the properties throughout the service life.
• Oil demulsibility.
• Anti-oxidation and anti-foaming properties.

Check the original oil type from the machine card or maintenance instructions.

Choosing the oil according to the application

The following issues must be considered:

• Sandvik’s oil recommendation
• The component’s manufacturer oil recommendation (Diesel engine, transmission, etc.)
• Environmental/site-specific/safety requirements.
• Biodegradable oils•Less flammable fluids

Mistakes in choosing and using oil

• Components can be damaged if:

• The wrong oil type has been chosen.
• The wrong oil viscosity has been chosen.
• The recommended oil change interval is exceeded.

Oil must be changed at certain intervals since the properties of the oil and its additives deteriorate and are
lost as the oil ages.

Observe the colour and clearness of the oil. Water and other contamination in oil can cause
instability of hydraulic system and serious component damage (in rock drill for example). If oil is
light grey or muddy change oil even before oil change interval runs out. Find out the reason of
contamination!

Oil contamination maximum rates

• The oil cleanliness must be at a maximum level of 18/16/13 according to ISO 4406 - 1999 (class 7
NAS 1638).
• Water must be <= 0.05 % according to ISO 12922.These levels are for tramming as well as for drilling
circuits and stand for all our machines.

23
2. OIL VISCOSITY

SAE classification

(SAE = Society of Automotive Engineers) Viscosity indicates the oil’ stability to flow. Viscosity is measured
at high and low temperatures and is indicated as an SAE grade, SAE40 for example. For multi-grade oils,
5W-40 for example, the first value (5W) indicates the viscosity at low temperatures and the second value (40)
indicates the oil viscosity when it is hot.

ISO classification

(ISO = International Organization for Standardization) The viscosity of industrial lubricants is determined by the
ISO-VG standard (ISO3448). The ISO grade number indicates the oil viscosity at +40°C, expressed in centi-
stokes (cSt, kinematic viscosity). For example, oil graded as ISO-VG 68 has a viscosity of 68 cSt at +40°C.

Too low viscosity causes:

• Breaking of the lubrication film between contact surfaces. The resulting metal-to-metal contact
between the surfaces causes rapid wear and increases the need for maintenance.
• Internal leaks in components are increasing causing reduced efficiency.

Too high viscosity causes:

• Flow losses in the system and thus also reduces efficiency.
• The load on the seals increases due to increased return line pressure.
• For certain rock drills, wear of the rotation shaft and thrust bearing due to increased return line
pressure.
• Too thick oil increases the risk of cavitation in pumps.

3. TRAMMING & DRILLING HYDRAULIC SYSTEM

The oil recommendations are based on the operating temperature of the oil. Hydraulic and engine oils,
biodegradable hydraulic oils, and less flammable hydraulic fluids can be used. Sandvik recommends hydraulic
oils to be used in hydraulic systems, still remembering viscosity requirements.

Never mix different types of hydraulic system oils. Mixing can damage the hydraulic components.

The selected hydraulic oil has to be of high quality retaining its properties at varying temperatures. Furthermore,
it must contain additives typical of high performance hydraulic oils. Oils and fluids suitable for hydraulic
systems are:
Shell Tellus (hydraulic oil)
• Shell Rimula (engine oil)
• Shell Naturelle HFE (biodegradable hydraulic oil, synthetic ester)
• Fuchs Plantoflux 68-AT-S (less flammable hydraulic fluid)
When choosing the viscosity of the oil to be used the temperature of the drilling environment is important.
Pay attention to temperature variation.

24
WHEN CHOOSING THE OIL CONSIDER THE FOLLOWING ISSUES:

1. Check or estimate the operating temperature of the oil.

2. The viscosity of oils at their operating temperature should be close to 60 cSt, and any variation in
continuous use should remain within the range of 50-110 cSt.

The following variation limits are allowed temporarily (but not constantly):
• 10-200 cSt as a result of a low temperature peak, or
• 30-50 cSt as a result of a high temperature peak.

The values indicated in the tables should be considered first and foremost. In each case it must always
be ensured that the product in question contains the required properties.

3. If the drilling environment temperature does not vary much, it is most recommendable to use single
grade oil which viscosity level changes the least as a result of use.
4. If the drilling conditions are such that single grade oils do not remain within the given
viscosity limits, a multi-grade oil should be chosen.
5. The oil should be changed once a year unless heavy use requires more frequent intervals.
This change interval recommendation is based on knowledge that in a year the oil ages and collects
moisture so much that changing it is necessary.

For Arctic conditions, (temperatures below -20°C), synthetic oils are recommended.

4. ENGINE OILS

Viscosity / temperature table

25
5. HYDRAULIC OILS

Viscosity / temperature table

Biodegradable hydraulic oils

Sandvik sets the same high technical quality requirements for biodegradable oils as a reset for conventional
mineral oils. In addition, they must be environmentally compatible, which means quality requirements relating
to

• Biodegradability
• Ecotoxicity
• Use and disposal.

The international standard ISO15380 specifies the requirements for environmentally acceptable hydraulic
fluids.

Viscosity / temperature table

26
Instructions related to the biodegradable oil change can be found in the manual “Biodegradable Hydraulic Oils
Change instructions for biodegradable hydraulic oils”, Sandvik instruction B00540.

Sandvik factory fill oils are SHELL NATURELLE HFE46 orHFE68 (synthetic ester). THE GUARANTEE IS
VALID ONLY WHEN THESE OILS ARE USED.

Less flammable hydraulic fluids

Sandvik sets the same high technical quality requirements for less flammable hydraulic fluids as a reset for
conventional mineral oils. In addition, they should be less flammable with self-extinguishing properties. There
are different types of these less flammable fluids available with a number of different properties.

For hazardous conditions, Sandvik recommends type HFDU fluid (synthetic, based on organic esters) to be
used.
Miscibility with hydraulic mineral oils and compatibility with the majority of metals and seals are necessary
features for these fluids.

HOWEVER, SANDVIK DOES NOT ALLOW MIXING OF DIFFERENT HYDRAULIC OILS/FLUIDS FOR SAFETY,
PERFORMANCE, AND ENVIRONMENTAL REASONS.

Further benefits related to environmental compatibility (ISO15380) are

• Biodegradability and
• Non-toxicity.

Sandvik uses the following less flammable and biodegradable HFD-U fluids as factory fill oils: Fuchs Plantoflux
68-AT-S (Tampere plant) and Condat D68 (Lyon plant). Sandvik recommends these fluids to be used in drilling
rigs. Since the availability of these fluids can be limited in certain market areas, Sandvik also approves the
following alternative:

• Quintolubric 888-68 (Quaker Chemicals)

Sandvik factory fill oils are totally miscible with the fluid mentioned above. Thus, the factory filled oil can be
changed, if necessary, without flushing the hydraulic system while performing the rig start-up inspection.
Sandvik does not accept continuous mixing of hydraulic fluids.

THE GUARANTEE IS VALID ONLY WHEN THESE RECOMMENDED FLUIDS ARE USED.

6. RECOMMENDATIONS & QUANTITIES

Recommended oil

UNDERGROUND TEMPERATURE GRADE OF OIL OIL

(SUPPLIED AT DEPARTURE FROM FACTORY)

From 10oC up to 30oC ISO 68 cSt SHELL TELLUS T68

Above 30 C
o
ISO 100 cSt SHELL TELLUS T100
For temperatures below 10 C, please consult SANDVIK. (For Artic conditions below -20oC, synthetic
o

oils are recommended.)

27
 For more information check :
• Original oil type from the «machine card»
• Lubrication maintenance operations in the «machine lubrication schedule» (include in section 2 of
the maintenance manual).
In case of other oil choose, be sure that the oil typical characteristics are respected.

Quantities

7. SHANK LUBRICATION OF ROCK DRILL

Oil lubrication Caution.

Use only proper shank lubrication oils.

Using water-based lubricants for this purpose is forbidden.

28
The oil recommendations are based on ambient temperature.

Examples of rock drill oils:

• SHELL Torcula
• ESSO (EXXON) Arox
• GULF Gulstone
• MOBIL Almo
• BP Energol RD-E
• TEXACO Rock drill lub

Recommendations & quantities

SSD (8L) / KVL10 (10L) / SLU14 (14L) / SLU22 (22L)

Type SHELL TORCULA 100
(Supplied at departure from factory)

The biodegradable oil CONDAT Purity FG 100 can be used as a biodegradable alternative.3.3.

Grease lubrication

The grease to be used must ensure sufficient lubrication properties at high temperatures.

29
Recommendations

Recommended greases:

• VISO Viso 808-2

• MOBIL Mobilith SHC460
• RELY Kernite
• LUBRICATION ENGINEERS Almagard 3751

8. DIESEL ENGINE

8.1 API ENGINE OIL CLASSIFICATION(API = AMERICAN PETROLEUM INSTITUTE)

This diesel engine oil classification has two-letter designations, the first letter being “C”. The current
classification designations for four-stroke diesel engines are APICF, APICF4, APICG4, APICH4, and APICI4.
The higher the second letter in the alphabet, the higher quality the oil is.

8.2 FUEL SULPHUR CONTENT

If the fuel sulphur content exceeds 0.5%, it can affect the selection of oil and the length of oil change intervals.
For more information, refer to the engine manufacturer’s maintenance instructions.
30
 For choosing the engine oil, refer to the engine manufacturer’s maintenance instructions.

9. DEUTZ

• API CI-4 multi-grade oil (preferred oil)

• API CH-4 multi-grade oil (preferred oil)
• API CG-4 multi-grade oil (preferred oil)

10. RECOMMENDATIONS & QUANTITIES

Recommendations

All the engine lubrication recommendations are given by the manufacturer.

SEE Section 8 of the maintenance manual.

You can find the main operations in the machine lubrication schedule to.

31
Recommended oil

ALL DISEL ENGINES

Type SHELL HELIX SAE 15W40
(Supplies at departure from factory)

In case of other oil choose, be sure that the oil typical characteristics are respected. You will find enclosed
supplier recommendations which indicate these characteristics.

Quantities

DIESEL ENGINE CAPACITY (WITH FILTER)

DEUTZ BF4M 1012 C 10L
DEUTZ BF4M 1013 C 14L
DEUTZ BF4M 1011 10.5L
DEUTZ BF4M 1012 10.5L
DEUTZ F3L 912W 9.5L
DEUTZ F4L 912W 13.5L
DEUTZ F6L 912W 18.5L
DETROIT D704 LTE 6.4L

11. COMPRESSOR

Gardner Denver / Tamrotor / Bendix compressor

Mineral based engine oil or synthetic compressor oil can be used in the compressor.

Never mix different types of oils. Mixing can damage the compressor.

When changing the oil type, the compressor circuit must be flushed with new oil:
1. Drain the oil from the compressor circuit.
2. Fill the compressor circuit with new oil and run the compressor to warm it up.
3. Drain the oil from the compressor circuit.
4. Replace the oil filter and oil separators.
5. Fill the compressor circuit with new oil.

Mineral-based engine oil

Engine oil is recommended for the compressor. The flash point must be above 180°C / 356°F. The lowest
allowed viscosity at the operating temperature is 7 cSt.

If the operating temperature is continuously over +90°C /194°F, the oil change interval with
mineral-based oils is 300 engine hours (600 engine hours with synthetic compressor oils).

32
The mineral-based engine oil recommendations are based on ambient temperature.

Synthetic compressor oil

If the operating temperature is continuously over +100°C/+212°F (ambient temperature over

+40°C / +104°F), synthetic compressor oil must be used. In Arctic conditions, (below -20°C/
-4°F), synthetic compressor oil must be used.

The synthetic compressor oil recommendations are based on ambient temperature.

CHOICES OF RECOMMENDED SYNTHETIC OILS:

• Shell Corena D46
• Mobil Rarus SHC1025
• Esso Cetus Pao 46
• BP Enersyn RC-S46

Recommendations & quantities

Tarotor C1000 / Gardner Denver CT10 / CT16 (~5L)

Type SHELL CORENA D46
(Supplied at departure from factory)

Bedix TUFLO 500 / TUFLO 1000 (~4.7L)

Type SHELL HELIX SAE 15W40
(Supplied at departure from factory)

33
12. TRANSMISSION AND DRIVELINE OILS

Quality classifications

API classification

(API = American Petroleum Institute) This transmission oil classification designations are from API-GL-1 to
API-GL-5. The higher the last number, the higher quality the oil is. For example, APIGL5 is an EP oil with high
additive level for heavy use, suitable for hypoid gears.

ISO 12925-1 classification

(ISO = International Organization for Standardization) This industrial gear oil classification designations are
from ISO 12925-1 type CKB to ISO 12925-1 type CKD. The higher the third letter in the alphabet, the higher
quality the oil is. For example, ISO 12925-1 type CKD are lubricants with oxidation resistance, anti-corrosion,
anti-foam, pressure resistance, and anti-wear properties. Improved temperature / oxidation resistance
properties enable use at high temperatures.

Viscosity classifications

SAE classification

(SAE = Society of Automotive Engineers)This viscosity indicates the oil’ stability to flow. Viscosity is measured
at high and low temperature and is indicated as an SAE grade, SAE90 for example. For multi-grade oils, 75W-
90, the first value (75W) indicates the viscosity at low temperatures and the second value (90) indicates the
oil viscosity when it is hot.

ISO classification

(ISO = International Organization for Standardization) This viscosity (ability to flow) of industrial lubricants is
determined by the ISO-VG standard (ISO3448). The ISO grade number indicates the oil viscosity at +40°C,
expressed in centi-stokes (cSt, kinematic viscosity). For example, oil graded as ISO-VG 150 has a viscosity of
150 cSt at +40°C.

6.3 RECOMMENDATIONS & QUANTITIES

Axles

CNH D45 (22L) / D63 (28L)

Type SHELL DONAX TD 10W-30
(Supplied at departure from factory)

NAF FL22 / FL23 (7L)

Type SAE 90
(Supplied at departure from factory)

34
Tracks final drive

SAMPIERANA S6/16 (~2L)

Type SAE 90
(Supplied at departure from factory)

Gear box
CLARK-HURTH 305 (~2.5L)
Type SHELL DONAX TD 10W-30
(Supplied at departure from factory)

NAF FL23 (integrated to axle) (0.8L)

Type SAE 90
(Supplied at departure from factory)

13. THREAD GREASE FOR DRILL RODS

The recommended lubricating grease: SANDVIK 795-1960

14. LUBRICATING GREASES

The hardness of greases is indicated as an NLGI grade showing the grease’s penetration value determined in
laboratory tests. The NLGI grade can be, for example, 000, 00, 0, 1, 2, 3, 4, 5, or 6. Grade 2 grease represents
so-called normal bearing grease hardness. The higher the number, the harder the grease. The hardness grade
of a grease is usually indicated after the product name.

Never use the greases listed below for lubricating the shank of a rock drill!

General lubricating greases and greases for Lincoln central lubrication system

THE RECOMMENDED LUBRICATING GREASES FROM DIFFERENT MANUFACTURERS:

• SHELL Retinax EP2
• SHELL Retinax HDX
• ESSO Beacon EP2
• ESSO Beacon Q2
• MOBIL Mobilux EP2
• MOBIL Mobilgrease Special

GREASE
SHELL ALVANIA EP2
(Supplied at departure from factory)

35
15. ENGINE COOLANT

Engine coolant is a mixture of water and corrosion inhibitors / anti-freeze. This mixture must be used in the
cooling system year-round to prevent corrosion and to increase coolant boiling point.

For choosing the coolant corrosion inhibitors / anti-freeze, refer to the engine
manufacturer’s maintenance instructions.

Coolant must be changed at certain intervals. The properties of the coolant and its ad-
ditives deteriorate and are lost as the coolant ages. Refer to the engine manufacturer’s
maintenance instructions.

Mixing different coolants is strictly prohibited. Mixing can cause blockages in the radiator
core and serious engine damage.

Deutz engines

The engine cooling system is filled at the factory with a mixture of 50% water and 50% Shell Glyco Shell anti-
freeze, which is a blue ethylene glycol-based fluid. Only this same Glyco Shell anti-freeze or pure water can be
added to the cooling system.

Coolant mixing ratio:

Anti-freeze protection to °C / °F Water % by volume GlycoShell anti-freeze % by volume

-37°C / -34°F 50 50
About -45°C / -49°F 45 Max. 55

16. SHELL / ESSO LUBRICANTS TABLE

Target Standard Shell Esso

Diesel motor API CH-4/CG-4/CF-4/CF, Shell Rimula X 15W- Essolube XT 5 15W-40
ACEA E3, MB228.3 40 81879879 Mobil Delvac MX 15W-40

Hydraulics DDIN51524 part 2 (HLP), Shell Tellus S68 Mobil DTE 26, Esso Nuto H68
ISO 6743-4 (HM) 81882019 Mobil DTE Excel 68 (zinc free if
needed)

Shank lubrication Sandvik Shell Torcula oil 100 Mobil Almo 527
81879749

Torque converter GM Allison C-4, GM A Shell Donax TM Mobil ATF 220

(Clark) Suffix A 81880259 (Molitrans HD 10W recommended
also for Clark)

Axles API GL-4 Shell Donax TD 10W- Esso Torque Fluid 56

30 85305659 Mobilfluid 426

Gear boxes API GL-5 Shell Spirax AX 80W- Mobilube HD 80W-90

90 81879879

36
 Compressor API CE / CF Shell Corena D46 Mobil Rarus 425
55052647

Lub grease Shell Retinax EP 2 Esso Beacon EP 2

81880409 Mobilus Ep 2

Cooling of diesel BS 6580, AFNOR, ASTM GlycoShell Mobil Antifreeze

engine D 3306 81885179 Mobil Antifreeze Extra

17. SAMPLE EXTRACTION

Oil analysis is like a blood sample.

The taking of an oil analysis sample is where the whole process starts.

If the sample is not representative of the oil that is in the machine then the result will not reflect the true picture
of what is happening inside it.

There are three ways to take an oil sample

- From the drain plug

- Using a sample extraction pump

- Using a dedicates sample valve

Drain plug sampling

• You have a 15 minute window to get the sample after shutdown

• Scrub the area around the plug thoroughly with a wire or plastic brush
• Blow off with compressed air if possible
• Wipe off with clean paper towel, not a rag
• Open the drain plug and let several litres of oil out
• Open the sample bottle, collect some oil, and close immediately
• Do not use an intermediate container to catch the oil

Sample extraction pump

• You have a 15 minute window to get the sample after shutdown

• USE A NEW TUBE FOR EVERY SAMPLE
• Insert the sump-end of the tube halfway down into the oil
• The tube entering the sample pump should only protrude just past the base of the pump, no more
• Keep the bottle capped right up until threading it onto the pump
• Fill the bottle no more than three quarters full
• Cap the bottle immediately after removing it from the pump

37
Dedicated sample valve

• This is the best way to sample

• Machine is running, so oil is hot and well mixed
• Consistent sample location leads to good trend
• Flushing requirement are minimal, so then is cross contamination from the previous sample

18. THE DIAGNOSTIC PROCESS

Two elements to good analysis

• Trend analysis is used to highlight non-conforming results in the test slate

• Experience is used to tell if a tread shift is significant or not

Analysis

• Trend analysis is the most important aspect of interpreting oil samples

• Use approximately a 30% change from sample 4 to 5 to determine whether a trend shift is
significant or not.
• If the trend shift is significant, circle the result in sample 5
• If wear or contamination levels have trended significantly downwards, ignore them. This is good
(most of the time)
• Do not rely on OEM-specified limits to decide whether a parameter is acceptable or not. All
parameters are functions of period oil in use, environment, operator technique, altitude etc.

38
The diagnostic process

1. Information. Gather information about the machine, environment and sample history.
2. Additives and lubricant condition. Perform a trend analysis.
3. Contamination. Perform a trend analysis
4. Machine wear. Perform a trend analysis
5. Diagnosis. A statement of the status quo. Fit the elemental families to the results highlighted in the
trend analysis in steps 2, 3 and 4.
6. Prognosis. The most important step. Make a decision about what to do, based on the diagnosis.

39
40
MODULE 3 - ROCK DRILL HLX5

1. OPERATION AND MAINTENANCE

1.1 GENERAL

These instructions describe in brief the main maintenance procedures for hydraulic rock drills. Service is always
ready to help and give advice in all maintenance problems. The qualified Sandvik maintenance personnel of
your Sandvik dealer and original Sandvik spare parts ensure reliable operation of your drilling equipment.

1.2 SAFETY PRECAUTIONS

DANGER
Beware of moving and rotating parts. Carry out maintenance and repair work only when the
rig is not running. Make sure that the rig cannot be started unintentionally during maintenance
work.

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

Only personnel with specific operation and service training are permitted to perform
operation, maintenance and adjustment procedures. Read the operating, maintenance,
and safety instructions before using or servicing the rig.

1.3 MAIN COMPONENTS

1 Flushing housing
2 Gear housing
3 Rotary actuator
4 Body cylinder
5 Pressure accumulators

41
1.4 TAKING A NEW ROCK DRILL IN USE

1.4.1 PREPARATIONS

New rock drills are delivered with the pressure accumulators not pressurized and the hose
connections plugged.

Pressurize the accumulators according to the instructions. See “Pressure accumulator for hydraulic rock drill;
Repair instructions”.

Before a new rock drill is installed the drilling equipment hydraulic system must be checked and flushed
thoroughly.

1.5 HOSE CONNECTIONS

1 Shank lubrication 2 Percussion mechanism pressure side (H.P.)

3 Percussion mechanism return side (L.P.) 4 Rotation, pressure (H.P.)
5 Rotation, return (L.P.) 6 Flushing

1.6 TEST RUN

Test run the rock drill and make sure that it operates properly before starting production drilling.
During test run observe:
• Shank lubrication
• Flushing
• Pressures and temperatures
• Possible oil leakages

Avoid use of full percussion power if the steel is not against the rock. This will reduce the
breakage of the accumulator’s diaphragm, the wear of flushing housing, drilling tools
and the cavitation of the percussion mechanism. This type of ”idling drilling” is the most
critical while drilling upwards or cleaning the holes with pumping motion.

42
1.7 LUBRICATION SYSTEM

The rock drill percussion mechanism and the rotation motor are lubricated by the hydraulic oil flow through
them.

FIGURE: LUBRICATION SCHEME: 1 SURFACE MODEL, 2 UG MODEL

The rotation mechanism and the shank have oil mist lubrication. The lubrication line from the lubrication unit
is connected to end of the rock drill. From there the oil mist is ducted through piston rear end to the front end
of the rock drill where the flow will lubricate the rotation mechanism, coupling and the bushings of the flushing
housing.

Leakage oil from the rear seals of the piston is also ducted to the front end of the rock drill through a channel.
The oil that has circulated through the rock drill lubrication system is removed through the shank lubrication
collector or can be led via return channels and gear housing to the feed rail.

Never connect the used oil mist to the hydraulic system return line.

43
 FIGURE: SHANK LUBRICATION

1 Rock drill
2 SLU 1/2/3
3 Drain valve
4 Filler cap

1. The shank lubrication oil consumption can be adjusted. (See the instruction manual for SLU 1/2/3).
2. The shank lubrication does not work if the oil level in the receiver does not lower during drilling.
(See the instruction manual for SLU 1/2/3).
3. Drain regularly the water that has collected in the receiver. The draining interval depends on the
local conditions.
4. Use only oils according to lubrication recommendation.
5. Refill the receiver regularly.

44
1.8 CHECKING THE FLUSHING HOUSING SEALS AND THE SEAL HOUSING GUIDE RINGS

Flushing housing seals (1) 5 pcs and the seal housing guide rings (2) 2 pcs must be replaced when the flushing
air or water escapes from the sides of the seal housing, and they should be checked whenever the shank is
changed. Seals are easier to install when they are lubricated. Install the new flushing housing seals making
sure they face the right direction (shown in the figure). The use of a spare flushing housing is recommended,
as it speeds up on-site maintenance of the rock drill.

FIGURE: THE FLUSHING HOUSING SEALS MUST BE INSTALLED FACING THE RIGHT DIRECTION, DETERMINED BY THE
FLUSHING MODE: WATER FLUSHING (A), AIR FLUSHING (B)

In addition, a damaged seal plate (3) must be replaced due to risk of corrosion.

45
1.9 INSPECTION OF THE FRONT END WITH THE ROCK DRILL ON A FEED RAIL

When you remove the flushing housing and shank, turn the rock drill to a horizontal position.
The coupling can fall out and cause injury.

If the shank lubrication is clogged (no air comes from the shank lubrication return hose),
stop the compressor. Before opening the flushing housing bolts, carefully open the locking
screw and let the air pressure out. Otherwise the air pressure can blow/ burst out the flushing
housing and cause injury.

By opening the bolts (4) the flushing housing (1), the shank (2), and the coupling (3) can be pulled out without
removing the rock drill from the feed rail. The lock-screw (5) holds the rotation bushing (6) in the housing, for
example while changing the shank. Check the condition of the rotation bushing rear end (6) and the bearing
(7).

FIGURE: DISMOUNTING OF THE FLUSHING HOUSING

1.9.1 CHECKING THE BEARINGS OF THE FLUSHING HOUSING

The bearings must be replaced if the indicator groove is worn off any place.

1.9.2 COUPLING
1. Pull the coupling out from the rotation bushing.
2. Check and replace, if the edges of the inner teeth are worn sharp or visible cracks are
seen.

1.9.3 ROTATION BUSHING

The rotation bushing must be replaced if the shoulder A is worn to the same level with the
face or damages are observed. Make sure that also the outer surfaces of the rotation bushing
are in good conditions.

1.9.4 CHUCK
The chuck inside the rotation bushing must be changed if the wear is over 1 mm from the
original surface B or if there are some hair cracks.

46
1.9.5 ROTATION BUSHING BEARINGS INSIDE THE GEAR HOUSING

The bearings must be changed if the wear indication groove has worn out from any area.

1.9.6 WEAR LIMITS OF THE SHANK

The shank must be changed if the 1 mm bevel of the striking head is worn out or any
other wear limit is exceeded.

When installing a new shank, take care that no dirt enters inside the
rock drill with the shank. Insert the shank carefully through the flushing housing, so that
the flushing device seals are not damaged.

1.10 CHECKING AND TIGHTENING BOLTS AND TIE RODS

The most important maintenance task is to check the tightness of the bolts, particularly the tie rods and
mounting bolts. Loose tie rods cause rapid wear of the body section faces, shortening the service life of the
rock drill.

Following procedure is recommended for checking the bolt tightness during normal maintenance:
1. Check the tightness of each bolt by using 10 % higher torque than specified and the correct
tightening order.
2. The joint being tested is loose if the wrench turns. In this case loosen all the bolts being tested and
re-tighten with the correct order.
3. If the threads are not clean the bolts cannot be tightened correctly. In such cases the bolt must be
removed, the threads checked, cleaned, and lubricated with grease.

Note! Use only an inspected, high-quality torque wrench.

FIGURE: ROCK DRILL BOLTS

1 Tie rod bolts (6 pcs)

2 Pressure accumulator bolts (4+4 pcs)
3 Flushing housing bolts (4 pcs)

47
1.10.1 TIE ROD TIGHTENING

The tools required:

• torque wrench
• 24 mm ring end

1. Lubricate the threads and the nut faces with grease.

2. Pre-tighten to 200 Nm (20 kpm). Correct tightening order is
(1-2-3-4-5-6).
3. Final tightening torque is 400 Nm (40 kpm). Same tightening
order (1-2-3-4-5-6) should be used.

1.10.2 PRESSURE ACCUMULATOR BOLTS

The tools required:

• Torque wrench
• 24 mm socket

1. Lubricate the bolt threads with grease.

2. Pre-tighten all four bolts to 100 Nm (10 kpm). Correct
tightening order is (1-2-3-4).
3. Final tightening torque is 200 Nm (20 kpm). Same tightening
order (1-2-3-4) should be used.

1.10.3 FLUSHING HOUSING BOLTS

The tools required:

• Torque wrench
• 24 mm ring end

1. Lubricate the bolt threads with grease.

2. Pre-tighten all four bolts to 200 Nm (20 kpm). Correct
tightening order is (1-2-3-4).
3. Final tightening torque is 400 Nm (40 kpm). Same tightening
order (1-2-3-4) should be used.

2. PERIODIC MAINTENANCE

The idea of periodic maintenance is that the rock drill is serviced before any breakdown occurs. This way
expensive additional damages and unwanted production interruption can be avoided.

The maintenance interval is 500 percussion hours, but depends on the local conditions, and it must therefore
be determined according to this experience. Searching for the correct maintenance interval, it is advisable to
start the periodic maintenance as specified, and then lengthen the intervals until a period that suits the local
conditions has been found. In addition the rock drill should always be taken in for service when the operator
reports of a fault on the rock drill that can cause major damage or a production interruption.

48
2.1 REPLACING THE FLUSHING HOUSING BEARINGS

NOTE! Make sure that the lubrication channels are flushed clean with compressed air.

Remove the front cover.

FIGURE: REMOVING THE FRONT COVER.

Remove the bearings using a hydraulic press and punches from the toolkit.

FIGURE: REMOVING THE SHANK BUSHING WITH SPECIAL TOOLS 3 AND 5

FIGURE: REMOVING THE FRONT COVER BEARING WITH SPECIAL TOOLS 1 AND 7.

49
 FIGURE: REMOVING THE FRONT COVER BEARING WITH SPECIAL TOOLS 1 AND 7.

FIGURE: REMOVING THE BEARING BUSHING FROM THE SHANK BUSHING WITH SPECIAL TOOLS 1 AND 7.

2.2 USE OF ROCK DRILLS

1 Tank
2 Electric motor
3 Double pump
4 Control valve (percussion)
5 Control valve (rotation)
6 Pressure-relief valve
7 Pressure gauge (percussion)
8 Pressure gauge (rotation)
9 Return filter
10 Differential pressure valve

50
Test run

1. Connect the rock drill according to the hydraulics diagram.

2. Make sure that:
• There is enough oil in the tank (1)
• The levers of the control valves (4) and (5) are in middle position
3. Turn on the power pack.
4. Start percussion by pulling the lever of the control valve (4) toward yourself.
5. Start rotation by pulling the lever of the control valve (5) toward yourself. You can change the
rotation direction by pushing the lever to the opposite extreme position.
6. Continue the test run for about five minutes, and note any possible leaks.

51
52
MODULE 4 -CYLINDER FEED T5 500/TFX 500

1. GENERAL

The TF 500 cylinder feed is designed for use with the HLX 5 rock drills. The design of the feed aims at simplicity
of structure and ease of maintenance. The main components and the operating principle of the cylinder feed
are described later.

These instructions also include a description of the most common maintenance tasks. SANDVIK service
department is always willing to give advice and help in any service-related problems. The trained service
personnel of your Sandvik dealer use the proper tools and modern instruments, and the required original
Sandvik spare parts.

2. SAFETY

Before starting maintenance work, move the rig away from the site where you have just been
drilling.

Perform maintenance and repair work only when the rig is stopped. Remember to make sure that
the rig cannot be accidentally started during repair.

Follow all safety instructions, and always protect yourself with the necessary safety devices.
Use proper tools.

Keep all inflammable material, such as oily rags, etc. at a required distance from the working
position.

Do not work under devices that are supported by hydraulics only. Use separate supports during
maintenance and repairs.

Watch out for rotating parts.

WARNING
Control the condition of hoses regularly, and check that they run properly
in the guides. Remember that a hose breakage can also cause personal inju-
ry. When checking the hydraulic circuit for leaks, look and listen, do not feel
about with hands – high-- pressure oil sprays can penetrate the skin and cause
serious injuries.

Certain work phases require the use of a feed cylinder during repair. Make sure that it does
not cause any danger, the rig can be stopped if necessary and that the power-pack is stopped
again before continuing the repair work.

53
3. TECHNICAL DATA

Type identifier: TF 500

Maximum feed force: 25kN

TF 500 10’ 12’ 14’ 16’ 18’ 20’

Length [mm] 4660 5270 5880 6490 7100 7710
Feed travel [mm[ 2830 3440 4050 4660 5270 5880
Drill rod length [mm] 3090 3700 4305 4915 5525 6135
Weight [kg] 480 510 530 560 600 630

Weight is without rock drill

4. LIFTING POINTS

5. MAIN COMPONENTS

1 Rock drill 2 Beam

3 Feed cylinder 4 Front centraliser
5 Intermediate centraliser 6 Hose reel
7 Hose support

54
6. OPERATING PRINCIPLE

The feed is constructed so that the cylinder tube (1) is a moving part, and the piston rod (2) is fixed to the rear
end of the feed beam. The intermediate centraliser (3) and the hose reel (4) are fixed to the cylinder tube (1),
and move along with the cylinder tube. The travel speed of the rock drill (5) is doubled with a system of wire
ropes (6 and 7) and return wheels (8 and 9) fixed to the intermediate centraliser and the hose reel

7. BEAM AND CARRIAGE SLIDE PIECES

The beam of the TF 500 is made of an aluminium profile with the sliding surfaces faced with stainless steel
strips.

The carriers of the rock drill, hose reel, and intermediate centraliser move along the feed beam on similar
slide pieces. Each slide piece is fastened to the carrier with three screws and nuts through the frame strip.
The screws lock the slide piece lengthwise. The form of the slide pieces and their supports function as lateral
locking.

1 Carriage 2 Locating shoulder

3 Adjusting holes 4 Slide piece
5 Frame strip 6 Steel strip

55
7.1 ADJUSTING THE SLIDE PIECES

The slide pieces normally require no adjustments when replaced,

as the pieces are located to correct clearances at the beam
centre line with the aid of locating shoulders on the carriers and
the frame strips.

If the slide pieces are so worn that the clearance is more than 3
mm, the clearance can be adjusted to the specified value with
the slotted holes in the carriages. After adjustment, the screws
are tightened to 120 Nm.

A = max. 1,5mm
B = 0 (clearance)

7.2 REPLACING STEEL STRIP ON BEAM

It is recommended that you remove the wear pieces of the rock drill, hose reel and
centraliser to make the change easier.

1. Open the four front centraliser mounting screws (2). Remove the front centraliser body (1) from the
front end of the beam.
2. Remove all slide pieces (3) and their frames (6) from one side of the cylinder feed.
3. Remove the mounting pieces (4). Remove the old steel strip. Wash the rail.
4. Slide the new steel strip (5) on the feed and put it in place by turning the steel strip. Use silicone for
sealing as described by lubrication symbols in the .
5. Push the steel strip (5) against the rear end, and cut the steel strip to length.
6. Use mounting pieces (4) to tighten the steel strip (5).
7. Replace the slide pieces (3).
8. Repeat steps 1 to 7 to the other side of the cylinder feed.
9. Mount the front centraliser body to the beam. Tighten the screws (2) to 300 Nm.

56
8. HOSE REEL

The hose reel keeps the rock drill hoses in the correct order and
proper tightness. The hose reel is mounted to the base plate with four
screws. The base plate is mounted to the feed cylinder tube with four
bolts.

Hose order

1 Percussion (pressure) 2 Percussion (return)

3 Flushing 4 Shank lubrication
5 Rotation 6 Rotation
7 Stabilizer

57
8.1 CHECKING THE CONDITION OF THE HOSE REEL COMPONENTS

Check the condition of the hose reel components at least in conjunction with
every second rock drill overhaul.
1. Disconnect the rock drill hoses and plug them.
2. Lift the hoses off the drum.
3. Disconnect the return wire.
4. Disconnect the hose drum base plate from the hose drum carriage and lift
the hose drum off.
5. Open the four bolts (13).
6. Remove the cover (12).
7. Open the axle nut (9) and remove the securing plate (10).
8. Lift the hose reel (1) off the axle.
9. Remove the bushing (4).
10. Lift the return wheel (5) and its bearings (7, 8) off.
11. Check the condition of the ball bearings (6, 7 and 8). Replace if necessary.

9. HOSE SUPPORT

The hose support is mounted to the side of the feed beam. The rock drill hoses are mounted to it in the order
shown in the figure. The feed cylinder hoses are also connected to the hose support as shown.

1 Percussion (pressure) 2 Percussion (return)

3 Flushing 4 Shank lubrication
5 Rotation 6 Rotation
7 Stabilizer 8 Feed cylinder hoses

58
10. ADJUSTING HOSE TENSION

The rock drill hoses are fastened to the hose support by clamping them between pieces. Both clamping
pieces hold hoses.

When adjusting hose tensions, leave the percussion pressure hose slightly less
tensioned than the others.

1. Open the two bolts (3) on the side of the hoses to be tightened.

2. Pull the hoses to appropriate tightness (the suitable slack of the hoses is approximately 5 cm).
3. Clamp the hoses between pieces (1) and (2) by tightening the two bolts (3).

59
11. ADJUSTING WIRE TENSION

A new wire tends to stretch at first until the wire strands have become somewhat straightened. Therefore, re-
tighten the wires after replacement when, for instance, one round has been drilled. Adjustment is done when
the wire is unloaded and the hose reel is in the rear position.

1. Adjust the return wire (5) at the wire end connected to the hose support. The wire end is provided with a
threaded piece and locking nuts.
a. Open the locking nut (2) at the hose support and use the other nut (1) to tighten the wire. Use a suitable tool
to prevent the wire from turning.
b. Tighten the locking nut (2).
2. Tighten the pulling wire (6) using the tubular nut (3) at the rear end of the feed.
a. Open the locking nut (4) through the opening at the rear end of the beam.
b. Use a suitable tool to prevent the wire from turning, and tighten the wire so that a correct clearance (C) (85
to 88 mm for stabiliser model or 150 to 153 mm for basic model) is left between the rear of the rock drill
and the front edge of the hose reel.
c. Tighten the locking nut (4).

Check the adjustment of wire tensioning when drilling with full feed power. The return
wire may not have a greater slack than (D) 50 mm.

60
12. IMPULSE CYLINDERS

Impulse cylinders

1 Impulse cylinder and inductive sensor

2 Bleeding screw

Impulse cylinders must be bled after repair operation.

Impulse cylinder and inductive sensors

1 Inductive sensor mounting position

2 Impulse cylinder mounting position

The stopping device must not touch the inductive sensor’s cap when the feed cylinder is in its extreme
position.

61
13. FRONT AND INTERMEDIATE CENTRALIZERS

The front (A) and intermediate (B) centralizers are equipped with wear pieces (2) made of steel. The pieces are
locked to the body (1) with jaw pieces (3). The jaw pieces are mounted to the body with screws (4), tightening
torque 300 Nm.

The buffer (5), acting as a stinger, is mounted to the front centraliser body (1) with four bolts (6) (4 pcs, tightening
torque 100 Nm).

The front centraliser (A) is mounted to the feed beam with four bolts (7), tightening torque 300 Nm. The
intermediate centraliser (B) is mounted to the base plate (8) with four bolts (11). The base plate
is mounted to the return wheel bracket (9) with four bolts (10).

62
14. RETURN WHEEL

The pulling wire return wheel is mounted to the return wheel bracket as shown in the figure. When replacing
the bearings, drive the pin through the axle so that the axle can be removed.

Before assembling new bearings, remove inner seals.

To make the replacement of the bearings easier, remove the return wheel bracket from the cylinder tube end
after opening the three retaining screws.

15. ADJUSTING THE SIDE PIECES

Adjusting slide pieces using (1 = adjusting screws). The adjustment is carried out before tightening of the

screws. Adjust the slide piece frames so that the clearance between the slide piece and the steel strip is less
than 1.5 mm.
A = max. 1,5mm
B = 0 (clearance)

63
16. PERIODIC MAINTENANCE

16.1 CHECKING THE TIGHTNESS OF BOLTS AND NUTS ID: 24784

1. Check all self-locking nuts.

2. Replace all loosened self-locking nuts.
3. Check all ordinary bolts.
4. Tighten all loosened ordinary bolts.

If an ordinary bolt connection loosens repeatedly, use a self-locking nut or chemical

thread locking compound.

16.2 CHECKING THE FEED BEAM

1. Check the inside of the feed beam for loose rocks and excessive amounts of drill cuttings.
2. Remove this material if necessary.

16.3 CHECKING THE CONDITION AND CONNECTIONS OF THE HOSES

1. Make visual inspection of the hoses.

2. Report possible faults immediately

16.4 CHECKING THE FEED CYLINDER

Check the feed cylinder.

16.5 CHECKING THE DRILL ROD RETAINER

Check the condition of the drill rod retainer.

16.6 CHECKING THE CENTRALIZER BUSHINGS

Check the condition of the centralizer bushings.

16.7 WASHING THE FEED

Wash the feed with a high-pressure washer as often as possible.

16.8 CHECKING THE CONDITION AND MOUNTING OF THE IMPULSE CYLINDERS

Check the condition and mounting of the impulse cylinders.

64
 Impulse cylinders must be bled after repair operation.

16.9 CHECKING THE RUBBER BUFFER

Check the rubber buffer.

16.10 LUBRICATING THE HOSE REEL

Lubricate the hose reel.

16.11 CHECKING THE CONDITION OF THE STEEL STRIP

The steel strips on the beam can become damaged, for instance,
by rocks falling on the beam. The steel strip is available as a spare
part in 7.5 m lengths. Check the condition of the steel strip. Replace
as necessary.

65
66
MODULE 5 - BOOM

1. DESCRIPTION

1.1. EXPLANATION

B26 NV - B26XL NV - B16 NV BOOM are multi-directional and telescopic booms fitted with an hydraulic
parallelism system. They can be used for face, wall, roof or floor drilling and for initiating cross-cuts, by swinging
the drill feed through a combination of 9 movements.

1.2 FEATURES

• Boom Weight without hoses: B26 NV : 1900kg (4185.7lb) / B26XL NV : 2010kg (4428.03lb) / B16 NV :
1650kg (3634.95lb)
• Hydraulic pressure in cylinders : 210 bar (3045psi)
• Movements amplitude :

71
1.3. MAIN COMPONENTS

The boom is fixed to the chassis by the boom swing cradle 1.

PAGE 9 (22)

The extension tube 9 slides in the armature tube 4 driven by the chrome cylinder situated inside the armature.
The boom movements are controlled by the cylinders 2 and 3.
The rotation of the drill feed in relation to the boom’s axis is make with the rotary actuator 5 allows 360°. The
rotary actuator 6 allows a 95° rotation on both sides of the drill feed’s axis.
The drill feed support 8 is fitted with a feed cylinder 7. The cylinder 10 makes the divergency movement.
Hydraulic parallelism system enable to keep a constant drill feed’s direction while swinging the boom on both
vertical and horizontal motions. Parallelism by a vertical plane is obtained with an hydraulic link between the
master lifting cylinder 3 and the slave cylinder 11.
Parallelism by a horizontal plane is obtained with an hydraulic link between the master cylinder 12 and the
slave cylinder 13.
NOTE: The master cylinder 12 is not powered, its purpose is only to acquire boom swinging movements and
keep parallelism.
The articulations are featured with adjustable expendable pin sets.

2. CHECK WELDING CONDITION USING CRACK DETECTOR PRODUCTS

Stress, vibrations, impacts, corrosive agents could cause invisible cracks in weldings. Then it is extremely
important to checks them in order to prevent breakdowns, accidents and injuries risks.

72
3. CONTROL/ADJUSTMENT OF CLEARANCE BETWEEN ARMATURE AND
EXTENSION TUBE

Gap check
• Line up the boom horizontally and align it with jumbo’s axis.
• Remove plate 1 and dust seal 2.
• Fully extend the tube and clean it.
• Gauge the gap A between tube and armature.
• Sling the end of the tube and raise it.
• Gauge the gap B between tube and armature.
• The clearance between the tube and the armature is
estimated as following:

Skids’s clearance: J= A - B CAUTION:

MAXIMUM CLEARANCE J= 2mm (0.08in)

Untie and let the boom rest by its own weight then remove plate, shims and skids LOWER2
and UPPER1.
• Measure the skid’s thickness, it must be above 27mm (1.08in).
• Measure the shims + skid stack, it must be above 37mm (1.48in)

Minimum thickness of all the skids = 27mm (1.08in) Minimum thickness of shims + skid stack = 37mm (1.48in)
• Replace all the 16 skids if one reaches the minimum thickness.
• It will be helpful to note for the next step: the thickness value of LOWER2 and UPPER1 stacks.

Maximum thickness difference between LOWER2 & UPPER1 stacks must not exceed 3mm (0.12in).
• Reassemble LOWER2 & UPPER1 shims and skids and affix plates.
• Sling the end of the tube and raise it. Remove LOWER1 & UPPER2 skids.
• Check skids condition and replace if they are beyond limits.
• Adjust shim stack in order to have the same thickness for LOWER1 & LOWER2. Then Adjust shim
stack in order to have the same thickness for UPPER1 & UPPER2.

This levelling ensure a good parallelism between tube and armature axis.
• Refit all parts and check J clearance, if it stays beyond limit value put shims on UPPER1 &
UPPER2 stacks. (There are two type of shims: 0.5mm (0.02in) and 1mm (0.04in)).

73
NOTE: Tighten plates screws at 150Nm (110.55ft.lbs) torque.
• Lubricate tube and proceed following tests:
Extend and retract tube in horizontal position. Gauge hydraulic operating pressure needed in cylinder
while operating backward and forward movements.
Max. pressure for forward translation: 120bar (2175psi) Max. pressure for backward translation:
180bar (2610psi)
• In overpressure situation, free the tube translation by removing a 0.5mm (0.02in) shim in
UPPER1 & UPPER2 stacks.

Proceed similar operations for lateral clearance adjustment.

74
MODULE 6 - DRILLING

1. SAFETY

Always follow WARNING- marked instructions. Do all your work carefully.

Do not touch pressurised hydraulic hoses. They may have unnoticeable cracks letting out thin
sprays of oil that may penetrate through the skin.

The oil circulating in the hydraulic system is hot enough to cause severe burns on the skin.

Take care of waste oil according to the local regulations.

Observe absolute cleanliness when disassembling or assembling hydraulic equipment.

Blow all parts clean with pressurised air and wipe them with clean, non-fluffy cloth
before assembling.

Service and adjustment procedures are only allowed to persons who have been given specific
service training. Read the control panel adjusting instructions before making any adjustments
on it.

75
2. CONTROLS OF THE THC 561 DRILLING SYSTEM

1 TFX - control switch (S80)

2 Water mist flushing potentiometer (S76) (optional)
3 Joystick of Two Rod System (S702) A) Push lever forwards to close clamping device.
B) Push lever right to withdraw rod handler.
C) Pull lever backwards to open clamping device.
D) Push lever left to extend rod handler.
4 Flushing flow control selector switch (S79) A) Water flushing flow control ON
(optional feature) B) Flushing flow control OFF
C) Air mist flushing flow control ON
5 SLU oil flow / air pressure error / stabiliser Indicator light is on (continuous) if SLU oil flow /
pressure low indicator light (H72) air pressure error occurs.
Indicator light is on (flashing) if stabiliser pressure
is too low or too high.
6 Emergency stop button (S77) Stops all electric motors and the diesel engine.
7 Power extractor push button (S90) (optional)
8 Water mist flushing selector switch (S75)
(optional)
9 PITO -control switch (S700) A) PITO close
B) PITO open
10 Power pack start/stop switch (S78) A) Turn the switch into the START-position and
release to start the power pack.
B) Power-pack running
C) Turn the switch into the 0-position to stop the
power pack.

76
11 Return automatics switch with air blowing (S74) * M) Manual
A) Automatic
B) Forced return
12 Return automatics switch (S73) * M) Manual
A) Automatic
B) Forced return
13 Boom lift and swing lever A) Boom lowering
B) Boom swing right
C) Boom lifting
D) Boom swing left
14 Boom zoom and boom head rotation lever A) Boom zoom out
B) Boom head rotation clockwise
C) Boom zoom in
D) Boom head rotation counter-clockwise
15 Feed tilt and swing lever A) Feed tilt down
B) Feed swing right
C) Feed tilt up
D) Feed swing left
16 Feed transfer and extra tilt lever A) Feed transfer forwards
B) Bolting cylinder in
C) Feed transfer backwards
D) Bolting cylinder out
17 Bolting percussion control lever (optional) Pull lever backwards to control bolting percussion
on.
18 Rotation control lever (S72) A) Push lever forwards to rotating clockwise
(thread opening).
B) Pull lever backwards to rotating counter-
clockwise (drilling).
19 Percussion control lever (S70) A) Push lever forwards for full percussion (used to
loosen the bit).
B) Pull lever backwards to activate percussion in
drilling.
20 Feed control lever (S71) A) Push lever forwards to activate feed
backwards.
B) Pull lever backwards to activate feed forwards.
21 Rotation speed control knob Turn clockwise to increase rotation speed.
Turn counter-clockwise to decrease rotation
speed.
22 Flushing control lever A) Push lever forwards to activate air flushing.
B) Pull lever backwards to activate water flushing.
23 Fast feed control lever A) Push lever forward to activate fast feed
backwards.
B) Pull lever backwards to activate fast feed
forwards.
24 Feed force regulating knob A) Turn clockwise to increase feed and percussion
pressure.
B) Turn counter-clockwise to decrease feed and
percussion pressure.
77
 25 Feed deviation knob (on the front wall of the A) Turn clockwise to increase feed force, i.e. to
panel) decrease the pressure difference between
percussion and feed.
B) Turn counter-clockwise to decrease feed
force, i.e. to increase the pressure difference
between percussion and feed.

* Function of the switches 11 (S74) and 12 (S73)

• Basic situation when S73 is in use and S74 is off

-- S73 (position M) and S74 (position M) = Automatic return is not in use
-- S73 (position A) and S74 (position M) = Automatic return from the front limit and without
returning delay
-- S73 (position B) and S74 (position M) = Forced return without air blowing and without returning
delay
• Basic situation in air blowing when S74 is in use and S73 is off
-- S74 (position A) and S73 (position M) = Automatic return from the front limit after the air blowing
-- S74 (position B) and S73 (position M) = Forced return after the air blowing
• Situation when both of the switches S73 and S74 are in use
-- S73 (position A) and S74 (position A) = Automatic return from the front limit with the air blowing
and without returning delay
-- S73 (position B) and S74 (position A) = Forced return with the air blowing and without returning
delay
-- S73 (position A) and S74 (position B) = Forced return with the air blowing and without returning
delay

78
 7.3.

216

ID: 34501
58 14 31 102 33
20
51 11 21
61 62
103 220
44
32

59

60

221 222

Figure: Free circulation

3. HYDRAULIC DIAGRAM

28
100
13
Testing and adjusting

130 129
54 101

137
Free circulation ID: 34440

143
140
141
138 42
142
145 7 10

144
211
8 18

124 5
126
118 119 30 9
120 121 52 24
125 123 26 6
57
55 65 3
127 4
205 53
56 29
25 23 43
139 16 15
22 2

210

12

37 112
115 36
35 209 117 116
208
38
135
1 50
207
315
34
206 39

122
131
200
111

202 110 113

79
3.1 COMPONENTS

1 Variable displacement pump Output for percussion, feed, boom hydraulics, and
pilot control
2 Percussion line pressure compensator Keeps percussion pressure constant, irrespective
of variations in input pressure
3 Percussion main valve Controls oil flow to rock drill, controlled by
percussion selector valve (4)
4 Percussion selector valve Opens and closes percussion main valve (3)
according to pilot control valve (14)
5 Percussion pressure selector valve Selects half or full power percussion
6 Percussion half-power pressure relief valve Determines pressure level for percussion half
power
7 Percussion max. pressure relief valve Determines percussion max. pressure
8 Rattling on/off valve Switches off feed-percussion monitoring
9 Orifice Restricts oil flow in percussion LS line
10 Shuttle valve Directs percussion, feed, or boom LS signal to
variable displ. pump
11 Percussion pressure gauge Indicates percussion line pressure
12 Pressure switch Switches on percussion hour meter and controls
SLU air line on/off valve
13 Percussion mechanism
14 Percussion pilot control valve Turns percussion on for drilling and thread-
loosening
15 Shuttle valve Directs pressure from percussion pilot valve (14)
to percussion selector valve (4)
16 Shuttle valve Directs pressure from percussion pilot valve (14)
or feed pilot valve (31) to percussion pressure
selector valve (5)
18 Monitoring valve Determines min. percussion pressure when drilling
at full power and generates feed/percussion
monitoring
20 Feed pressure regulating valve Determines feed pressure for collaring and in
full power drilling, affects not only feed pressure
but also percussion pressure (feed/percussion
monitoring)
21 Feed pressure gauge Indicates feed pressure
22 Feed line pressure compensator Keeps feed pressure constant, irrespective of
input pressure variations
23 Feed directional valve Directs oil flow to feed according to pilot valves
(31) and (33)
24 Feed line B max. pressure relief valve
25 Feed line A max. pressure relief valve
26 Shuttle valve Directs oil flow in LS line of feed directional valve
28 Feed cylinder
29 Feed LS line selector valve Selects normal feed pressure or fast feed pressure
according to pilot valves (31) and (33)
30 Fast feed max. pressure relief valve Determines max. pressure for fast feed movement

80
31 Feed pilot control valve Determines feed speed and direction, and sets
percussion to full power for drilling
32 Selector valve for feed LS line return circuit Selects correct return line automatically for
forward/reverse feed
33 Fast feed pilot control valve Determines fast feed speed and direction
34 Anti-jamming valve Controls feed direction in an anti-jamming
situation
35 Shuttle valve Directs pressure information of feed pilot valve
(31) to percussion pressure selector valve (5) and
to feed LS line selector valve (29)
36 Shuttle valve Directs pressure information of feed pilot valve
(31) to percussion pressure selector valve (5) and
to feed LS line selector valve (29)
37 Shuttle valve Directs pressure information of feed pilot valve (31)
or fast feed control valve (33) to feed directional
valve (23) (reverse feed)
38 Shuttle valve Directs pressure information of feed pilot valve
(31), fast feed pilot valve (33), or return automatics
selector valve (39) to feed directional valve (23)
39 Return automatics selector valve Controls feed directional valve (23) according to
the value set by pilot pressure regulating valve (43)
42 Shuttle valve Directs LS signal of feed or boom circuit to variable
displ. pump
43 Pilot pressure regulating valve Sets pilot circuit pressure
44 Directional valve Directs oil flow into the tank or into the feed circuit
50 Variable displacement pump Output of oil flow to rotation circuit
51 Rotation pressure gauge Indicates rotation pressure
52 Pressure compensator
53 Rotation directional valve Controls oil flow to rotation motor (54)
54 Rotation mechanism
55 Regulating valve Controls oil flow of rotation valve into tank during
stand-by-situation and during rotation control.
Determines max. pressure of rotation circuit.
56 Flow regulator LS-pressure relieving valve
57 Non-return valve Prevents oil flow back to pump (50)
58 Rotation pilot control valve Determines direction of rotation
59 Rotation speed regulating valve Sets rotation speed to desired value
60 Shuttle valve Directs pilot control pressure info to rot. speed
regul. valve (59)
61 Orifice Restricts oil flow to directional valve of rotation
(53) and to rotation speed regulating valve (59)
62 Orifice Restricts oil flow to directional valve of rotation
(53) and to rotation speed regulating valve (59)
65 Rotation LS-pressure relief valve
100 Water control valve Controls water flow to rock drill
101 Air control valve Controls air flow to rock drill
102 Selector valve for separate flushing Opens/closes water or air control valve

81
103 Shuttle valve Activates either automatic or separate water
flushing
110 Hydraulic oil tank
111 Hydraulic oil temperature gauge
112 Pressure filter Filters oil coming from variable displacement
pump (1)
113 Return oil filter Filters return oil coming from drilling and carrier
hydraulics
115 Collecting piece For drilling and carrier hydraulics return flows
116 Non-return valve Prevents oil flow back to variable displacement
pump
117 Non-return valve Prevents oil flow from drilling control circuit to
carrier circuit
118 Pressure relief valve Determines pressure level for rear limit impulse
cylinder
119 Pressure relief valve Determines pressure level for front limit impulse
cylinder
120 Orifice Stabilizes rear limit impulse cylinder pressure
121 Orifice Stabilizes front limit impulse cylinder pressure
122 Air filter / hydraulic tank
123 Pressure switch Monitors pressure of the front limit impulse
cylinder
124 Non-return valve Prevents return flow from front limit impulse
cylinder
125 Pressure switch Monitors pressure of the rear limit impulse cylinder
126 Non-return valve Prevents return flow from rear limit impulse
cylinder
127 Pressure regulator / relief valve Limits supply pressure for front and rear limit
impulse circuit
129 Front impulse cylinder
130 Rear impulse cylinder
131 Pressure switch Monitors pressure difference over the return oil
filter (113)
135 Collecting piece For non-pressure circuit hydraulic return flows
137 Pressure switch (optional) Monitors stabiliser maximum pressure (130 bar)
138 Pressure switch (optional) Monitors stabiliser minimum pressure (15 bar)
139 Shuttle valve Directs rotation pressure to control block of return
automatics
140 Directional control valve (optional) Closes the stabiliser pressure line and releases
stabiliser pressure to tank when rattling is on
141 Pressure reducing / relieving valve (optional) Controls stabiliser pressure and determines
maximum pressure level for stabiliser
142 Monitoring valve (optional) Monitors feed pressure and controls the valve
(141)
143 Orifice (optional) Supplies oil flow to the pilot control circuit of
valves (141) and (142)
144 Directional control valve (optional) Sets feed pressure monitoring for stabiliser off and
sets minimum pressure to stabiliser in collaring

82
145 Pressure reducing valve (optional) Sets fixed reference pressure to the monitoring
valve (142)
200 Oil level indicator
202 Drain cock Drain water content of oil
205 Pressure switch Monitors rotation pressure and controls SLU air
line on/off valve
206 Anti-jamming valve of flushing control (optional Controls anti-jamming valve (34) and directs LS
feature) signal to variable displ. pump (1)
207 Shuttle valve Directs anti-jamming pressure information from
rotation circuit or anti-jamming valve of flushing
control (206) to anti-jamming valve (34)
208 Shuttle valve Directs LS signal of anti-jamming valve of flushing
control (206) or drilling/boom circuit to variable
displacement pump (1)
209 Air blowing automatics on/off valve Directs pilot pressure to air control valve (101)
when using return automatics with air blowing
automatics
210 Pressure reducing/relieving valve of the boom Reduces maximum pressure for boom circuit
circuit
211 Main pressure relief valve Limits drilling and boom circuit maximum pressure
212 Power extractor pressure selecting valve Selects power extractor pressure adjusting line
(optional)
213 Power extractor pressure relief valve (optional) Determines power extractor pressure level
214 Power extractor mechanism (optional)
215 Power extractor on/off valve (optional) Controls the oil flow to power extractor
216 Feed deviation valve Reduces or increases feed force regardless of
percussion pressure
217 Pressure switch (optional) Recognises when flushing is switched on (when
air-mist flushing is on)
218 Air-mist flushing selector valve Prevents pilot pressure to open water control
valve (100) when air-mist flushing is selected
220 Shuttle valve Directs pressure information of selector valve of
separate flushing (102) or air blowing automatics
on/off valve (209) to air control valve (101)
221 Drilling module movement prevention valve Cuts off the feed pressure from the pilot-control
(pilot-control valve line) valves
222 Drilling module movement prevention valve Cuts off the boom pressure line
(boom line)
315 Cooler Oil cooler for drilling and carrier hydraulics return
flows

83
4. HYDRAULIC COMPONENTS

4.1 GENERAL

The return automatics system has been controlled by impulse cylinders. Before any maintenance or adjusting
operations, identify the construction of the return automatics.
(See the picture).

4.2 LAY-OUT OF THE VALVE BLOCKS

1 Pressure switches percussion,

rotation, stabiliser [option])
2 Impulse cylinders control block
3 Rotation control block
4 Percussion and feed control
block
5 Anti-jamming and return
automatics control block
6 Stabiliser control block (option)
7 Double-flushing valves
8 Pressure-controlled non-return
valve
9 Shuttle valve

84
4.3 PERCUSSION AND FEED CONTROL BLOCK

No Component Tightening torque

[Nm] (for the cap)
2 Percussion line pressure compensator 40
6 Percussion half-power pressure relief valve 33.9
7 Percussion max. pressure relief valve 33.9
9 Orifice
10 Shuttle valve 33.9
15 Shuttle valve 33.9
16 Shuttle valve 33.9
23 Feed directional valve 22
25 Max. pressure relief valve for feed line A 40
43 Pilot pressure regulating valve 33.9
210 Pressure reducing/relieving valve of the boom circuit 60
213 Power extractor pressure relief valve (optional) 33.9

85
No Component Tightening torque Tightening torque
[Nm] (for the cap) [Nm] (for the coil)
3 Percussion main valve 240
4 Percussion selector valve 33.9
5 Percussion pressure selector valve 33.9
8 Rattling on/off valve 33.9
18 Monitoring valve 33.9
24 Max. pressure relief valve for feed line B 40
29 Feed LS line selector valve 33.9
30 Fast feed max. pressure relief valve 33.9
42 Shuttle valve 33.9
211 Main pressure relief valve 33.9
212 Power extractor pressure selecting valve (optional) 33.9 6.8
215 Power extractor on/off valve (optional) 56 8

86
4.4 ANTI-JAMMING AND RETURN AUTOMATICS CONTROL BLOCK

No Component Tightening torque Tightening torque

[Nm] (for the cap) [Nm] (for the coil)
34 Anti-jamming valve 8.9
35 Shuttle valve 33.9
36 Shuttle valve 33.9
37 Shuttle valve 33.9
38 Shuttle valve 33.9
39 Return automatics selector valve 33.9 6.8
206 Anti-jamming valve of flushing control 33.9 6.8
207 Shuttle valve 33.9
208 Shuttle valve 33.9
209 Hole blowing automatics on/off valve 33.9 6.8

4.5 ROTATION CONTROL BLOCK

No Component Tightening torque

[Nm] (for the cap)
52 Pressure compensator 70
53 Rotation directional valve
55 Regulating valve 100
56 Flow regulator 20
57 Non-return valve 15
65 LS-pressure relief valve 45

87
4.6 FEED PRESSURE CONTROL BLOCK

No Component Tightening torque

[Nm] (for the cap)
20 Feed pressure regulating valve 33.9

4.7 FEED DEVIATION CONTROL BLOCK

No Component Tightening torque

[Nm] (for the cap)
32 Return circuit selector valve for feed LS line 33.9
44 Directional valve 33.9
216 Feed deviation valve 33.9

88
4.8 ROTATION SPEED ADJUSTING BLOCK

No Component Tightening torque

[Nm] (for the cap)
59 Rotation speed regulating valve 33.9
60 Shuttle valve 33.9

4.9 IMPULSE CYLINDERS CONTROL BLOCK

No Component Tightening torque

[Nm] (for the cap)
118 Pressure relief valve (rear) 22
119 Pressure relief valve (front) 22
120 Orifice / impulse circuit (rear) 10
121 Orifice / impulse circuit (front) 10
123 Pressure switch (front)
124 Non-return valve (front) 20
125 Pressure switch (rear)
126 Non-return valve (rear) 20
127 Pressure regulator / relief valve 65
139 Shuttle valve

89
4.10 STABILISER CONTROL BLOCK (OPTION)

No Component Tightening torque

[Nm] (for the cap)
140 Directional control valve 33.9
141 Pressure reducing / relieving valve 60
142 Monitoring valve 33.9
143 Orifice
144 Directional control valve 33.9
145 Pressure reducing valve 33.9

4.11 DRILLING MODULE MOVEMENT PREVENTION VALVE BLOCK

No Component Tightening torque Tightening torque

[Nm] (for the cap) [Nm] (for the coil)
221 Drilling module movement prevention valve (pilot- 33.9 6.8
control valve line)
222 Drilling module movement prevention valve (boom 40.7 13.5
line)

90
5. OPERATION OF THE SYSTEM

5.1 OIL TEMPERATURE OF DRILLING

After cold start, hydraulic oil should be warmed up to drilling temperature before drilling is started. This can be
accomplished, for instance, by using an electric oil heater in the tank. The recommended oil temperature of
the drilling is between 40-60 degrees (depending on the type of the oil).

5.2 READING DIAGRAMS

The following colours have been used in hydraulic diagrams for explaining different drilling operations.

Blue Percussion Dash blue --- --- --- --- Percussion return line
Short dash blue --------- Percussion LS-line
Red Feed Dash red --- --- --- --- Feed return line
Short dash red --------- Feed LS-line
Short dash pink --------- Feed deviation LS-
line
Green Rotation Dash green --- --- --- --- Rotation return line
Short dash - - - - - - - - - Rotation LS-line
green
Yellow Pilot control Dash yellow --- --- --- --- Pilot return line
Short dash - - - - - - - - - Pilot line
yellow
Violet Stabiliser Dash violet --- --- --- --- Stabiliser return line
Brown Return automatics Dash brown --- --- --- --- Return automatics
return line

5.2.1 VALVES

The number of the coil is coloured red when the coil is activated.

91
92
30 (116)
216

ID: 34501
58 14 31 102 33
5.3 FREE

20
51 11 21
61 62
103 220
44
32

59

60

221 222

Figure: Free circulation

7.3. CIRCULATION

28
100
13
Testing and adjusting

130 129
54 101

137
Free circulation ID: 34440

143
140
141
138 42
142
145 7 10

144
211
8 18

124 5
126
118 119 30 9
120 121 52 24
125 123 26 6
57
55 65 3
127 4
205 53
56 29
25 23 43
139 16 15
22 2

210

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34
206 39

122
131
200
111

202 110 113

Free circulation means a situation where the power-pack is running, but no hydraulic actuators are used.

5.3.1 ROTATION CIRCUIT

The variable displacement pump (50) takes oil in from the tank (110), through the intake connection (B), and
pumps it into the rotation circuit. As there is no consumption of oil in the rotation circuit, it means that there is
no pressure in the load sensing line. The swash plate of the pump (50) is at 0 angle and the pump (50) maintains
a free circulation pressure in the pressure line. The stand-by pressure is regulated by the flow controller of the
pump (50).

5.3.2 PERCUSSION AND FEED CIRCUITS

The variable displacement pump (1) takes oil in through the intake connection of the tank (110) and pumps it
into the percussion and feed circuits. As there is no consumption of oil in these circuits during free circulation,
it means that there is no pressure in the load sensing line, either. The swash plate of the pump (1) is at 0 angle
and the pump (1) is merely maintaining a certain pressure (stand-by pressure) in the pressure line. The stand-
by pressure is regulated by the flow controller of the pump (1).

The pressure regulator / relief valve (43) regulates the pilot line pressure.

5.3.3 PILOT CIRCUIT

The variable displacement pump (1) takes oil in through the intake connection of the tank (110) and pumps it
into the pilot circuit via the pilot pressure regulating valve (43) which regulates the pilot line pressure. After the
pilot pressure regulating valve (43) oil flows to the pilot control valves (14, 31, 33, 58 and 102) via the drilling
module movement prevention valve (221). Oil flows also to the return automatics selector valve (39) and the
air blowing on/off valve (209).

93
94
32 (116)
7.4.

216

ID: 34502
58 14 31 102 33
20
51 11 21
61 62
103 220
44
32
5.4 ROTATION

59

Figure: Rotation
60

221 222

28
Rotation ID: 34442

100
13
Testing and adjusting

130 129
54 101

137

143
140
141
138 42
142
145 7 10

144
211
8 18

124 5
126
118 119 30 9
120 121 53 52 24
125 123 26 6
55 65 57 3
127 4
205
56 29
25 23 43
139 16 15
22 2

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115 36
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208
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1 50
207
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34
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122
131
200
111

202 110 113

When the control lever of the rotation pilot control valve (58) is locked into a back position (rotation to counter-
clockwise), pilot pressure will be able to affect the port a of the rotation directional valve (53) and to the port
P1 of the rotation speed regulating valve (59).

The oil produced by the variable displacement pump flows now to the port P of the rotation directional valve
(53). From there the oil flows through the rotation directional valve (53), pressure compensator (52), non-return
valve (57), again through the rotation directional valve (53) to the rock drill rotation motor (54). The oil flows also
from the port P to the regulating valve (55), the rotation pressure gauge (51), the anti-jamming valve (34) via
the shuttle valve (207).

Through the pressure compensator (52) the oil flows into the LS-line of the rotation directional valve (53). The oil
flows also to the LS-pressure relief valve (65), to the regulating valve (55) and to the port X of the flow regulator
of the variable displacement pump (50). In this situation the flow regulator of the variable displacement pump
(50) is activated and it tries to keep the pressure in the main pressure line P always 20-23 bar (depending
on the adjustment) higher than LS-line pressure (= load pressure) resulting a constant pressure difference
over the rotation directional valve (53). This means also constant rotation oil flow to the rotation motor set
by the regulating valve (59). The function of the flow regulator (56) is to unload the LS-line after stopping the
movement and centring the main spool. The flow regulator (56) is a small pressure compensated flow control
valve with a flow approximately 1 l/ min.

The return flow from the rotation motor (54) passes through the rotation directional valve (53), the collecting
piece (115), the cooler (315), and the return oil filter (113), and ends up into pressurised chamber of oil tank
(110).

The leak oil from rotation pilot control valve (58) and rotation speed regulating valve (59) will be first directed to
the collecting piece (135) and from there into unpressurised chamber of oil tank (110).

Oil flows also from the connection M of the rotation directional valve (53) through the shuttle valve (139) to the
connection P of the control block of return automatics. From there oil flows through the pressure reducing
and relieving valve (127) and the check valve (124) to the pressure switch (123), to the pressure relief valve
(119) and to the front impulse cylinder (129), through the check valve (126) to the pressure switch (125), to the
pressure relief valve (118) and to the rear impulse cylinder (130). Oil flows also through the orifices (121) and
(120) to the oil collector (135). From there oil flows into unpressurised chamber of oil tank (110).

When using rock drill with stabiliser oil flows also from the connection (P2) of the drilling control block to
the connection (P) of the stabiliser control block. From there oil flows to the pressure reducing valve (145) and
the pressure reducing/relieving valve (141). From here the oil continues to flow to the directional control valve
(140) and the stabiliser of the rock drill. Oil also affects to the monitoring valve (142), the directional control
valve (144) and the pressure switches (137) and (138).

95
96
34 (116)
7.5.

216

ID: 34503
58 14 31 102 33
5.5 FEED

20
51 11 21
61 62
103 220
44
32

59

Figure: Feed
60
Feed ID: 34443

221 222

28
100
13
Testing and adjusting

130 129
54 101

137

S126.2 143
140
141
138 42
142
145 7 10

144
211
8 18

124 5
126
118 119 30 9
120 121 52 24
125 123 26 6
57
55 65 3
127 4
205 53
56 29
25 23
43
139 16 15
22 2

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1 50
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122
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202 110 113

When the control lever of the feed pilot control valve (31) is locked into a back position (feed forward), pilot
control pressure will be able to affect to control line d of the feed directional valve (23) through the anti-jamming
valve (34) and the shuttle valve (36). In addition, the pilot pressure affects to the feed LS line selector valve (29)
through the shuttle valve (35), and to the percussion pressure selector valve (5) through the shuttle valve (16).
The pilot pressure affects also to the directional valve (44) via shuttle valve (35).

The oil produced by the variable displacement pump (1) flows through the non-return valve (116) and the
pressure filter (112) to the anti-jamming valve of flushing control (206) and the port P1 of control block of
drilling . From here the oil continues to flow through the feed line pressure compensator (22) to the control
spool of feed directional valve (23) and from there to the feed line A max. pressure relief valve (25) and through
the connector A to the feed cylinder (28).

From feed directional valve (23) oil flows also to the spring housing of the feed line pressure compensator (22)
and through the shuttle valve (26) and the feed LS line selector valve (29) to the feed pressure regulating valve
(20) and feed deviation valve (216). After the shuttle valve (26) the oil is able also to flow to the feed pressure
gauge (21), the monitoring valve (18) and through the shuttle valves (42), (10) and (208) to the flow control
valve of variable displacement pump (1).

From connector P1 of control block of drilling the oil is able to flow to the pilot pressure regulating valve (43),
the drilling module movement prevention valve (221) and from there to the rotation pilot control valve (58),
the percussion pilot control valve (14), the feed pilot control valve (31), the selector valve for separate flushing
(102), the fast feed pilot control valve (33) the return automatics selector valve (39) and the hole blowing
automatics on/off valve (209).

Oil from the feed cylinder (28) flows to the connection B of feed directional valve (23) and from there to feed
line B max. pressure relief valve (24). From here oil flows through the tank connector T3 of control block of
drilling to the collecting piece (115), via the oil cooler (315) to the return oil filter (113) and the oil tank (110).

The leak oil from the feed pilot control valve (31) is first directed to the collecting piece (135) and from there
to the hydraulic oil tank (110).

When using rock drill with stabiliser oil flows also from the connection (P2) of the drilling control block to the
connection (P) of the stabiliser control block. From there oil flows to the pressure reducing valve (145) and
the pressure reducing/relieving valve (141). From here the oil continues to flow to the directional control valve
(140) and the stabiliser of the rock drill. Oil also affects to the monitoring valve (142), the directional control
valve (144) and the pressure switches (137) and (138).

97
98
36 (116)
7.6.

216

ID: 34504
58 14 31 102 33
20
51 11 21
61 62
103 220
44
32

59
5.6 PERCUSSION

60

221 222

28
100
13
Testing and adjusting

130 129
54 101
Percussion ID: 34444

Figure: Percussion half-power

137

143
140
141
138 42
142
145 7 10

144
211
8 18

124 5
126
118 119 30 9
120 121 52 24
125 123 26 6
57
55 65 3
127 4
205 53
56 29
25 23 43
139 16 15
22 2

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1 50
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122
131
200
111

202 110 113

When the percussion pilot control valve (14) is locked into the back position, pilot control pressure affects the
water control valve (100) through the shuttle valve (103), and turns water flushing on.

Pilot control pressure also activates the pressure switch (12) of the operating hour meter, and affects the
percussion selector valve (4) through the shuttle valve (15). The percussion selector valve (4) opens the
percussion main valve (3), and the output of the variable displacement pump flows through the non-return
valve (116), the pressure filter (112), the compensator (2), and the percussion main valve (3) to the percussion
mechanism (13). In addition, the percussion circuit pressure reaches the pressure relief valve (6) for half-power
percussion, passing through the orifice (9) and the percussion pressure selector valve (5). After the orifice (9),
the pressure also affects the pressure compensator (2), the percussion max. pressure relief valve (7), the
rattling on/off valve (8), the monitoring valve (18), and reaches the load-sensing line of the variable displacement
pump (1) through the shuttle valves (10) and (208). The pressure also affects to the main pressure relief valve
(211) and the pressure reducing/relieving valve of the boom circuit (210).

The pressure after the percussion main valve (3) also affects the percussion pressure gauge (11). The pressure
after the pressure filter (12) also affects the anti-jamming valve of flushing (206). The return flow from the rock
drill (13) passes via the collecting piece (115), the cooler (315), and the return oil filter (113) to the hydraulic oil
tank (110). Leak oil from the percussion pilot control valve (14) is directed first to the collecting piece (135) and
from there to the hydraulic oil tank (110).

When using rock drill with stabiliser oil flows also from the connection (P2) of the drilling control block to
the connection (P) of the stabiliser control block. From there oil flows to the pressure reducing valve (145) and
the pressure reducing/relieving valve (141). From here the oil continues to flow to the directional control valve
(140) and the stabiliser of the rock drill. Oil also affects to the monitoring valve (142), the directional control
valve (144) and the pressure switches (137) and (138).

99
100
38 (116)
7.7.

216

ID: 34505
58 14 31 102 33
20
51 11 21
61 62
103 220
44
32

59
5.7 COLLARING

Figure: Collaring
60

221 222

28
100
13
Collaring ID: 34447
Testing and adjusting

130 129
54 101

137

S126.2 143
140
141
138 42
142
145 7 10

144
211
8 18

124 5
126
118 119 30 9
120 121 53 52 24
125 123 26 6
55 65 57 3
127 4
205 29
56
25 23
43
139 16 15
22 2

210

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202 110 113

Collaring is composition of rotation, feed and percussion.

With the THC 561 system, collaring can be done accurately and smoothly by using the stepless feed and
rotation speed, and feed pressure adjustments. In collaring, feed and percussion are connected in parallel.

The control lever of feed pilot control valve (31) is used for selecting collaring and full-power drilling. The lever
offers two operating ranges: half-power and full-power drilling. On the lever movement, these two ranges are
separated from one another by a noticeable step. Full-power drilling starts when this step is passed.

Drilling is started by locking the levers of the pilot control valves for rotation (58) and percussion (14) into the
back position. When the lever for the feed pilot control valve (31) is pulled backwards, the rock drill moves at
the desired speed until the drill bit has sufficiently penetrated the rock. Full-power drilling is started by locking
the control lever of the feed pilot control valve (31) into the back position.

Another method for collaring is to turn the feed pressure regulating valve (20) fully open (counter-clockwise)
and then lock all three control levers (rotation, percussion and feed) into the back position. Drilling starts now
with half power, and continues so until the drilling values are returned to correspond to full-power drilling by
turning the feed pressure regulating valve (20). In this collaring method, percussion and feed are also all time
connected in series.

When using rock drill with stabiliser oil flows also from the connection (P2) of the drilling control block to
the connection (P) of the stabiliser control block. From there oil flows to the pressure reducing valve (145) and
the pressure reducing/relieving valve (141). From here the oil continues to flow to the directional control valve
(140) and the stabiliser of the rock drill. Oil also affects to the monitoring valve (142), the directional control
valve (144) and the pressure switches (137) and (138). The directional control valve (144) is active during
collaring, so the stabiliser pressure does not follow the feed pressure (stabiliser pressure is minimum).

101
102
40 (116)
7.8.

216

ID: 34506
58 14 31 102 33
20
51 11 21
61 62
103 220
44
32
5.8 DRILLING

59

Figure: Drilling
60

221 222
Drilling ID: 34448

28
100
13
Testing and adjusting

130 129
54 101

137

S126.2 143
140
141
138 42
142
145 7 10

144
211
8 18

124 5
126
118 119 30 9
120 121 53 52 24
125 123 26 6
55 65 57 3
127 4
205 29
56
25 23
43
139 16 15
22 2

210

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115 36
35 209 117 116
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1 50
207
315
34
206 39

122
131
200
111

202 110 113

After successful collaring, full-power drilling is started by locking the control lever of the feed pilot control
valve (31) into the back position. The percussion pressure selector valve (5) changes its position and closes
a connection through the percussion half-power pressure relief valve (6). Oil flows furthermore through the
rattling on/off valve (8), the collecting piece (115) and cooler (315) to the pressurised tank (110). Feed pressure
is directed to monitoring valve (18), which then controls percussion pressure as a function of feed pressure.

The pressure difference between feed and percussion is determined by feed deviation valve (216) and the
monitoring valve (18). The min. pressure of percussion is determined by the monitoring valve (18). The max.
pressure of percussion is determined by the percussion max. pressure relief valve (7).

When using rock drill with stabiliser oil flows also from the connection (P2) of the drilling control block to the
connection (P) of the stabiliser control block. From there oil flows to the pressure reducing valve (145) and
the pressure reducing/relieving valve (141). From here the oil continues to flow to the directional control valve
(140) and the stabiliser of the rock drill. Oil also affects to the monitoring valve (142), the directional control
valve (144) and the pressure switches (137) and (138).

5.8.1 FEED-PERCUSSION MONITORING

Basic principle of feed-percussion monitoring is that the percussion pressure is adjusted as a function of feed
pressure.

With the help of the feed deviation it is also possible to:

• Compensate frictions of the feed beam
• Compensate the mass of the drilling equipment in uphole and downhole drilling
• Compensate the feed force suitable for different feed models
• Change the feed force suitable for different rock drill models
• React to feed-percussion monitoring ratio in different rock conditions

Function of feed-percussion monitoring

FIGURE: PERCUSSION PRESSURE BEHAVIOUR AS

A FUNCTION OF FEED PRESSURE

103
Feed pressure varies during drilling depending on the rock conditions (soft rock, fragmented rock, cavity).
During drilling operator restricts feed max. pressure with the feed force regulating knob (20).

Feed pressure rises for that value at the maximum. Percussion pressure follows feed pressure with a certain
ratio (determined by the monitoring valve). Operator determines the starting moment of the feed-percussion
monitoring with the feed deviation knob (216). By increasing the feed deviation i.e. turning the knob clockwise
feed force increases without changes in percussion pressure. By decreasing the feed deviation i.e. turning the
knob counter-clockwise feed force decreases without changes in percussion pressure.

FIGURE: DRILLING BEHAVIOUR

Factory setting of the feed deviation

RD525
• Percussion 210 bar
• Feed
-- TF500 115 bar
-- TFX500 130 bar
• TFX500 upper cylinder back pressure approx. 30 bar

RD520/HLX5
• Percussion 210 bar
• Feed
-- TF500 105 bar
-- TFX500 120 bar
• TFX500 upper cylinder back pressure approx. 30 bar

To the required feed force affect:

• Rock drill model
• Rock conditions

To the required feed pressure affect:

• Feed model (TF/TFX)
• Frictions of feed beam
• Mass of the drilling equipment, uphole/downhole

104
 44 (116)
7.9.

216

ID: 47040
58 14 31 102 33
20
51 11 21
61 62
103 220
44
32

59
5.9 STABILISER

Figure: Stabilizer
60

221 222

28
100
13
Testing and adjusting

130 129
54 101

137

S126.2 143
140
141
Stabilizer (option) ID: 46918

138 42
142
145 7 10

144
211
8 18

124 5
126
118 119 30 9
120 121 53 52 24
125 123 26 6
55 65 57 3
127 4
205 29
56
25 23
43
139 16 15
22 2

210

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1 50
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315
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200
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202 110 113

105
Stabiliser control block function is to adjust the stabiliser pressure as a function of feed pressure during
drilling. During half-power drilling and collaring stabiliser pressure remains in the minimum. During loosen the
bit function there is no pressure in the stabiliser and stabiliser line has been connected to the tank.

Operation during full-power drilling

When drilling is started oil flows from the variable displacement pump (1) through the non-return valve
(116) and the pressure filter (112) to the port P1 of the percussion and feed control block. From here the oil
continues to flow to the connection P of the stabiliser control block via the port P2 of the percussion and feed
control block. From there oil flows to the pressure reducing valve (145) and the pressure reducing/relieving
valve (141). Pressure reducing/relieving valve (141) adjusts the stabiliser pressure and also limits maximum
stabiliser pressure. From here the oil continues to flow to the directional control valve (140), to the pressure
switches (137) and (138) and the stabiliser of the rock drill. Oil flows also to orifice (143) which supplies oil to
pilot circuit.

Feed pressure affects to the monitoring valve (142) via the directional control valve (144). The monitoring
valve (142) adjusts pilot pressure and according to that pressure reducing/relieving valve (141) adjusts
stabiliser pressure. Pressure reducing valve (145) sets a constant pressure, so called reference pressure, to
the monitoring valve (142). When the feed pressure is lower than adjustment of pressure reducing valve
(145) (e.g. 50 bar), monitoring valve (142) does not control the pressure reducing/relieving valve (141) and
stabiliser pressure stays at minimum level. This feature can be used for example to compensate the mass of
the drilling equipment and the frictions of the feed beam.

Operation during half-power drilling and collaring

During half-power drilling and collaring the directional control valve (144) is activated via port X8. Feed
pressure is not affecting to the monitoring valve (142) and stabiliser pressure stays at minimum level. Minimum
stabiliser pressure is set with spring force of monitoring valve (142).

Operation during loosen the bit

During loosen the bit function the directional control valve (140) is activated via port X7. There is no pressure
in the stabiliser and the oil flows from the stabiliser via the oil collector (115), the oil cooler (315) and the return
oil filter (113) into the hydraulic oil tank (110).

106
 46 (116)
216

ID: 47041
58 14 31 102 33
5.10 7.10.

20
51 11 21
61 62
103 220
44
32
POWER

59
Power

60

221 222

Figure: Power extractor

28
100
13
Testing and adjusting

EXTRACTOR

130 129 214

54 101
extractor

137

143
140
141
138 42
215
(OPTION)

142 213
145 7 10

144
211
8 18
212
124 5
(option) ID: 46919

126
118 119 30 9
120 121 52 24
125 123 26 6
57
55 65 3
127 4
205 53
56 29
25 23 43
139 16 15
22 2

210

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12

37 112
115 36
35 209 117 116
208
38

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135
1 50
207
315
34
206 39

122
131
200
111

202 110 113

107
When using the power extractor, rattling must be switched on by locking the percussion pilot control valve
(14) in the front position. When the power extractor is switched on by pushing the button (S90) on the control
panel, power extractor pressure selecting valve (212) and power extractor on/off valve (215) are activated.
Oil flows to the power extractor mechanism (214) through the percussion line pressure compensator (2),
percussion main valve (3) and power extractor on/off valve (215). Oil flows also through the orifice (9) and
power extractor pressure selecting valve (212) to the power extractor pressure relief valve (213). This valve
(213) determines the power extractor pressure level.

Oil flows also to percussion mechanism (13). When using the power extractor, pressure level for the percussion
and the power extractor is the same. The return oil from the power extractor mechanism flows through the
collecting piece (115) and cooler (315) to the pressurised tank (110).

108
 Testing and adjusting

5.11 DRILLING MODULE

7.11. Drilling MOVEMENT
module PREVENTION
movement prevention ID: 46920

210
43
10
42

12
21

18

50
222

15
4
8

16
5
7
221
11

112

116
9

1
3

117
2
20

13

211

30

29
32
216

26
44

22
23
28

145
141
101

25
144
142
143

24
33

220

140
138
102

137
103

209

39
38
37

35

34
100

36

206
207
31

208
14

111
52
62

54
58

61

53
57
65
51

56

115
55

131
315
205

113
139

122
123

110
60
59

200
121

135
119
129

127
124
126
130

118
120

202
125

ID: 47042

Figure: Drilling module movement prevention

The drilling module movement prevention valves (221) and (222) are activated always when the diesel engine
or power-pack is on. At this situation oil flows through these valves (221) and (222) to the pilot control valves
and the boom valves.
48 (116) Copyright © Sandvik Mining and Construction
ID: 510 1 en 2009-11-18
When the drilling module movement are prevented, valves (221) and (222) change the position and now the
oil flow to the pilot control and boom valves is prevented and oil from the pilot control and boom valves flows
to the tank (110) via drilling module movement prevention valves (221) and (222) and collecting piece (135).

109
110
50 (116)
216

ID: 34507
58 14 31 102 33
20
51 11 21
61 62
103 220
44
32

59

60

221 222

28
100
13
Testing and adjusting

130 129
54 101

Figure: Anti-jamming automatics

137

S126.2 143
140
141
138 42
5.12 ANTI-JAMMING AUTOMATICS

142
145 7 10

144
211
8 18

124 5
126
7.12. Anti-jamming automatics ID: 34449

118 119 30 9
120 121 53 52 24
125 123 26 6
55 65 57 3
127 4
205 29
56
25 23
43
139 16 15
22 2

210

ID: 510 1 en 2009-11-18

12

37 112
115 36
35 209 117 116
208
38

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1 50
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315
34
206 39

122
131
200
111

202 110 113

The anti-jamming system operates in a situation where the rotation pressure of the drill rod rises above a set
value due to, for instance, a fissure in the rock. In this situation, the operation of the hydraulic system differs
from normal as follows:

When rotation pressure rises above the value set with the anti-jamming valve (34), the valve (34) changes
its position. The pilot control pressure now reaches the port c of the feed directional valve (23) through the
shuttle valves (37) and (38). This means that the feed directional valve (23) also changes its position, and feed
pressure enters the feed line B, and feed starts pulling backwards.

Feed pressure also reaches the load-sensing line of the variable displacement pump (1) through the LS
channel of the feed directional valve (23) and the shuttle valves (26), (42), and (10). After the shuttle valve (26),
the pressure in the feed LS line also reaches the pressure gauge (21). As feed backwards is on, the reversing
pressure affects the tank line T1 of the feed deviation control block. In this situation, the feed pressure
regulating valve (20) does not determine the max. reversing pressure but it is determined by the max. pressure
regulating valve (24) of the feed line B of the feed directional valve (23).

During the reversing phase, the rock drill (13) operates with full-power percussion. The percussion pressure
is restricted by the percussion max. pressure relief valve (7). Feed reversing stays on until rotation pressure
drops below the value set with the anti-jamming valve (34). After this, the anti-jamming valve (34) changes
its position and the control pressure from the pilot control valve (31) reaches the control line d of the feed
directional valve (23) through the shuttle valve (36). The feed directional valve (23) changes its position and feed
pressure reaches the feed line A, whereby feed starts forwards. Feed and percussion pressures are lower than
normal, which is caused by the lower feed resistance and the feed/percussion monitoring. Monitoring valve
(18) doesn’t allow the percussion pressure go under the setting value. The feed and percussion pressures
return to their normal set values as the feed resistance rises normal.

The return flow from the rock drill rotation motor (54) passes through the rotation directional valve (53), the
collecting piece (115), the cooler (315), and the return oil filter (113), and ends up into the hydraulic oil tank
(110). The return flow from the percussion mechanism (13) passes through the collecting piece (115), the
cooler (315), and the return oil filter (113), ending up into the hydraulic oil tank (110). The return flow from the
feed cylinder (28) passes through the feed directional valve (23), the collecting piece (115), the cooler (315),
and the return oil filter (113), and ends up into the hydraulic oil tank (110).

The return flow from the control block of return automatics passes through the collecting piece (135) and
ends up into the hydraulic oil tank (110). The leak oil of the pilot control valves (14), (31) and (58) is directed
first to the collecting piece (135) and from there to the hydraulic oil tank (110).

When using rock drill with stabiliser oil flows also from the connection (P2) of the drilling control block to
the connection (P) of the stabiliser control block. From there oil flows to the pressure reducing valve (145) and
the pressure reducing/relieving valve (141). From here the oil continues to flow to the directional control valve
(140) and the stabiliser of the rock drill. Oil also affects to the monitoring valve (142), the directional control
valve (144) and the pressure switches (137) and (138).

111
112
52 (116)
216

ID: 34508
58 14 31 102 33
5.13 7.13.

20
51 11 21
61 62
103 220
44
32

59
FLUSHING

60
Flushing

221 222

28
FLOWflow

100
13
Testing and adjusting

130 129
54 101

137
CONTROL

S126.2 143
140

Figure: Flushing flow control (option)

141
138 42
142
145 7 10

144
211
8 18

124 5
126
9
control(OPTION)

118 119 30
120 121 53 52 24
125 123 26 6
55 65 57 3
127 4
205 29
56
(option) ID: 34484

25 23
43
139 16 15
22 2

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115 36
35 209 117 116
208 38

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34
206 39

122
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200
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Flushing flow control is an optional function. When this function is required, the rig will be supplied with a water
or air flow switch in the flushing circuit. Each boom has its own separate water or air flow switch.

When the water or air flow in the flushing circuit drops below the set value of the flow switch (for example,
due to lack of water or blocked drill bit), the anti-jamming valve of flushing control (206) is activated. Now
oil flows through the anti-jamming valve of flushing control (206) and shuttle valve (207) and gives a pilot
control pressure to an anti-jamming valve (34) which changes its position. The feed pilot control pressure now
reaches the port c of the feed directional valve (23) through the shuttle valves (37) and (38). This means that
the feed directional valve (23) also changes its position, and feed pressure enters the feed line B, and feed
starts pulling backwards until the water or air flow is normal.

Oil flows also to the LS-line of the variable displacement pump (1).

113
114
54 (116)
216

ID: 47760
58 14 31 102 33
5.14 7.14.

20
51 11 21
61 62
103 220
44
32

59
AIR-MIST

60
Air-mist

217

221 222

Figure: Air-mist flushing

218 28
100
FLUSHING

13
130 129
54 101
flushing

137

143
140
141
138 42
(OPTION)

142
145 7 10

144
211
8 18

124 5
(option) ID: 47757

126
118 119 30 9
120 121 52 24
125 123 26 6
57
55 65 3
127 4
205 53
56 29
25 23 43
139 16 15
22 2

210

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12

37 112
115 36
35 209 117 116
208
38

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1 50
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315
34
206 39

122
131
200
111

202 110 113

When drilling with water flushing, pilot pressure reaches the water control valve (100) via the air-mist flushing
selector valve (218) when percussion or separate flushing is switched on.
When drilling with air-mist flushing, air-mist flushing must be switched on with the switch (S75) on the THC-
panel and at the same time air flushing must be switched on by pulling the control lever (102) backwards.

When air-mist flushing is activated, the air-mist flushing selector valve (218) is activated, whereby the pilot
pressure can’t reach the water control valve (100). In this situation the pressure switch (217) reacts and
recognizes that air-mist flushing has to be started. The pressure switch (217) controls (via the relays) the
electrically controlled air-mist valve which lets the small amount of water to mix into air.

115
116
56 (116)
216

ID: 34509
58 14 31 102 33
5.15 7.15.

20
51 11 21
61 62
103 220
44
32
IMPULSE

59

60
Impulse

221 222

28
CYLINDER

Figure: Return automatics

100
13
Testing and adjusting

130 129
54 101
cylinder

137

143
140
141
138 42
142
145 7 10

144
211
8 18
CONTROLLED

124 5
126
118 119 30 9
120 121 53 52 24
125 123 26 6
55 65 57 3
127 4
205
controlled return

56 29
25 23 43
139 16 15
2
RETURN

22

210

ID: 510 1 en 2009-11-18

12

37 112
115 36
automatics

35 209 117 11
208
38

Copyright © Sandvik Mining and Construction

135
1 50
207
315
34 39
AUTOMATICS
ID: 34487

206

122
131
200
111

202 110 113

When return automatics is on and the rock drill reaches
the front limit, starts the return movement, with rotation
turned on. As the rock drill reaches the rear limit, fast feed
is switched off and relay K70 is delaying by 0.2 sec and
during this time the rotation of drill rod stops. If the return
automatics is desired to use without rotation, the control
diode V19 in the JB 102 -box must be removed.

Return automatics can also be used as an auxiliary function. In this case, the selector switch S73 for return
automatics must be turned to the right and then back, whereby the rock drill starts return movement with
rotation.

When the rock drill reaches the front impulse cylinder (129), the pressure switch (123/S80) is activated,whereby
percussion and feed control valves (14) and (31) are centralized (the rotation pilot control valve (58) remains
on). After that the control pressure in the said control lines disappears, and the percussion selector valve (4)
changes its position and closes the percussion main valve (3).

Control pressure is also removed from the water control valve (100), and water flushing is shuts off. The
pressure switch (123/S80) activates the coil Y47 of the return automatics selector valve (39), whereby the
pilot control pressure is able to reach the control line c of the feed directional valve (23) through the return
automatics selector valve (39) and the shuttle valve (38). In this situation, the feed directional valve (23)
immediately changes its position, and fast feed is switched on.

Feed pressure also reaches the load sensing line of the variable displacement pump (1) through the shuttle
valve (26), (42), and (10), and after the shuttle valve (26), also the feed pressure gauge (21). Fast feed backwards
is on until the rear impulse cylinder (130) is activated the limit switch (125/S81). At the same time, the rotation
pilot control valve (58) is centralized, and rotation is turned off, also fast feed to backwards stops.

The return flow from the rock drill rotation motor (54) passes through the rotation directional valve (53), the
collecting piece (115), the cooler (315), and the return oil filter (113), into the hydraulic oil tank (110). The return
flow from the feed cylinder (28) passes through the feed directional valve (23), the collecting piece (115), the
cooler (315), and the return oil filter (113), into the hydraulic oil tank (110). The return flow from the control
block of return automatics passes through the collecting piece (135) and ends up into hydraulic oil tank (110).

The leak oil of the pilot control valves (14), (31) and (58) is directed first to the collecting piece (135) and from
there to the hydraulic oil tank (110).

117
5.15.1 THE FUNCTION OF THE RETURN AUTOMATICS

5.16 PROXIMITY SWITCH CONTROLLED RETURN AUTOMATICS (ALTERNATIVE)

5.16.1 GENERAL

The function principle of the proximity switch controlled return automatics is the same as in the impulse
cylinder controlled return automatics. The main differences are as follows:
• Impulse cylinders are replaced with proximity switches
• Return automatics control block is removed from the control system
• Main functions (percussion, feed, rotation) are controlled directly via proximity switches

5.16.2 FUNCTION

When the rock drill reaches the front limit proximity switch (S80), the percussion and feed control valves (14)
and (31) are centralized (the rotation pilot control valve (58) remains on). After that the control pressure in
the aforementioned control lines disappears and the percussion selector valve (4) changes its position and
closes the percussion main valve (3).

Control pressure is also removed from the water control valve (100) and air control valve (101), and air mist
flushing is shutting off. The front limit proximity switch (S80) activates the coil Y47 of the return automatics
selector valve (39) whereby the pilot control pressure regulated by the pilot control pressure regulating valve
(43) is able to reach the control line c of the feed directional valve (23) through the return automatics selector
valve (39) and the shuttle valve (38). In the same time the control pressure after the valve (39) is able to reach
the shuttle valve (134) and the air valve (101).

In this situation the feed directional valve (23) immediately changes its position and fast feed is switched on
and air flushing is turned on. Feed pressure also reaches the load sensing line of the variable displacement
pump (1) through the shuttle valves (26), (42) and (10), and after the shuttle valve (26) also the feed pressure
gauge (21).

118
Fast feed backwards is on until the rear limit proximity switch (S81) is activated. At the same time the rotation
pilot control valve (58) is centralized and rotation is turned off. Also fast feed backwards stops.

The return flow from the rock drill rotation motor (54) passes through rotation directional valve (53), the
collecting piece (115), the cooler (114) and the return oil filter (113) into the hydraulic oil tank (110).

The return flow from the feed cylinder (28) passes through the feed directional valve (23), the collecting piece
(115),THC 561 DRILLING
the cooler (114) and theHYDRAULICS
return oil filter (113) into the hydraulic oil tank (110). The leak oil of the pilot
Testing and adjusting
control valves (14), (31) and (58) is directed into the hydraulic oil tank (110).

5.17 RETURN AUTOMATICS

7.17. Return automaticsWITH AIR
with air BLOWING
blowing AUTOMATICS
automatics ID: 46921

210
43
10
42

12
21

18

50
222

15
4
8

16
5
7
221
11

112
9

11

1
3

117
2
20

13

211

30

29
32
44
216

26

22
23
28

145
141
101

25
144
142
143

24
33

220

140
138
102

137
103

209

39
38
37

35

34
100

36

206
207
31

208
14

111
52
62

54
58

61

53

6557
51

56

115
55

131
315
205

113
139

122
123

110
60
59

200
121

135
119
129

127
124
126
130

118
120

202
125

ID: 47043

Figure: Return automatics with air blowing automatics

119
Return automatics can also be used with an air blowing. In this case return automatics with air blowing must
be selected with the switch S74 on the THC-panel, whereby air is blown to the hole for 6 seconds before the
rock drill starts return movement with rotation.

When the rock drill reaches the front impulse cylinder (129), the pressure switch (123/S80) is activated,whereby
percussion and feed control valves (14) and (31) are centralized (the rotation pilot control valve (58) remains
on). After that the control pressure in the said control lines disappears, and the percussion selector valve (4)
changes its position and closes the percussion main valve (3).

Control pressure is also removed from the water control valve (100), and water flushing is shuts off. The
pressure switch (123/S80) activates the coil Y454 of the air blowing automatics on/off valve (209), whereby
the control pressure flows to the air control valve (101). After the air blowing the coil Y454 deactivates and
the coil Y47 of the return automatics selector valve (39) activates, whereby the pilot control pressure is able
to reach the control line c of the feed directional valve (23) through the return automatics selector valve (39)
and the shuttle valve (38). In this situation, the feed directional valve (23) immediately changes its position, and
fast feed is switched on.

Feed pressure also reaches the load sensing line of the variable displacement pump (1) through the shuttle
valve (26), (42), and (10), and after the shuttle valve (26), also the feed pressure gauge (21). Fast feed backwards
is on until the rear impulse cylinder (130) is activated the limit switch (125/S81) . At the same time, the rotation
pilot control valve (58) is centralized, and rotation is turned off, also fast feed to backwards stops.

The return flow from the rock drill rotation motor (54) passes through the rotation directional valve (53), the
collecting piece (115), the cooler (315), and the return oil filter (113), into the hydraulic oil tank (110).

The return flow from the feed cylinder (28) passes through the feed directional valve (23), the collecting piece
(115), the cooler (315), and the return oil filter (113), into the hydraulic oil tank (110). The return flow from the
control block of return automatics passes through the collecting piece (135) and ends up into hydraulic oil
tank (110). The leak oil of the pilot control valves (14), (31) and (58) is directed first to the collecting piece (135)
and from there to the hydraulic oil tank (110).

Factory setting time for the front limit air blowing is 6 seconds. Time can be adjusted by turning the blue
adjusting screw of the relay K78 in the JB 102 -box. Adjusting range is 1 to 10 seconds.

120
 62 (116)
216

ID: 34510
58 14 31 102 33
5.18 7.18.

20
51 11 21
61 62
103 220
44
32
MANUAL

59

60
Manual

221 222
CONTROL

28
100
13
Testing and adjusting

130 129
control

54 101

137

Figure: Manual control of fast feed

143
140
OFofFAST

141
138 42
142
145 7 10

144
211
fast FEED

8 18

124 5
126
118 119 30 9
120 121 52 24 26 6
feed ID: 34492

125 123 57
55 65 3
127 4
205 53
56 29
25 23 43
139 16 15
22 2

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115 36
35 209 117 116
208
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1 50
207
315
34
206 39

122
131
200
111

202 110 113

121
122
123
124
The manual control of fast feed is a proportional function, i.e. the inclination angle of the control lever for the
fast feed pilot control valve (33) determines the speed of fast feed (the bigger the angle the faster the speed).
The control lever of the fast feed pilot control valve (33) centralized by a spring.

Manual control of fast feed can, for instance, be used for flushing drilled holes. During fast feed (forwards) the
system operates as follows:

Rotation and percussion are not on in this situation, as the rotation pilot control valve (58) and the percussion
pilot control valve (14) are in the central position.

When the control lever of the fast feed pilot control valve (33) is pulled to the back position, pilot control
pressure passes through the shuttle valve (36) to the control line d of the feed directional valve (23). Now,
the spool of the feed directional valve (23) changes its position, and the pressure from the percussion circuit
passes through the compensator (22) and the feed directional valve (23) to the feed line A, and to the feed
cylinder (28). Feed pressure also passes through the shuttle valves (26), (42), and (10) to the load sensing line
of the variable displacement pump (1), and after the shuttle valve (26) to the feed pressure gauge (21). The
max. feed pressure of fast feed forwards is restricted by the max. pressure relief valve (25) for the feed line A of
the feed directional valve, and by the fast feed max. pressure relief valve (30) for fast feed backwards.

The return flow from the feed cylinder (28) passes through the feed directional valve (23), the collecting piece
(115), the cooler (315), and the return oil filter (113), and ends up into the hydraulic oil tank (110).

The leak oil of the pilot control valve (33) is directed first to the collecting piece (135) and from there to the
hydraulic oil tank (110).

125
126
8.

64 (116)
216 8.1.

ID: 34513
58 14 31 102 33
20
51 11 21
61 62
103 220
44
32

59
6.1 THREADING

60

Figure: Threading
221 222

28
6. SPECIAL FUNCTIONS

100
13
Testing and adjusting

130 129
54 101
Threading ID: 34493

137

S126.2 143
140
141
138 42
142
145 7 10

144
211
SPECIAL FUNCTIONS ID: 33516

8 18

124 5
126
118 119 30 9
120 121 53 52 24
125 123 26 6
55 65 57 3
127 4
205 29
56
25 23
43
139 16 15
22 2

210

ID: 510 1 en 2009-11-18

12

37 112
115 36
35 209 117 116
208
38

Copyright © Sandvik Mining and Construction

135
1 50
207
315
34
206 39

122
131
200
111

202 110 113

Threading means a situation where the drill rod is threaded on or off with a rock drill shank. Threading is done
with the control levers for the rotation pilot control valve (58) and the feed pilot control valve (31).

In threading, the system operates as follows:

Rotation is turned on by pulling back the control lever of the rotation pilot control valve (58) (if required, the
speed of rotation can be adjusted with the regulating valve (59) for rotation speed). Pull the control lever of
the feed pilot control valve (31) backwards to feed the rock drill forwards at a speed that corresponds to the
thread pitch. Keep the feed speed constant throughout the threading operation.

Feed pressure can be adjusted suitable with the feed pressure regulating valve (20) (normal feed pressure for
drilling can be used as the basic setting).

During threading, rotation pressure must be kept below the anti-jamming activation
pressure. If the pressure rises to this value, feed direction is reversed.

127
128
When
216

ID: 34514
58 14 31 102 33
20
51 11 21
61 62
103 220
44
32

59

60
8.2. the Loosen

Figure: Loosen the bit

221 222
percussion the
6.2 LOOSEN THE BIT

28
100
13
Testing and adjusting

130 129
54 101
pilot control
bit ID: 34494

137

143
140
141
138 42
142
145 7 10

144
211
THC 561 DRILLING HYDRAULICS

8 18

124 5
126
118 119 30 9
120 121 52 24
125 123 26 6
57
55 65 3
127 4
205 53
56 29
25 23 43
139 16 15
22 2

210

12

37 112
115 36
35 209 117 116
208
38
135
1 50
207
315
34
206 39

122
131
200
111

202 110 113

valve (14) is locked into the front position, pilot control pressure affects.
into the rattling on/off valve (8), into the percussion selector valve (4) through the shuttle valve (15) and
also into the percussion pressure selector valve (5) through the shuttle valve (16). The percussion pressure
selector valve (5) changes position and closes the connection to the percussion half-power pressure relief
valve (6). Also the rattling on/off valve (8) changes position and closes the connection to the monitoring valve
(18). The percussion selector valve (4) opens the percussion main valve (3), and the output of the variable
displacement pump (1) flows through the non-return valve (116), the pressure filter (112), the compensator
(2), and the percussion main valve (3) into the percussion mechanism (13). After the orifice (9), the pressure
affects into the pressure compensator (2), and reaches the load-sensing line of the variable displacement
pump (1) through the the shuttle valve (10). Oil flows also to the percussion pressure selector valve (5), the
rattling on/off valve (8) and the percussion max. pressure relief valve (7) which determines the rattling pressure.

The pressure after the percussion main valve also affects into the percussion pressure gauge (11). The return
flow from the percussion mechanism (13) passes through the collecting piece (115), the cooler (315), and the
return oil filter (113), ending up into the hydraulic oil tank (110). Return flow from the feed deviation valve (216)
passes through the directional valve (44), the collecting piece (115), the cooler (315) and the return oil filter
(113) ending up into the hydraulic oil tank (110). The leak oil of the pilot control valve (14) is directed first to the
collecting piece (135) and from there to the hydraulic oil tank (110).

When using rock drill with stabilizer oil flows also from the connection (P2) of the drilling control block to
the connection (P) of the stabilizer control block. From there oil flows to the pressure reducing valve (145) and
the pressure reducing/relieving valve (141). From here the oil continues to flow to the the directional control
valve (140). Oil also affects to the monitoring valve (142), the directional control valve (144) and the pressure
switches (137) and (138). The directional control valve (140) is activated when using loosening the thread
function. In this situation the re is no pressure in the stabilizer and the oil flows from the stabilizer via the oil
collector (115), the oil cooler (315) and the return oil filter (113) into the hydraulic oil tank (110).

129
 Testing and adjusting

6.3 SEPARATE
8.3. FLUSHING
Separate flushing ID: 34495

210
43
10
42

12
21

18

50
222

15
4
8

16
5
7
221
11

112

116
9

1
3

117
2
20

13

211

30

29
32
216

26
44

22
23
28

145
141
101

25
144
142
143

24
33

220

140
138
102

137
103

209

39
38
37

35

34
100

36

206
207
31

208
14

111
52
62

54
58

61

53
57
65
51

56

115
55

131
315
205

113
139

122
123

110
60
59

200
121

135
119
129

127
124
126
130

118
120

202
125

ID: 34515

Figure: Separate flushing

The THC 561 drilling system is equipped with a selector valve (102) for separate flushing. This makes it
possible to flush the drilled hole with air or water as a separate function after the actual drilling. The selector
valve (102) for separate flushing can be locked, so that flushing can be left on for longer periods. When the
separate flushing selector valve is locked into the rear position, water flushing is turned on, while the front
68 (116) is for air flushing.
position Copyright © Sandvik Mining and Construction
ID: 510 1 en 2009-11-18

130
When water flushing (selector valve 102) is selected, the separate flushing function is as follows:
When the selector valve is locked to the rear position, the pressure from the pilot control pressure regulating
valve (43) passes through the separate flushing selector valve (102) and the shuttle valve (103) to the water
control valve (100), and water flushing is turned on. The leak oil of the pilot control valve (102) is directed first
THC 561 DRILLING HYDRAULICS
to the collecting piece (135) and from there to the hydraulic oil tank (110).
Testing and adjusting
6.4 USING THE DIESEL ENGINE FOR RUNNING ROCK DRILL
8.4. Using the diesel engine for running rock drill ID: 34497

210
43
10
42

12
21

18

50
222

15
4
8

16
5
7
221
11

112

116
9

1
3

117
2
20

13

211

30

29
32
216

44

26

22
28

23
145
141
101

25
144
142
143

24
33

220

140
S126.2

138
102

137
103

209

39
38
37

35

34
100

36

206
207
31

208
14

111
52
62

54
58

61

53
57
65
51

56

115
55

131
315
205

113
139

122
123

110
60
59

200
121

135
119
129

127
124
126
130

118
120

202
125

ID: 34516
T h e
Figure: Using diesel engine for running rock drill
131
THC 561 drilling system also allows the use the feed of rock drill with diesel. This function is convenient in
maintenance work, when the power-packs cannot be used.When the rock drill needs to be fed forwards or
backwards with diesel power, the boom control operating valve for zoom or feed transfer must be used in
addition to the feed pilot control valve (31). The directions of these two movements must always be chosen
so that no danger is caused to the operator or the rig.

When diesel power is used for running the rock drill forwards, the system operates as follows:
When the feed pilot control valve (31) is pulled to the back position and, simultaneously, the boom zoom
cylinder, for instance, is run inwards, the pressure that comes from the pilot control pressure regulating valve
(43) reaches the feed control line d through the feed pilot control valve (31), the antijamming valve (34), and the
shuttle valve (36). In addition, pilot control pressure passes through the shuttle valve (35) to the feed LS line
selector valve (29). The pilot pressure affects also to the directional valve (44) via the shuttle valve (35).

The oil produced by the carrier’s gear pump passes through the non-return valve (117), the pressure filter
(112), the pressure compensator (22), and the feed directional valve (23) and to the feed cylinder (28) and
through the pressure reducing/relieving valve of the boom circuit (210) and the port P5 of the percussion and
feed control block to the boom control valve via the drilling module movement prevention valve (222). The
pressure in the LS line of the feed directional valve passes through the shuttle valve (26) and selector valve
(29) of the feed LS line, to the feed pressure regulating valve (20), the feed deviation valve (216) and further
through the selector valve (32) of the feed LS line return circuit to the return line of the feed cylinder (28). The
pressure in the feed LS line also affects the feed pressure gauge (21). The pressure in the feed A line affects
the pressure relief valve / intake valve (25), and the feed B line pressure affects the pressure relief valve / intake
valve (24).

Never use percussion mechanism with diesel. Low pressure of diesel controlled hydraulic system can
damage components of the pressure accumulator.

7. ADJUSTMENTS OF HYDRAULIC COMPONENTS

7.1 ADJUSTMENTS OF VARIABLE DISPLACEMENT PUMP (1) AND (50)

Before starting the power-pack, make sure that the adjusting screws of the flow
controllers (controller A) of both variable displacement pumps (1) and (50) are turned
almost fully open (counter-clockwise).

Before starting adjustments, make sure that the percussion main valve (3) is fully closed.

Before starting any adjustments remember that the hydraulic oil temperature must be
between 40-50 °C.

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7.1.1 ADJUSTING VARIABLE DISPLACEMENT PUMP (1)

1. Remove the caps from the flow controller (A) and the pressure controller
(B) and undo the locking nuts of their adjusting spindles.
2. Open the adjusting screws of the pressure controller (B) and the flow
controller (A) almost fully open (counter-clockwise).
3. Connect the pressure gauge to the pressure measuring point (M1) of
the drilling control block.
4. Start the power-pack.
5. Turn the adjusting screw of the flow controller (A) fully closed (clockwise).
Note! The pump is now operating at constant pressure.
6. Turn the adjusting screw of the pressure controller (B) clockwise until the
pressure gauge shows 100 bar. Let the LS-line bleed into a separate
container by loosening the hose connection of the flow controller
(A). Let the connection stay loosened until all air has escaped. Then
tighten the hose connection of the flow controller (A).
7. Turn the adjusting screw of the pressure controller (B) clockwise until
the pressure gauge shows 250 bar. Read the pressure value from the pressure gauge connected to the
measuring point M1.
8. Lock the adjustment of the pressure controller (B) with the locking nut.
9. Turn the adjusting screw of the flow controller (A) almost fully open (counter-clockwise).
10. Allow the pressure stabilize in the pressure gauge connected to the measuring point M1.
11. Adjust the stand-by pressure to 22-30 bar from the flow controller (A) by turning the adjusting screw
clockwise.
12. Lock the adjusting screw of the flow controller (A) with the locking nut.
13. Stop the power-pack.
14. Allow the pressure come down (to zero) in the pressure gauge connected to the measuring point M1.
15. Start the power-pack.
16. Allow the pressure stabilize in the pressure gauge connected to the measuring point M1.
17. If the stand-by pressure is in the recommended range in the pressure gauge connected to the measuring
point M1, install the protective caps to the flow controller (A) and pressure controller (B).
18. If the stand-by pressure is not in the right range, please readjust the flow controller (A) according to the
steps 9-18.
19. Stop the power-pack.
20. Remove the pressure gauge from the measuring point M1.

7.1.2 ADJUSTING VARIABLE DISPLACEMENT PUMP (50)

1. Prevent the rock drill rotation (shank or rod) with special tool or disconnect the A-line control hose from the
rock drill and plug the hose end and the hose connection in the rock drill.
2. Remove the protection caps of the flow controller (A) and the pressure controller (B) of the variable
displacement pump (50) and undo the locking nuts of the adjusting screws.
3. Remove the protection cap of the LS- pressure relief valve (65) of the rotation directional valve (53) and
undo the locking nut of the LS- pressure relief valve (65).
4. Turn the adjusting screw of the LS- pressure relief valve (65) fully close (clockwise).
5. Connect the pressure gauge to the pressure measuring point (M) of the rotation control valve (53).
6. Turn the rotation speed regulating valve (59) fully closed (clockwise).
7. Start the power-pack.

133
8. Turn the adjusting screw of the flow controller (A) fully closed (clockwise).
Note! The pump (50) is now operating at constant pressure.
9. Put the rock drill rotation on by pulling and locking the rotation control lever to the rear position (towards the
operator).
10. Turn the adjusting screw of the pressure controller (B) clockwise until the pressure gauge shows 100 bar.
Let the LS-line bleed into a separate container by loosening the hose connection of the flow controller (A).
Let the connection stay loosened until all air has escaped. Then tighten the hose connection of the flow
controller (A).
11. Turn the adjusting screw of the pressure controller (B) clockwise until the pressure gauge shows 200 bar.
Read the pressure value from the pressure gauge connected to the measuring point M.
12. Lock the adjustment of the pressure controller (B) with the locking nut.
13. Turn the adjusting screw of the LS- pressure relief valve (65) counter-clockwise until the pressure gauge
shows 180 bar.
14. Lock the adjustment of the LS- pressure relief valve (65) with the locking nut.
15. Put the rock drill rotation off by releasing the rotation control lever to the middle posiiton.
16. Turn the adjusting screw of the flow controller (A) almost fully open (counter-clockwise).
17. Allow the pressure stabilize in the pressure gauge connected to the measuring point M.
18. Adjust the stand-by pressure to 20-23 bar from the flow controller (A) by turning the adjusting screw
clockwise.
19. Lock the adjusting screw of the flow controller (A) with the locking nut.
20. Stop the power-pack.
21. Allow the pressure come down (to zero) in the pressure gauge connected to the measuring point M.
22. Start the power-pack.
23. Allow the pressure stabilize in the pressure gauge connected to the measuring point M.
24. If the stand-by pressure is in the recommended range in the pressure gauge connected to the measuring
point M, install the protective caps back to the flow controller (A) and pressure controller (B).
25. If the stand-by pressure is not in the right range, please readjust the flow controller (A) according to the
steps 15-24.
26. Remove the special tool / reconnect the A-line control hose to the rock drill.
27. Adjust the drill steel rotation speed to the desired value by turning the rotation speed regulating valve (59)
counter-clockwise.
28. Stop the power-pack.
29. Remove the pressure gauge from the measuring point M.

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7.2 ADJUSTING SYSTEM MAIN PRESSURE

The system main pressure is adjusted with the main pressure relief valve (211). The adjusting procedure is as
follows:
1. Loosen the locking nut of the adjusting screw of the main pressure relief valve (211).
2. Tighten the adjusting screw of the main pressure relief valve (211) almost to its end (over 270 bar).
3. Remove the caps from the flow controller (A) and the pressure controller (B) and undo the locking nuts of
their adjusting spindles.
4. Open the adjusting screws of the pressure controller (B) and the flow controller (A) almost fully open
(counter-clockwise).
5. Connect the pressure gauge to the pressure measuring point (M1) of the drilling control block.
6. Start the power-pack.
7. Turn the adjusting screw of the flow controller (A) fully closed (clockwise).
Note! The pump is now operating at constant pressure.
8. Turn the adjusting screw of the pressure controller (B) clockwise until the pressure gauge shows 270 bar.
9. Loosen the adjusting screw of the main pressure relief valve (211) until adjusting begins to effect. Valve
begins to fizz when restricting pressure. Check the pressure value from the percussion pressure gauge
(11).
10. Adjust the variable displacement pump (1) back to its value (250 bar / 22-30 bar), according to the chapter
“Adjusting variable displacement pump (1)”
11. Tighten the locking nut of the adjusting screw of the main pressure relief valve (211).
12. Stop the power-pack.

Hydraulic system is getting warmer while the main pressure relief valve restricts pressure. Take care that
the main pressure relief valve does not penetrate a flow for a long time.

135
7.3 ADJUSTING PILOT CONTROL PRESSURE

The pilot control pressure is adjusted with the pilot control pressure regulating valve (43).
The adjusting procedure is as follows:
1. Loosen the locking nut of the adjusting screw of the pilot control pressure regulating valve (43).
2. Turn the adjusting screw of the valve (43) almost fully open (counter-clockwise).
3. Connect a pressure gauge to the pressure measuring point M8 of the percussion and feed control block.
4. Start the power-pack.
5. Push the control lever of the feed pilot control valve (31) to the front position (feed backwards).
6. Adjust the pilot control pressure to 30 bar by turning the adjusting screw of the pilot control pressure
regulating valve (43) clockwise. Read the pressure value in the gauge connected to the measuring point M8.
7. Release the control lever of the feed pilot control valve (31) to the middle position (feed backwards off).
8. Lock the adjusting screw of the pilot control pressure regulating valve (43).
9. By turning on feed backwards, check the adjusted pressure value in the pressure gauge connected to the
measuring point M8. If the reading is not as recommended, readjust the pilot control pressure.
10. Stop the power-pack.
11. Remove the pressure gauge from the measuring point M8.

7.4 ADJUSTING THE MAX. PRESSURE OF ROTATION CIRCUIT

The maximum pressure for rotation is adjusted with the rotation LS-
pressure relief valve (65) located in the rotation control valve.

The adjusting procedure is following:

1. Start the power-pack.
2. Run the rock drill against the rear stopper.
3. Stop the power-pack.
4. Loosen the locking nut of the pressure relief valve (65) mounted to
the rotation control valve.

136
5. Turn the pressure relief valve (65) adjusting screw almost fully open (counter-clockwise).
6. Prevent the drill rod from rotating (drilling rotation).
7. Turn the rotation speed regulating valve (59) closed (clockwise).
8. Start the power-pack.
9. Lock the control lever of the rotation pilot control valve (58) in the back position.
10. Adjust the rotation max. pressure to 180 bar with the pressure relief valve (65). Read the pressure in the
rotation pressure gauge (51).
11. Lock the adjusting screw of the max. rotation pressure relief valve (65).
12. Release the control lever of the rotation pilot control valve (58) to the middle position.
13. Stop the power-pack.
14. Remove the tool preventing the drill rod rotation.
15. Start the power-pack.
16. Turn drilling rotation on again by locking the control lever of the rotation pilot control valve (58) in the back
position.
17. Adjust the drill steel rotation speed to the desired value by turning the rotation speed regulating valve (59)
counter-clockwise.
18. Release the control lever of the rotation pilot control valve (58) to the middle position.
19. Stop the power-pack.
NOTE! The regulating valve (55) adjusts the max system pressure of the rotation. This pressure is 15 bar
over the value of the rotation LS-pressure.

7.5 ADJUSTING OF THE SPOOL STROKE OF THE ROTATION DIRECTIONAL VALVE

The rotation directional valve is supplied with the stroke limitation possibility. The stroke limit adapters with
which limitation is done are located at the end of the hydraulic control covers. The adjustment of the stroke
limitation is recommended to be done to prevent unnecessarily high rotation speed and to avoid the overload
of the electric motor.

137
The adjustment is done as follows:

1. Move the booms so that there is a possibility to measure safely the revolutions of the drilling rod or
the shank of the rock drill.
2. Install a suitable oil container under the rotation directional valve.
3. Disconnect the hydraulic hose from the end of the hydraulic control cover b and plug the hose end.
4. Remove the adapter from the end of the hydraulic control cover b.
5. Turn the screw of the spool limiter counter-clockwise until it reaches the face of the stroke limit adapter.
6. Start the power pack (if not running).
7. Activate the rotation counter-clockwise on by locking the rotation control lever backwards (towards
the operator).
8. Adjust the max revolutions of the drilling rod or the shank of the rock drill by the rotation speed
regulating valve (59) according to the size of the rotation motor used in rock drill.
Adjusting value is ±10 % of the recommended rotation speed.
9. Keep the rotation counter-clockwise on and turn the adjusting screw of the spool limiter clockwise
until it reaches the spool end.
10. Release the rotation control lever to the middle position.
11. Stop the power pack.
12. Install the adapter back to the end of the hydraulic control cover b.
13. Reconnect the hydraulic hose to the adapter at end of the hydraulic control cover b.
14. Disconnect the hydraulic hose from the end of the hydraulic control cover a and plug the hose end.
15. Remove the adapter from the end of the hydraulic control cover a.
16. Turn the screw of the spool limiter counter-clockwise until it reaches the face of the stroke limit adapter.
17. Start the power pack.
18. Activate the rotation clockwise on by locking the rotation control lever forwards (away from the
operator).
19. Adjust the max revolutions of the drilling rod or the shank of the rock drill according to the step 8.
20. Keep the rotation clockwise on and turn the adjusting screw of the spool limiter clockwise until it
reaches the spool end.
21. Release the rotation control lever to the middle position.
22. Stop the power pack.
23. Install the adapter back to the end of the hydraulic control cover a.
24. Reconnect the hydraulic hose to the adapter at end of the hydraulic control cover a.
25. Remove the oil container under the rotation directional valve.

7.6 ADJUSTING ANTI-JAMMING PRESSURE

The activation pressure of the anti-jamming automatics can be adjusted

according to rock type. The range recommended by the manufacturer
is 110 to 140 bar, and the factory setting is 120 bar. The activation
pressure is adjusted with the anti-jamming valve (34), and it can be done
during drilling. However, the adjustment is recommended to be done as
follows:

138
1. Loosen the locking nut of the anti-jamming valve (34) adjusting screw.
2. Turn the anti-jamming valve (34) adjusting screw first fully closed (clockwise), and open it then 2 turns
(counter-clockwise).
3. Start the power-pack.
4. Run the rock drill against the rear stopper.
5. Stop the power-pack.
6. Loosen the locking nut of rotation LS-pressure relief valve (65) of rotation control block adjusting
screw.
7. Turn the LS-pressure relief valve (65) adjusting screw almost fully open (counter-clockwise).
8. Turn the rotation speed regulating valve (59) closed (clockwise).
10. Prevent the drill rod from rotating (drilling rotation).
11. Install a pressure gauge to the measuring point M3 of the anti-jamming/return automatics block.
12. Start the power-pack.
13. Lock the control levers of rotation and feed pilot control valves (58) and (31) to the back position.
14. Adjust the desired anti-jamming activation pressure with the rotation LS-pressure relief valve (65) by
turning the adjusting screw clockwise (factory setting 120 bar).
Read the pressure value in the rotation pressure gauge (51).
15. Adjust the anti-jamming valve (34) so that it directs feed pilot control pressure at the set pressure to
the measuring point M3 of the anti-jamming/return automatics block.
Read the feed pilot control pressure (approx. 19-21 bar) in the pressure gauge installed in the
measuring point M3.
16. When the anti-jamming valve (34) is correctly adjusted, lock the adjusting screw of the valve (34).
17. Adjust rotation pressure with the rotation LS-pressure relief valve (65) to 180 bar by turning the
adjusting screw clockwise.
Read the pressure in the rotation pressure gauge (51).
18. Release the control levers of rotation and feed pilot control valves (58) and (31).
19. Stop the power-pack.
20. Remove the tool preventing the drill steel from rotating.
21. Remove the plugs from the feed cylinder pressure side feed line (Cf. point 9), and reconnect the hose
to the feed cylinder.
22. Start the power-pack.
23. Turn drilling rotation on again by locking the control lever of rotation pilot control valve (58) in the
back position.
24. Adjust the drill rod rotation speed to the desired value by turning the rotation speed regulating valve
(59) counter-clockwise.
25. Release the control lever of the rotation pilot control valve (58).
26. Stop the power-pack.
27. Remove the pressure gauge from the measuring point M3 for the anti-jamming/return automatics.

7.7 ADJUSTING ANTI-JAMMING PRESSURE (ALTERNATIVE METHOD)

1. Loosen the locking nut of the anti-jamming valve (34) adjusting screw.
2. Prevent the drill rod from rotating (for example with the special tool ) so, that the feed can be ran
forwards/backwards.
3. Start the power pack.
4. Run the feed forwards slowly.
5. Engage the rotation carefully with the rotation pilot control valve (58).

139
6. Read from the feed and rotation pressure gauges (21 and
51) when the anti-jamming will be activated.
Rotation pressure has to be in the desired anti- jamming
value (for example 100 bar), when the feed moves
backwards and the feed pressure falls.
7. Turn the anti-jamming valve (34) adjusting screw and
repair the previous steps until the anti-jamming pressure
is required.
8. When the anti-jamming valve (34) is correctly adjusted,
lock the adjusting screw of the valve (34).
9. Release the control levers of rotation and feed pilto
control valves (58) and (31).
10. Stop the power pack.
11. Remove the tool preventing the drill rod from rotating.

7.8 ADJUSTING PERCUSSION HALF-POWER

Monitoring valve (18) and percussion half-power pressure relief valve (6) locate in parallel in percussion LS-
circuit. Lower adjusting value of these valves determines the percussion half-power pressure. However,
adjusting values for both of these valves have to be the same. See the adjusting of monitoring valve (18),
according to the chapter “Adjusting min. percussion pressure” (p. 83) . Percussion half-power can vary
between 80-100 bar. Factory setting is 100 bar.

Percussion half-power is adjusted with the percussion half-power pressure relief valve (6) as follows:
1. Loosen the locking nut of the adjusting screw of percussion half-power pressure relief valve (6).
2. Turn the adjusting screw of the percussion half-power pressure relief valve (6) first fully closed
(clockwise), and then open it by 7 1/4 turns (counter-clockwise).
3. Start the power-pack.
4. Turn percussion half-power on by locking the control lever of percussion pilot control valve (14) to
the back position.
5. Adjust percussion half-power pressure to 100 bar with the percussion half-power pressure relief
valve (6).
Read the pressure value from the percussion pressure gauge (11).
6. Tighten the locking nut of the adjusting screw for the percussion half-power pressure relief valve (6).
7. Release the control lever of the percussion pilot control valve (14).
8. Stop the power-pack.

140
7.9 ADJUSTING MIN. PERCUSSION PRESSURE

Monitoring valve (18) and percussion half-power pressure relief valve (6) locate in parallel in percussion LS-
circuit. Lower adjusting value of these valves determines the percussion half-power pressure. However,
adjusting values for both of these valves have to be the same. See the adjusting of percussion half-power,
according to the chapter “Adjusting percussion half-power” (p. 82) .

Min. percussion pressure is adjusted with the monitoring valve (18) as follows:
1. Loosen the locking nuts of the monitoring valve (18).
2. Turn the adjusting screw of the monitoring valve (18) fully open (counter-clockwise).
3. Start the power-pack.
4. Turn percussion half-power on by locking the control lever of percussion pilot control valve (14) to
the back position.
5. Loosen the adjusting screw of the monitoring valve (18) as long as it begins to affect to percussion
half-power pressure.
6. Adjust min. percussion pressure to the same value as the percussion half-power pressure (100 bar).
Read the pressure value from the percussion pressure gauge (11).
7. Tighten the locking nut of the adjusting screw for the monitoring valve (18).
8. Release the control lever of the percussion pilot control valve (14).
9. Stop the power-pack.

7.10 ADJUSTING PERCUSSION FULL-POWER

141
The pressure of percussion full-power is adjusted to the desired value with the percussion full-power pressure
relief valve (7). Percussion full-power pressure should be adjusted according to the hardness of the rock and
the drill steels used. The max. pressure of percussion may vary between 150-250 bar with respect to the
above factors. The factory setting is 230 bar.

Percussion full-power pressure is adjusted as follows:

1. Loosen the locking nut of the adjusting screw of the percussion full-power pressure relief valve (7).
2. Turn the adjusting screw of the percussion full-power pressure relief valve (7) first fully closed
(clockwise) and then open the adjusting screw 5 turns (counter-clockwise).
3. Start the power-pack.
4. Lock the control lever of the percussion pilot control valve (14) to the front position.
5. Adjust the percussion full-power pressure to the desired level with the adjusting screw of the
percussion full-power pressure relief valve (7). Turn clockwise to increase the pressure and
counter-clockwise to decrease it.
Read the pressure value from the percussion pressure gauge (11).
6. Tighten the locking nut of the adjusting screw of the percussion full-power pressure relief valve (7).
7. Release the control lever of the percussion pilot control valve (14).
8. Stop the power-pack.

7.11 ADJUSTING FEED PRESSURE

Feed pressure is adjusted with the feed pressure regulating valve (20). This valve is used for adjusting the max.
feed pressure in the system for the time when feed is run through the feed pilot control valve (31). In addition to
this, the feed lines A (25) and B (24) are equipped with a fixed pressure relief/ intake valve cartridges as follows:

Feed A line (25) B line (24)

Cylinder feed TF 500 160 bar 210 bar
Cylinder feed TFX 500 160 bar 210 bar

The max. feed pressures for cylinder feed equipment are following:
Feed Max. feed pressure
Cylinder feed TF 500 140 bar
Cylinder feed TFX 500 160 bar

142
NOTE! The min. feed pressure for all feeds is about 20 bar. Factory settings for percussion and feed pressures
are following:

Rock drill Feed Percussion pressure Feed pressure

RD525 TF 500 210 bar 115 bar
RD525 TFX 500 210 bar 130 bar
RD520/HLX5 TF 500 210 bar 105 bar
RD520/HLX5 TFX 500 210 bar 120 bar

7.12 ADJUSTING FAST FEED MAX. PRESSURE

The max. pressure of fast feed is adjusted with the fast feed max. pressure relief valve (30). The adjustment is
done as follows:
1. Loosen the locking nut of the fast feed max. pressure relief valve (30).
2. Start the power-pack.
3. Run the rock drill against the rear stopper by locking the control lever of fast feed pilot control valve
(33) into the front position and adjust at the same time the fast feed max. pressure by the pressure
relief valve (30).
Read the pressure value from the pressure gauge (21).
The value of fast feed pressure relief valve depends on the feed in use as follows:

Feed Value of the fast feed relief valve (30)

TF 500 210 bar
TFX 500 180 bar

4. Release the control lever of the fast feed pilot control valve (33).
5. Lock the adjusting screw of the fast feed max. pressure relief valve (30).
6. Stop the power-pack.

143
7.13 ADJUSTING FAST FEED MAX. SPEED

The max. fast feed speeds are adjusted with the adjusting screws at the feed directional valve (23). The lower
screw (A) is for adjusting fast feed max. speed forwards and the upper (B) for max. speed backwards.

Sandvik recommends the following fast feed speeds:

Direction of fast feed Sandvik recommendation

Forwards TF 500 ≈ 0.3 m/s
TFX 500 ≈ 0.3 m/s
Backwards TF 500 ≈ 0.5 m/s
TFX 500 ≈ 0.3 m/s

Fast feed speeds are adjusted as follows:

1. Remove the drill rod from the rock drill to enable free running of rock drill from end to end on the feed.
2. Start the power-pack.
3. Loosen the locking nuts of the adjusting screws for fast feed speeds at the feed directional valve (23).
4. Lock the control lever of the fast feed pilot control valve (33) to the back position to run fast feed
forwards.
Adjust the movement speed to approx. 0.3 m/s with the lower adjusting screw at the feed directional
valve.
5. Release the control lever of the fast feed pilot control valve (33).
6. Lock the lower adjusting screw for fast feed speed at the feed directional valve (23).
7. Check the adjustment and readjust as necessary.
8. Lock the control lever of the fast feed pilot control valve (33) to the front position to run fast feed
backwards.
Adjust the movement speed to approx. 0.5 m/s (0,3 m/s with TFX500) with the upper adjusting screw
at the feed directional valve.
9. Release the control lever of the fast feed pilot control valve (33).
10. Lock the upper adjusting screw for fast feed speed at the feed directional valve (23).
11. Check the adjustment and readjust as necessary.
12. Stop the power-pack.

144
7.14 ADJUSTING ROTATION SPEED

The drill rod rotation speed is adjusted with the rotation speed regulating valve (59). Turn the adjusting knob
counter-clockwise to decrease the speed and clockwise to increase the speed. The correct drill rod rotation
speed depends on the hardness of the rock and on the hole diameter. Sandvik recommends the following
rotation speeds for different hole diameters:

Drill bit size Rotation speed ± 10 % (HLX5/ Rotation speed ± 10 % (RD525[/

RD520) HFX5T])
Ø32 250 350
Ø38 250 350
Ø45 200 275
Ø51 200 275
Ø64 150 200
Ø76 150 200
Ø89 110 150
Ø102 110 150
Ø115 80 110
Ø127 80 110

7.15 ADJUSTING BOOM CIRCUIT MAX. PRESSURE

145
The boom circuit max. pressure is adjusted with the pressure reducing/relieving valve (210). The adjusting
procedure is as follows:

1. Loosen the locking nut of the adjusting screw of the pressure reducing/relieving valve (210).
2. Connect a pressure gauge to the pressure measuring point M10 of the percussion and feed control
block.
3. Start the power-pack.
4. Run the boom control operating valve for zoom or feed transfer..
The directions of these two movements must always be chosen so that no danger is caused to the
operator or the rig.
5. Adjust the boom circuit max. pressure to 230 bar with the pressure reducing/relieving valve (210).
Read the pressure value in the gauge connected to the measuring point M10.
6. Tighten the locking nut of the adjusting screw of the pressure reducing/relieving valve (210).
7. Stop the power-pack.

7.16 BLEEDING OF THE IMPULSE CYLINDER BLOCK

Pressure switches (S80 and S81) of the impulse cylinder block is bled
as follows:
1. Start the power-pack.
2. Remove the cover from the measuring plugs (MF and
MR) of the impulse cylinder block.
3. Install end of the overflowhoses to themeasuring plugs
(MF and MR) and the other ends to overflow receptacle.
4. Bleeding is performed, when out coming oil is free of
air bubbles.
5. Remove the overflow hoses from the measuring plugs
(MF and MR).
6. Stop the power-pack.

7.16.1 ADJUSTING THE PRESSURE SWITCHES (123, 125)

Adjusting the pressure switches (S80 and S81) of impulse cylinder block, must be done in special test bench.
Activating pressure of the pressure switches is 18 bar.

9.16.2 BLEEDING OF THE IMPULSE CYLINDERS (129, 130)

Bleeding of the impulse cylinders are bled as follows:

1. Start the power-pack.
2. Locate the overflow receptacle under the impulse cylinder.
3. Rotate the bleeding screw (A) of the impulse cylinder carefully
open (counter-clockwise).
4. When all of the air has came out, tighten the bleeder-screw (A)
(clockwise).
5. Stop the power-pack.

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7.17 BLEEDING OF THE PRESSURE SWITCH (12)

1. Locate the overflow receptacle under the pressure switch.

2. Start the power-pack.
3. Loosen a joint between pressure switch and hose joint.
4. When all of the air has came out, tighten the joint.
5. Stop the power-pack.

7.18 ADJUSTING PERCUSSION HOUR METER / SLU ON/OFF PRESSURE SWITCH

(12)

The adjusting value is 5 bar.

Adjust the pressure switch as follows:
1. Turn the adjusting screw of the pressure switch (12) almost closed (clockwise).
2. Start the power-pack.
3. Lock the control lever of the percussion pilot control valve (14) to the back position.
4. Turn the adjusting screw of the pressure switch (12) counter-clockwise until it makes contact.
Then, turn the pressure switch (12) adjusting screw another 2 1/2 turns counter-clockwise. Use a
multimeter for determining switch operation.
5. Stop the power-pack.

7.19 ADJUSTING ROTATION PRESSURE SWITCH (205)

The adjusting value is 5 bar.

Adjust the pressure switch as follows:
1. Turn the adjusting screw of the pressure switch (205 almost closed (clockwise).
2. Start the power-pack.
3. Lock the control lever of the rotation pilot control valve (58) to the back position.
4. Turn the adjusting screw of the pressure switch (205) counter-clockwise until it makes contact. Then,
turn the pressure switch (205) adjusting screw another 2 1/2 turns counter-clockwise. Use a
multimeter for determining switch operation.
5. Stop the power-pack.

7.20 ADJUSTING STABILIZER MAX. PRESSURE SWITCH (137)

The adjusting value is 130 bar.

Adjust the pressure switch as follows:
1. Turn the adjusting screw of the max. pressure switch (137) almost open (counter-clockwise).
2. Connect the pressure gauge to the pressure measuring point (M1) or (M2) of the stabilizer control
block.
3. Start the power pack.
4. Run the feed cylinder against the front limit.
5. Adjust the stabilizer pressure to 130 bar with the pressure reducing/relieving valve (141). Read the
pressure value in the gauge connected to the measuring point (M1) or (M2).
6. Tighten the adjusting screw of the max. pressure switch (137) until it makes contact and the stabilizer
indicator light (H72) starts to flash on the THC-panel.
7. Adjust the stabilizer max. pressure to the right value (110 bar).

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Note! The adjusting value of the stabilizer max. pressure switch (137) must be approx. 20 bar higher than
the stabilizer max. pressure.

7.21 ADJUSTING STABILIZER MIN. PRESSURE SWITCH (138)

The adjusting value is 15 bar.

Adjust the pressure switch as follows:
1. Turn the adjusting screw of the min. pressure switch (138) almost closed (clockwise).
2. Connect the pressure gauge to the pressure measuring point (M1) or (M2) of the stabilizer control
block.
3. Start the power pack.
4. Adjust the stabilizer pressure to 15 bar with the monitoring valve (142).
5. Open the adjusting screw of the min. pressure switch (138) until it makes a contact and the stabilizer
indicator light (H72) starts to flash on the THC-panel.
6. Adjust the stabilizer min. pressure to the right value (50 bar).

7.22 ADJUSTING PRESSURE SWITCH OF AIR-MIST FLUSHING SELECTING (217)

The adjusting value is 15 bar.

Adjust the pressure switch as follows:
1. Turn the adjusting screw of the pressure switch (217) almost closed (clockwise).
2. Switch on the air-mist flushing with the switch (S75) on the THC-panel.
3. Start the power pack.
4. Pull the flushing control lever (102) backwards and open the adjusting screw of the pressure switch
(217) so that it will be activated about on a half-way of the control lever movement (approx. 15 bar).
5. Stop the power pack.

7.23 ADJUSTING STABILIZER MAX. PRESSURE

Stabilizer max. pressure depends on the used feed pressure.

The stabilizer max. pressure is adjusted with the pressure reducing/relieving valve (141). Factory setting is 110
bar.

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The adjusting procedure is as follows:
1. Loosen the locking nut of the adjusting screw of the pressure reducing/relieving valve (141).
2. Connect a pressure gauge to the pressure measuring point M1 or M2 of the stabilizer control block.
3. Start the power-pack.
4. Run the feed cylinder against the front limit.
5. Adjust the stabilizer max. pressure, for example 110 bar, with the pressure reducing/relieving valve
(141).
Read the pressure value in the gauge connected to the measuring point M1 or M2.
Note! During drilling percussion pressure must be all the time at least 20 bar higher than stabilizer
pressure.
6. Tighten the locking nut of the adjusting screw of the pressure reducing/relieving valve (141).
7. Stop the power-pack.

7.24 ADJUSTING STABILIZER MIN. PRESSURE

The stabilizer min. pressure is adjusted with the monitoring valve (142). Factory setting is 50 bar. The adjusting
procedure is as follows:
1. Loosen the locking nut of the adjusting screw of the monitoring valve (142).
2. Connect a pressure gauge to the pressure measuring point M1 or M2 of the stabilizer control block.
3. Start the power-pack.
4. Run the feed cylinder against the rear limit.
5. Adjust the stabilizer min. pressure, for example 50 bar, with the monitoring valve (142). Read the
pressure value in the gauge connected to the measuring point M1 or M2.
Note! Stabilizer min. pressure must be at least 15-20 bar higher than the pressure of the
accumulators of the rock drill.
6. Tighten the locking nut of the adjusting screw of the monitoring valve (142).
7. Stop the power-pack.

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7.25 ADJUSTING STABILIZER REFERENCE PRESSURE

In stabilizer pressure adjustment, the reference pressure is used to compensate the mass of the drilling
equipment and the frictions of the feed beam.

The stabilizer reference pressure is adjusted with the pressure reducing valve (145). Factory setting is 30 bar.
The adjusting procedure is as follows:
1. Loosen the locking nut of the adjusting screw of the pressure reducing valve (145).
2. Connect a pressure gauge to the pressure measuring point R of the stabilizer control block.
3. Start the power-pack.
4. Run the rock drill against the rear limit.
5. Adjust the stabilizer reference pressure, max. 30 bar, with the pressure reducing valve (145). Read the
pressure value in the gauge connected to the measuring point R.
6. Tighten the locking nut of the adjusting screw of the pressure reducing valve (145).
7. Stop the power-pack.

7.26 ADJUSTING POWER EXTRACTOR PRESSURE

Power extractor pressure is adjusted with the power extractor pressure relief valve (213). Factory setting is
150 bar.
The adjusting procedure is as follows:
1. Loosen the locking nut of the adjusting screw of the power extractor pressure relief valve (213).
2. Start the power pack.

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3. Engage rattling by locking the control lever of the percussion pilot control valve (14) to the front
position.
4. Switch on the power extractor by pushing the push button (S90) on the THC-panel.
5. Adjust the power extractor pressure to the 140-180 bar with the power extractor pressure relief
valve (213).
Read the pressure value from the percussion pressure gauge (11).
6. Tighten the locking nut of the adjusting screw of the power extractor pressure relief valve (213).
7. Switch off the power extractor.
8. Release the control lever of the percussion pilot control valve (14).
9. Stop the power pack.

8. TROUBLESHOOTING

8.1 GENERAL

If the drilling system is not working as it should, check the following points before making any further
measurements:
• Signal lights, e.g.
- hydraulic oil level
- hydraulic oil temperature
- pressure differences over return and pressure filters
- water and air pressure control
- powerpacks’ direction of rotation
• External leaks at hoses, connection, adapters, and other hydraulic components.
• Mechanical functions (e.g. sliding pieces, rollers and return wheels)
• Supply voltage to the drilling rig / the different devices.
• External cable damage.
• Mounting of electric plugs.
• Pressure gauge readings.

8.2 PUMPS (1) AND (50) DO NOT ROTATE AT ALL, OR THEIR SPEED IS NOT NORMAL

1. Measure the supply voltage to the power-pack. If the voltage is correct, it is likely that the fault is
mechanical. If the electric motor does not receive sufficient control voltage, refer to electric system
troubleshooting.
2. Check if a mechanical damage prevents the pumps from rotating.
3. Repair or replace the damaged component.

Noisy power-pack normally predicts a mechanical fault. It is best to immediately

repair (or replace) the component that causes the noise, in order to avoid any greater
damage.

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8.3 VARIABLE DISPLACEMENT PUMP (1) ROTATES NORMALLY, BUT THE SETTINGS
OF ITS REGULATOR ARE NOT NORMAL

The settings of the variable displacement pump (1) regulator are as follows:
• Flow regulator (A) 22-30 bar
• Pressure regulator (B) 250 bar

These settings of the variable displacement pump (1) can be easily checked as follows:
1. Install a pressure gauge to the measuring point M1 for feed and percussion.
2. Start the power-pack.
3. Read the stand-by pressure value in the pressure gauge at the measuring point M1 (allow the
pressure to stabilize).
4. Run, for instance, the zoom cylinder inwards and read the pressure, at the same time, in the pressure
gauge at the measuring point M1.
5. Stop the power-pack.
6. Remove the pressure gauge from the measuring point M1.

8.3.1 FLOW REGULATOR (A) VALUE DEVIATES FROM THE SET VALUE 22-30 BAR

1. Install a pressure gauge to the measuring point M7 for feed and percussion.
2. Start the power-pack.
3. If the pressure at the measuring point M7 of the feed and percussion control block is normal tank
pressure, it is likely that the regulator A of the pump (1) is incorrectly adjusted or sticking. Adjust the
free circulation pressure of the pump (1) to the correct value with the regulator A
4. If the above measures did not help, stop the power-pack and repair or replace the whole regulator
unit. Adjust the regulator A or the regulator unit
5. If the pressure at the pressure measuring point M7 of the feed and percussion control block is over
the normal tank pressure, it may be that one of the valves (3), (4), (14), (23), (31), (33), (39), or of the
boom valves, is sticking (i.e. one of the above valves is leaking, and giving a control signal to the
pump (1).
6. Start troubleshooting by checking the condition of the pilot control valves (14), (31), and (33), and the
return automatics selector valve (39).

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They can be inspected as follows:
a. Start the power-pack.
b. Install a pressure gauge to the following measuring points alternately:
• measuring point M9 of the feed and percussion control block
• measuring points M1, M2, and M3 of the anti-jamming and return automatics control block
c. If the measuring point M9 receives pressure, it is likely that the spool of the percussion pilot control
valve (14) is sticking.
d. If the measuring point M2 or M3 of the anti-jamming and return automatics control block receives
pressure, it is likely that the fast feed pilot control valve (33) or the return automatics selector valve
(39) is sticking.
e. If the measuring points M1 and M2 or M1 and M3 of the anti-jamming and return automatics control
block receive pressure simultaneously, it is likely that the feed pilot control valve (31) is sticking.
f. If the measuring points M1 and M2 of the anti-jamming and return automatics control block do not
receive pressure, but port LS1 does, it is likely that the anti-jamming valve of flushing control (206) is
sticking.
g. Stop the power-pack and replace the faulty valves.

7. If the above measures did not help, check the operation of the valves (3), (4), (23), and of the boom
valve. They are inspected as follows:
a. Install a pressure gauge to the measuring point M1 of the feed and percussion control block.
b. Start the power-pack.
c. If the readings of the percussion (11) and feed (21) pressure gauges is zero, but the pressure at the
measuring point M1 is over stand by-pressure, it is likely that the boom valve is sticking.
d. Stop the power-pack.
e. Clean, repair, or replace the boom valve.
f. Remove the pressure gauge from the measuring point M1.
g. If pressure reaches the percussion pressure gauge (11) and percussion operates normally when the
power-pack is running, it is likely that the percussion main valve (3) or the percussion selector valve
(4) is faulty. In this case, do as follows:
• Stop the power-pack.
• Clean and repair, or replace the faulty valve.
h. If pressure reaches the feed pressure gauge (21) when the power-pack is running, it is likely that the
spool of the feed directional valve (23) is sticking. In this case, do as follows:
• Stop the power-pack.
• Remove the spool of the feed directional valve (23).
• Clean the spool and the spool housing carefully.
• Reinstall the spool (do not use excessive force).

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8.3.2 PRESSURE REGULATOR (B) VALUE DEVIATES FROM THE SET VALUE 250 BAR

1. Install a pressure gauge to the measuring point M1 of the feed and percussion control block.
2. Start the power-pack.
3. Run, for instance, the zoom cylinder inwards and adjust, at the same time, the pressure regulator
(B) of the pump (1) to the set value 250 bar.
4. If the pressure regulator does not react to adjustment, it is either sticking or faulty.
5. Stop the power-pack.
6. Clean and repair the regulator (B), or replace the whole regulator unit
7. If the pressure regulator (B) operates normally during drilling, but the max. pressure value of 250 bar
is not reached when the boom is run, it is likely that the boom valve’s main pressure limit is faulty. In
this case, look up into “Hydraulic TB boom” manual.

8.4 PERCUSSION NOT WORKING AT ALL

1. If the percussion pressure gauge (11) shows a reading, but percussion does not work when the
control lever of the percussion pilot control valve (14) is locked into the rear position, it is likely that
the rock drill is faulty. In this case, do the following:
a. Stop the power-pack.
b. Repair or replace the rock drill (refer to rock drill manuals).
2. If the percussion pressure gauge (11) does not show any reading when the percussion control
lever (14) is locked into the rear position, it is likely that either the percussion main valve (3) or the
percussion selector valve (4) is sticking. Check the operation of the valves as follows:
a. Stop the power-pack.
b. Clean and repair, or replace the faulty valve(s).
3. If the percussion pressure gauge (11) shows a reading, but percussion starts only partially (or not at
all) when the control lever of the percussion pilot control valve (14) is locked into the rear position,
and while boom functions are normal, it is likely that the orifice (9) in the load-sensing line is blocked.

Check the orifice as follows:

a. Stop the power-pack.
b. Remove the adapter from the port 9 of the feed and percussion control block.
c. Remove the orifice (9) and check if it is blocked (clear the hole as necessary).
d. Mount the orifice (9) carefully back on the port 9 of the feed and percussion control block.

8.5 PERCUSSION IS ON ALWAYS WHEN THE POWER-PACK OR THE DIESEL ENGINE

IS RUNNING

1. First, check tank line pressure of the drilling pilot control valves (58), (14), and (31). This pressure
should be less than 1 bar. The tank pressure is checked as follows:
a. Stop the power-pack.
b. Install a pressure gauge to the tank line of the drilling pilot control valves (58), (14), and (31).
c. Start the power-pack.
d. If the pressure in the tank line is over 1 bar, check if the tank line is correctly installed or is
there something blocking the line.

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2. If the tank line pressure of the pilot control valves (58), (14), and (31) is below 1 bar, it is likely that
either the valves (3) and (4) or the valve (14) is sticking. The operation of the valves can be checked
as follows:
a. Install a pressure gauge to the measuring point M9 of the feed and percussion control block.
b. Start the power-pack.
c. If the measuring point M9 shows no pressure, it is likely that the valve (3) or (4) is sticking.
Check the valves as follows:
• Stop the power-pack.
• Clean and repair, or replace the faulty valve(s).
d. If the measuring point M9 shows a pressure reading, it is likely that the valve (14) is sticking
(leaking). Check the operation of the valve as follows:
• Stop the power-pack.
• Replace the percussion pilot control valve (14).

8.6 PERCUSSION FULL-POWER MAX. PRESSURE TOO HIGH

1. If the rattling on/off valve (8) is faulty or sticking, clean and repair, or replace the valve.
2. If the percussion pressure is too high, start troubleshooting by checking the adjustment of the
percussion max. pressure relief valve (7)
3. If the above measures do not make the pressure level correct, the fault may be that the load- sensing
line orifice (9) has loosened. The mounting of the orifice (9) is checked from the port 9 of the feed
and percussion control block as follows:
a. Stop the power-pack.
b. Remove the adapter from the port 9 of the feed and percussion control block.
c. Check if the orifice (9) is properly seated at the bottom of the drilling port 9.
d. If the orifice has loosened, retighten it carefully.
e. Mount the adapter back on the port 9 of the feed and percussion control block.

8.7 PERCUSSION FULL-POWER MAX. PRESSURE TOO LOW

1. If the percussion pressure is too low, start out by checking the operation of the percussion max.
pressure relief valve (7). If the percussion pressure relief valve (7) does not adjust as described in the
said chapter, clean and repair, or replace the valve.
2. Next, check the feed pilot control pressure value:
a. Remove the drill rod.
b. Install a pressure gauge to themeasuring point M1for the anti-jamming and return automatics.
c. Start the power-pack.
d. Run the rock drill against the front stopper by locking the control lever of the feed pilot
control valve into the rear position.
e. If the pressure at the measuring point M1 is not 19-21 bar, it is likely that the feed pilot control
valve (31) is faulty.
f. Stop the power-pack.
g. Replace the feed pilot control valve (31).
h. If the pressure at the measuring point M1 is approx. 19-21bar, it is likely that the percussion
pressure selector valve (5) and/or the monitoring valve (18) is faulty or sticking. Check the
operation of the valves as follows:
• Stop the power-pack.
• Clean and repair, or replace the faulty valve (5) and/or (18).

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3. Percussion pressure may also drop if the load-sensing line orifice (9) becomes blocked. Check the
orifice (9) as follows:
a. Start the power-pack.
b. Turn percussion on by locking the control lever of the percussion pilot control valve (14) into
the rear position, and move the boom at the same time.
c. If the boom functions are normal, but the percussion pressure remains low, it is likely that the
orifice (9) in the load--sensing line is at least partly blocked. Check the orifice (9) hole as follows:
• Stop the power-pack.
• Remove the adapter from the port 9 of the feed and percussion control block.
• Remove the orifice (9) to check it (clear the hole as necessary).
• Mount the orifice (9) back carefully.
4. If the output of the pump (1) is insufficient, the percussion pressure will drop. The output of the pump
(1) can be checked by installing flow meters to the percussion and feed lines. The flow rates for
percussion (HLX5/RD) and feed (TF500/TFX500) are following:

Percussion Feed
100-115 l/min 4-8 l/min

If the flow rates are higher than those given above, you should immediately check the condition of the rock
drill or the feed cylinder.
5. A drop in percussion pressure may also be caused by a leaking shuttle valve (10) and/or (208). Check
the shuttle valves as follows:
a. Stop the power-pack.
b. Clean or replace the valve (10) and/or (208).
6. Check the condition of the pressure gauge (11) with a calibrated reference gauge.

8.8 PERCUSSION HALF-POWER PRESSURE TOO HIGH

1. If the percussion half-power pressure is too high, check the adjustment of the percussion half-
power pressure relief valve (6) and the monitoring valve (18) . If the pressure relief valve (6) or the
monitoring valve (18) does not work as it should, clean and repair, or replace the faulty valve.
2. If the pressure level is not correct after the above repair, the reason may also be that the orifice
(9) of the load-sensing line has loosened. The mounting of the orifice (9) is checked from the port 9
of the feed and percussion control block as follows:
a. Stop the power-pack.
b. Remove the adapter from the port 9 of feed and percussion control block.
c. Check if the orifice (9) is properly seated at the bottom of the drilling port 9.
d. If the orifice has loosened, retighten it carefully.
e. Mount the adapter back on the port 9 of the feed and percussion control block.
3. High pressure level of percussion half-power may also result if the percussion pressure selector
valve (5) is sticking. Check the operation of the valve as follows:
a. Stop the power-pack.
b. Clean and repair, or replace the valve (5).

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8.9 PERCUSSION HALF-POWER PRESSURE TOO LOW

1. If the percussion half-power pressure is too low, check the adjustment of the percussion half- power
pressure relief valve (6) and/or the monitoring valve (18). If the pressure relief valve (6) and/or the
monitoring valve (18) do not work as they should, clean and repair, or replace the valves.
2. If the pressure level is not correct after the above repair, the reason may also be that the orifice
(9) of the load-sensing line has become blocked. Check the orifice (9) from the port 9 of the feed and
percussion control block as follows:
a. Stop the power-pack.
b. Remove the adapter from the port 9 of feed and percussion control block.
c. Remove the orifice (9) at the bottom of the drilling.
d. Clear the orifice hole as necessary.
e. Mount the orifice (9) back to the bottom of the hole carefully.
f. Mount the adapter back on port 9 of the feed and percussion control block.

8.10 FEED NOT WORKING AT ALL (DRILLING)

If drilling feed is not working at all, check the adjustment of feed pilot control pressure. Feed pilot control
pressure is checked as follows:

1. Install a pressure gauge to the measuring point M1 of the anti-jamming and return automatics block.
2. Start the power-pack.
3. Lock the control lever of the feed pilot control valve (31) into the rear position.
4. If the pressure at the measuring point M1 is approx. 19-21 bar, and the feed pressure gauge (21) also
shows a pressure reading, it is likely that the feed cylinder is faulty, or a mechanical fault prevents
feed. Repair or replace the faulty component(s).
5. If the pressure at the measuring point M1 is approx. 19-21 bar, but the feed pressure gauge (21)
does not show any reading, it is likely that the spool of the feed directional valve (23) is sticking.
Check the operation of the spool as follows:
a. Stop the power-pack.
b. Remove the front cover of the feed directional valve (23). The spool comes out with the cover.
c. Clean the spool and the valve housing carefully.
d. Mount the spool back with care.
6. If there is no pressure at the measuring point M1, it is likely that the feed pilot control valve (31) is faulty.
Repair as follows:
a. Stop the power-pack.
b. Replace the valve (31).

8.11 DRILLING FEED PRESSURE TOO LOW

Troubleshooting should be started by checking the operation of the feed regulating valve (20). This is done as
follows:
1. Start the power-pack.
2. Lock the control lever of the feed pilot control valve (31) into the front position.
3. Check if the feed pressure regulating valve (20) adjusts the feed pressure. Read the pressure value in
the pressure gauge (21).
4. Release the control lever of the feed pilot control valve (31) into the middle position.
5. Stop the power-pack.

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6. If the feed pressure regulating valve (20) does not adjust it is likely that either the valve (20) or the
feed cylinder is faulty. Check the condition of the components as follows:
a. Stop the power-pack.
b. Plug the feed pressure line.
c. Start the power-pack and check if the feed pressure regulating valve (20).
d. If the valve (20) adjusts it is likely that the feed cylinder is faulty. Repair or replace the faulty
component.
e. If the feed pressure regulating valve (20) is still not adjusting, it is likely that the valve (20) is
faulty. Clean and repair or replace the valve.
7. If the above repairs did not remedy the feed pressure adjustment, check the feed pilot control
pressure value. It should be approx. 19--21 bar. Check the pressure as follows:
a. Install a pressure gauge to the measuring point M1 of the anti-jamming and return automatics
block.
b. Remove the drill rod.
c. Lock the control lever of the feed pilot control valve (31) into the rear position.
d. If the pressure at the measuring point M1 is not approx. 19-21 bar, it is likely that the feed pilot
control valve (31) is faulty. Repair as follows:
• Stop the power-pack.
• Replace the faulty pilot control valve (31).

8.12 DRILLING FEED PRESSURE TOO HIGH

1. First, check the operation of the feed pressure regulating valve (20) as instructed steps 1-5. If the
pressure regulating valve (20) does not adjust it is likely that the valve (20) is faulty. Repair as follows:
a. Stop the power-pack.
b. Clean and repair, or replace the valve (20).
2. If the fault was not removed, follow the instructions in the chapter “Drilling feed pressure too low”,
step 5. If the pressure at the measuring point of the anti-jamming and return automatics block is well
over 21 bar, it is likely that the feed pilot control valve (31) or the fast feed pilot control valve (33) is
faulty. Check the operation of the valves as follows:
a. Install pressure gauges to the measuring points M1 and M2 of the anti-jamming and return
automatics block.
b. Start the power-pack.
c. If pressure reaches the measuring point M2 only, it is likely that the fast feed pilot control valve
(33) is faulty, but if both measuring points receive pressure simultaneously, it is likely that the
feed pilot control valve (31) is faulty.
d. Stop the power-pack.
e. Replace the faulty valve.
3. If the fault still was not removed, it is likely that the compensator (22) of the feed directional valve
(23) is faulty. In this case, the feed directional valve (23) must be replaced as a complete unit.

8.13 MANUALLY CONTROLLED FAST FEED NOT WORKING

1. If manually controlled fast feed is not working at all, troubleshooting should be started by checking
the pilot control pressure of fast feed. The pressure is checked as follows:
a. Install pressure gauges to the measuring points M2 and M3 of the anti-jamming and return
automatics block.
b. Remove the drill rod.

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 c. Start the power-pack.
d. Run fast feed back and forth by turning the control lever of the fast feed pilot control valve
(33) forwards and backwards.
2. If the measuring points M2 and M3 receive an approx. 30 bar pressure, and the feed pressure gauge
(21) also shows a pressure reading, it is likely that the feed cylinder is faulty, or a mechanical fault
prevents the movement.
a. Repair or replace the faulty component(s).
3. If the measuring points M2 and M3 receive an approx. 30 bar pressure, but the feed pressure gauge
(21) shows no reading, it is likely that the spool of the feed directional valve (23) is sticking. Check the
operation of the spool as follows:
a. Stop the power-pack.
b. Remove the front cover of the feed directional valve (23). The spool comes out with the cover.
c. Clean the spool and the valve housing carefully.
d. Insert the spool back with care, and mount the front cover.
4. If the measuring pointsM2 and M3 receive no pressure, it is likely that the fast feed pilot control valve
(33) is faulty. Repair as follows:
a. Stop the power-pack.
b. Replace the faulty valve (33).

8.14 MANUALLY CONTROLLED FAST FEED TOO SLOW

1. Start troubleshooting by checking the pilot control pressures of fast feed in both directions. The
pressures are checked as follows:
a. Install pressure gauges to the measuring points M2 and M3 of the anti-jamming and return
automatics block.
b. Remove the drill rod.
c. Start the power-pack.
d. Run fast feed back and forth by turning the control lever of the fast feed pilot control valve
(33) forwards and backwards.
2. If both measuring points show an approx. 30 bar pilot control pressure, it is likely that the fault is
caused by either the adjustments of fast feed max. speeds or the adjustment of fast feed max.
pressure. Check the adjustments as follows:
a. Run the rock drill against the rear stopper by locking the control lever of the fast feed pilot
control valve (33) into the front position.
b. If the feed pressure gauge (21) shows the set 210 bar pressure, it is likely that the fast feed
max. speeds are incorrectly adjusted. Adjust the fast feed max. speeds according to
instructions in chapter “Adjusting fast feed max. speed”
c. If the fast feed max. pressure is not at the set value, adjust the pressure according to chapter
“Adjusting fast feed max. pressure” . If the adjustment does not correct the situation, the fault
is caused by either the fast feed max. pressure relief valve (30) or the feed cylinder.
• Stop the power-pack.
• Plug the feed cylinder.
• Start the power-pack.
• Run fast feed forwards by pulling the control lever of the fast feed pilot control valve
(33) backwards.
• If the fast feed pressure now adjusts to the set value, it is likely that the feed cylinder is
leaking or the feed has mechanical fault. Repair or replace the faulty component(s).

159
 • If the pressure does not adjust with the fast feed max. pressure relief valve (30), it is
likely that the valve is faulty. Clean and repair, or replace the valve (30), and adjust as
instructed in chapter “Adjusting fast feed max. pressure”.

8.15 MANUALLY CONTROLLED FAST FEED TOO FAST

If manually controlled fast feed is too fast in either direction, the fast fed max. speeds are incorrectly adjusted.
Refer to chapter “Adjusting fast feed max. speed”.

8.16 VARIABLE DISPLACEMENT PUMP (50) ROTATES NORMALLY, BUT THE SETTINGS
OF ITS REGULATOR ARE NOT NORMAL

The settings of the variable displacement pump (50) regulator are as follows:
• Flow regulator (A) 20-23 bar
• Pressure regulator (B) 200 bar

Check the settings according to the chapter “Adjusting variable displacement pump (50)” (p. 74)

8.16.1 FLOW REGULATOR (A) VALUE DEVIATES FROM THE SET VALUE 22-30 BAR

1. Install a pressure gauge to the LS-connection of the rotation directional valve (53).
2. Start the power-pack.
3. If the pressure at the LS-connection of the rotation directional valve (53) is normal tank pressure,
it is likely that the regulator Aof the pump (50) is incorrectly adjusted or sticking. Adjust the free
circulation pressure of the pump (50) to the correct value with the regulator A (Cf. “Adjustments of
variable displacement pump (1) and (50)”.
4. If the above operations did not help, stop the power-pack and clean, repair or replace the whole
regulator unit. Adjust the regulator A or the regulator unit according to the Chapter “Adjustments of
variable displacement pump (1) and (50)”.

160
5. If the pressure at the LS-connection of the rotation directional valve (53) is over the normal tank
pressure, it is likely that the pilot control valve of rotation (58) is sticking or the rotation directional
valve (53) is sticking (i.e. are leaking, and giving a control signal to the pump (50).
6. Operate as follows:
a. Stop the power-pack.
b. Clean and repair, or replace the faulty valves.

10.16.2. PRESSURE REGULATOR (B) VALUE DEVIATES FROM THE SET VALUE 200 BAR

1. Check the setting of the pressure regulator (B) according to the chapter “Adjusting variable
displacement pump (50)”.
2. If the pressure regulator (B) does not react to the adjustment, it is either sticking or faulty.
3. Clean and repair the regulator (B), or replace the whole regulator unit (adjust according to the chapter
“Adjustments of variable displacement pump (1) and (50)”.
4. Check also the the value of the regulating valve (55) of the rotation control valve according to the
chapter “Adjusting the max. pressure of rotation circuit”.
5. Clean and repair the regulating valve (55) or replace it with new one.

8.17 ROTATION PRESSURE TOO LOW

1. If rotation pressure is insufficient during drilling, you should immediately check the setting of LS-
pressure relief valve (65) of the rotation control block. Refer to chapter “Adjusting the max. pressure
of rotation circuit”. If the LS-pressure relief valve (65) does not adjust to the recommended value (180
bar), it is likely that the valve (65) is faulty. In this case, clean and repair or replace the valve and adjust
it according to the instructions in chapter “Adjusting the max. pressure of rotation circuit”.
2. If the rotation pressure is lower than normal during drilling, the reasonmay be that the feed pressure
is too low or the oil flow to feed is too small. In this situation, there is a risk of underfeed, and the
following points should be checked:
a. Adjust feed pressure with the feed deviation valve (216) so that rotation pressure sets
between 80 and 100 bar. If this won’t help follow the steps 2b to 2g.
b. Install a pressure gauge to the measuring point M1 of the anti-jamming and return automatics
block.
c. Remove the drill rod.
d. Start the power-pack.
e. Lock the control lever of the feed pilot control valve (31) to the rear position.
f. If the pressure at the measuring point M1 is approx. 19-21 bar, it is likely that the feed
pressure is insufficient.
g. If the pressure is well below 19 bar, it is likely that the feed pilot control valve (31) is faulty.
Replace the faulty valve (31).
3. If the rotation pressure persistently remains low, it is likely that the rock drill rotation motor is leaking.
a. Replace the rock drill rotation motor.

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8.18 ROTATION PRESSURE TOO HIGH DURING DRILLING

1. Too high rotation pressure during drilling may be caused by too high feed pressure or incorrect drill
rod rotation speed.
a. Refer to chapter “Adjusting rotation speed” for rotation speed adjustment.
b. Adjust feed pressure with the feed deviation valve (216) so that rotation pressure sets
between 80 and 100 bar. Refer to chapter “Adjusting feed pressure”.
2. If the above adjustments did not bring down the rotation pressure, it is likely that the rock drill rotation
motor or the rotation mechanism is faulty.
a. Refer to the rock drill maintenance manuals.

8.19 ROTATION SPEED REGULATION NOT WORKING

1. If the regulation of rotation speed is not working, start troubleshooting by checking the rotation
speed pilot control pressure. The pressure is checked as follows:
a. Install measuring adapters and pressure gauges to the pilot control lines a and b of the
rotation control block.
b. Turn the rotation speed regulating valve (59) fully closed (clockwise).
c. Start the power-pack.
d. Lock the control lever of the rotation pilot control valve (58) into the rear position.
e. Lock the control lever of the rotation pilot control valve (58) into the front position.
f. Release the control lever of the rotation pilot control valve (58) to the middle position.
g. Stop the power-pack.
h. If the pilot control lines of the rotation directional valve (53) received an stand by-pressure, it
is likely that the rotation regulating valve (59) is faulty or the rotation directional valve (53) is
sticking. Check the operation of the valves as follows:
• Clean and repair, or replace the rotation speed regulating valve (59).
• Start the power-pack.
• Lock the control lever of the rotation pilot control valve (58) into the rear position.
• Turn the rotation speed regulating knob between extreme positions.
• Release the control lever of the rotation pilot control valve (58) to the middle position.
• Stop the power-pack.
i. If the rotation speed regulation still did not work, it is likely that the rotation directional
valve (53) is sticking. Check the operation of the valve (53) as follows:
• Stop the power-pack.
• Remove the the rotation directional valve (53).
• Clean the spool and the valve housing carefully.
• Mount the valve back in place.
2. If the above repairs did not help to remedy the rotation speed regulation, it is likely that the rock drill
rotation motor or the rotation mechanism is faulty.
a. Refer to the rock drill maintenance manuals.

162
8.20 RETURN AUTOMATICS FAST FEED NOT WORKING

If the rock drill does not start return movement automatically from the front limit, check if the return automatics
selector switch is in the correct position (middle). If it is, check if the coil Y47 of the return automatics selector
valve (39) at the anti-jamming and return automatics block is receiving control voltage.
• If the coil of the valve (39) receives control voltage, it is likely that the valve (39) is sticking.
- Clean and repair, or replace the valve.
• If the coil of the valve (39) is not receiving control voltage, refer to instructions in chapter
“Electric system troubleshooting”.

8.21 DISTURBANCE IN SHANK LUBRICATION

The SLU unit monitors the oil flow. If no flow is detected, the indicator light (H72) on the drilling panel is lit
and automatic drilling is stopped. This is reset by restarting the percussion or rotation and testing whether
lubrication starts.

In the shank lubrication system, the air pressure for shank lubrication is also monitored, separately for each
rock drill. If the air pressure falls below 2.8 bar, the indicator light (H72) on the drilling panel comes on and
automatic drilling is stopped.

The oil level in the SLU oil tank is monitored as well. If the oil level in the SLU oil tank drops below the preset
minimum level, all power packs are stopped and the low shank lubrication oil level indicator light (H608) on the
QN panel lights up.

8.21.1 PINPOINTING THE FAULT IN THE PNEUMATIC CIRCUIT

If the drilling is stopped repeatedly and the indicator light (H72) indicates that the fault is in shank lubrication,
the fault can be pinpointed in the pneumatic circuit as follows:
1. Turn rotation on.
Shank lubrication starts.
2. Check whether the rock-drill-specific SLU air valve on the carrier receives control (is the LED on the
valve cover lit?).
3. If the valve receives a control signal, measure the air pressure going to the pressure switch that
monitors the shank lubrication.
The pressure switch should be triggered at 2.8 bar and inform the monitoring system that the air
pressure is sufficient.
4. If the air valve is working properly and the air pressure at the switch is sufficient, the fault is either in
the air pressure switch or in the SLU pump unit – i.e., in the oil flow.

8.22 TOO LOW OR HIGH STABILIZER PRESSURE

The stabilizer pressure control system monitors for insufficient or excessive pressure. The control has a two-
second delay. The stabilizer pressure control is activated when the power pack of the boom in question
is started. If a stabilizer pressure fault occurs, the stabilizer indicator light (H72) on the drilling panel starts
blinking and automatic drilling is stopped.

The stabilizer pressure control has no separate reset procedure; drilling can be continued as soon as the
stabilizer pressure is within the permissible range.

163
8.23 ELECTRIC SYSTEM TROUBLESHOOTING

Trouble Reason Operation

Pilot control valves for drilling do S70, S71, and S72 do not stay on • Check power supply fuse
not stay on • Check power supply feed
cable
• Check if front limit pressure
switch S80 is activated
• Check operation of relays
K77, K74, K129, K70

Pilot control valves for drilling do S72 does not stay on although Check that V18 is fitted
not stay on S70 and S71 do
Drilling does not stop No automatic return of rock drill • Check position of switch S73
from front end and S74 (Return does not
work in manual position)
• Check operation of front limit
pressure switch S80
• Check relays (does relays
K70, K71pull at front limit)
• Check relay (does relay K78
pull at front limit with 6 sec
delay)
• Check Y47 operation at front
limit (LED indicator). If LED
illuminates, check operation
of hydraulic system

Drilling stops and rock drill tries to If forced return works with switch • Check operation of rear limit
return, but stops S73, rear limit S81 is maybe pressure switch S81
damaged • Check relay (does relay K72
pull at rear limit)

Forced return not working with Switch maybe damaged Check operation of switch S73
switch S73
Rock drill rotation stays on after Time relay K70 maybe damaged Check operation of time relay K70
rear end
Forced return not working with Switch maybe damaged Check operation of switch S74
switch S74
Drilling stops but air blowing does Rear limit S81 is maybe damaged • Check operation of rear limit
not start (switch S74 in position pressure switch S81
"automatic") • Check relay (does relay K72
pull at rear limit)

164
8.24 MAIN REFERENCE VALUES (FACTORY SETTINGS) FOR TROUBLESHOOTING OF
HYDRAULICS

Object Value
Variable displacement pump (1)
• pressure controller 250 bar
• flow controller 22-30 bar
Variable displacement pump (50)
• pressure controller 200 bar
• flow controller 20-23 bar
Pilot control pressure for rotation, percussion, flushing and fast feed 30 bar
Pilot control pressure for feed 19-21 bar
Half-power percussion pressure 100 bar
Full-power percussion pressure
• for TF 500 or TFX 500 230 bar
Max. pressure of rotation circuit (relief valve (65)) 180 bar
Max. fast feed pressure
• for TF 500 210 bar
• for TFX 500 180 bar
Anti-jamming sensitivity pressure 120 bar
Max. speed forwards (fast feed)
• for TF 500 ≈ 0.3 m/s
• for TFX 500 ≈ 0.3 m/s
Max. speed backwards (fast feed)
• for TF 500 ≈ 0.5 m/s
• for TFX 500 ≈ 0.3 m/s
Return automatics (hydraulic control)
• pressure reducing 10 bar
• max. pressure (impulse circuits) 30 bar
Main pressure relief valve (211) 270 bar
Boom max. operating pressure 230 bar
Control pressures of stabilizer (optional) min. 50 bar
max. 110 bar
ref. 30 bar
Power extractor pressure (optional) 150 bar

165
MODULE 7 - TRAMMING

1. MAIN COMPONENTS
1.1 STEERING

1: Steering cylinder 4: Central articulation expandable pin

2: Cylinder pin 5: Swing crown wheel
3: Cylinder greasing device

163
1.2 TRAMMING

1.2.1 EXPLANATION

First purpose of the charge circuit is to supply a pressure of 28 bar in any conditions of use (only when diesel
engine is running) to lubricate and cool down all internal moving parts.

Hydraulic fresh oil from the tank (1) enters the pump group (2). The oil pressure is increased in the charge
pump (3) (10=>28 bar) and directed through the filter (4).

Low pressure oil supplies the tramming circuit (include high pressure line) and allows the control of all elements.
The drained oil flows directly into the housing of the pump group. Thus fresh and proper oil always flows from
tank (1) to cooler (8) through the pump, without return filtration to prevent building up of back pressure.

Note: Due to this cooling circuit, a large flow is seen at the drain line. That does not means that the tramming
component are leaking or worn out. The tramming pump (5) can also deliver the needed pressure (28 => 440
bar) depending on informations coming from the tramming control panel and pedals.
Note: The charge pump (3) is linked to the main shaft therefore it runs at the same speed as the main pump (5).

The high pressurized oil is divided between the four wheel motors (6) in order to adapt the rotation speed at
the conditions (steering / grip of tyres) Each wheel motor can rotate in the two ways.

Optional HP filters (10) (one per way of rotation of the wheel motors) can be added between the tramming
pump (5) and the wheel motors (3).

SEE TRAMMING HYDRAULIC DIAGRAM, in section 1 of the spare parts manual.

164
1.2.2 ELEMENTS LOCATION

165
1.2.3 TRAMMING PUMP INLETS / OUTLETS

G: Charge pressure outlet

Ps: Pump control pressure gauge
Ma/Mb: High pressure line pressure gauge
R: Drain plug
S: Tank oil supply
T1: Drain (to cooler)
T2: Drain relief outlet
1: DA valve, control pressure adjusting
2: Charge pressure relief
3: Maxi high pressure adjusting
Fa: Charge pressure gauge
X1/X2: Cylinder pressure
Y1/Y2: Forward / backward control
HPa / HPb: Wheel motor supply Lines pressure relief

166
2. TIGHTENING TORQUES

2.1. STANDARD TIGHTENING TORQUES

For basic genuine SANDVIK screws and nuts use the following tightening torques:
Metric dimension Torque in Nm HEX BOLTS Torque in Nm “SIX CUT
GRADE 8.8 HOLLOW” BOLTS GRADE 12.9
M6 10 16
M8 25 40
M10 50 80
M12 85 140
M14 130 210
M16 200 330
M18 280 460
M20 400 650
M22 530 880
M24 670 1130
M27 1000 1650
M33 1780 2200
M36 2300 3850
M39 3000 5050
M42 3700 6250

2.2 HR BOLTS
FOR HR (HIGH RESISTANCE) BOLTS, YOU MUST FOLLOW THE TIGHTENING TORQUE INDICATED
ON THE BOLTS’ PACKAGING. THIS, BECAUSE FOR A SAME HR BOLT, THE TIGHTENING TORQUE
CAN CHANGE ACCORDING TO THE BOLT’S SUPPLIER AND TO THE THREAD TIGHTENING TORQUE
EFFICIENCY RATIO. A TOO HIGH TIGHTENING TORQUE CAN DEFORM THE BOLT.

The following tightening torques are only indicative for HR bolts originally mounted to the machine at Sandvik’s
workshop. Unit used is Newton metre (Nm).

TA L LY/ TYPE 8.8 TYPE 10.9

S I Z E GRADE 8.8 GRADE 10.9
(mm) HEXAGONAL “ALLEN”
K:0,12 K:0,13 K:0,14 K:0,15 K:0,12 K:0,13 K:0,14 K:0,15
M 16 170 185 200 210 240 260 280 300
TIGHTENING
TORQUES

M 20 330 360 385 415 465 505 545 580

M 22 450 490 525 565 635 685 740 795
M 24 590 620 665 715 805 870 940 1005
M 30 1135 1230 1325 1420 1600 1730 1865 2000
Nm Nm

K: Thread tightening torque efficiency ratio.

167
2.3. SPECIFIC TIGHTENING TORQUES

3. LUBRICATION

3.1. LUBRICANT
Use SHELL Alvania EP2 or equivalent (see lubricant & coolant recommendation manual).

3.2. GREASE POINTS

Grease nipples location :

168
4. OPERATING METHODS

4.1. PINS

• Check that the lock plate (2) is in contact to the support.

• Check that screws (1) are in place and tighten (85 Nm).

4.2. CENTRAL ARTICULATION EXPANDABLE PINS

MOUNTING :
• 1. Position the shaft (1) in the bore.
• 2. Using the non-threaded conical bush (2), push the shaft (1) down to 17.5
mm to the yoke (5).
• 3. Install the threaded conical bush (4).
• 4. Install the screw (3) and apply the torque progressively to the value of 290
Nm while maintaining the height of 17.5 mm approximately.
• 5. Install and torque the locking nut (6) at 290 Nm.
• 6. Steer the machine several times over a tramming distance of 100m.
• 7. Check the torques of 290 Nm.
• 8. Re-check after about 300 diesel hours.

4.3. TYRES
• Visually check the tyres (1), look for damages.
• Make sure the nuts (2) are correctly tighten (Wheel tightening
torque : 400 Nm).
• Make sure the lock ring (3) is correctly in place.
• Check the pressure (tyre pressure : 9,5 bar).

NOTE: For old tyres (MICHELIN & NOKIA), tyre pressure : 8 bar.

4.4. TRAMMING HYDRAULIC TANK

MANUAL FILLING PUMP

TRAMMING HYDRAULIC TANK
• Make sure that the tramming hydraulic oil level is above the
minimum mark (1) of the sight glass.
• Turn ball valve (2) for select tramming tank or drilling tank.
• If needed fill up the tank to the maximum mark using the hand
pump (3).
• Tramming oil level caution light (4)

169
ELECTRIC FILLING PUMP (OPTIONAL)

TRAMMING HYDRAULIC TANK

• Make sure that the tramming hydraulic oil level is above the
minimum mark (1) of the sight glass.
• Turn switch (2) for select tramming tank and push the button (3)
• If needed fill up the tank to the maximum mark using the electric
filling pump(4).
• Tramming oil level caution light (5).

TRAMMING TANK FILLING OIL FILTER

• Make sure that the oil filter clogging indicator (A) indicates the
green colour. If it is red, the oil filter is colmated and need to be
replaced

4.5. HP TRAMMING FILTERS (OPTIONAL)

• Make sure that caution light (1) is off, if is on, the tramming HP
filters (2) are colmated to 75% and need to be replaced.
• If the HP filters are colmated to 100%, the tramming is stopped
and not allowed.

170
4.6. BRAKE TESTS

ELECTRICAL EMERGENCY/PARKING BRAKE TEST

WARNING
Whenever an operator takes charge of the machine, he must perform the electrical
emergency/parking brake test and service brake before any other operation.

DANGER
Brake test shall not be done by pressing emergency/parking brake push button from full
speed!
The tramming wheel motors braking technology only enables 10 emergency stops at
full speed. After 10 emergency braking, all wheel motors brake discs must be replaced
in order to ensure safe operating of the machine. Emergency braking events must be
counted and immediately reported. Sandvik also recommends to always get wheel
motors brake discs kits in stock.
This test procedure must be performed in static mode and it is not counted as one of
these maximum 10 emergency brake stops from full speed.
DANGER
Mobile machinery hazard!
Unexpected movement of the drill rig during the brake test could cause death or severe
injury. Ensure there is nobody in the hazard zone indicated below during brake test.
Always sound the horn before starting the engine in order to perform the test.

• 5m zone toward the front end of the feed and 5m zone backward the rear end of the machine.
• 5m zones from right and left sides of the machine.

171
 WARNING
Use only 0-600 bar gauge due to the high pressure.

1. Emergency/parking brake
push button.
2. Tramming direction switch.
3. Speed selector switch.
4. Emergency/parking brake
test selector switch.
5. Accelerator pedal.
6. Service brake pedal.
T. Tramming pressure test
point.

1. TEST PREPARATION
• Perform the brake test in a safe, horizontal, flat and opened zone.
• Ensure the machine is in tramming position with normal oil temperature and operating conditions.
• Apply the emergency/parking brakes by pressing the push button (1).
• Install a 600 bar gauge at the tramming pressure test point (T).
• Turn the tramming speed selector switch (3) to slow speed range (turtle).

2. ELECTRIC EMERGENCY/PARKING BRAKE TEST

• Select one tramming direction (2), turn and keep the emergency/parking brake test selector switch (4)
on TEST position and accelerate (5) slowly until the engine reaches full RPM.
-- The tramming pressure gauge must reach 440 bar AND THE MACHINE MUST NOT MOVE.
NOTE: Both tramming directions must be tested.

DANGER
Uncontrolled movements hazard using a drill rig with faulty brakes will cause death or
severe injury.
If the machine doesn’t fulfil the emergency/parking brake test and service brake test, have
the brakes repaired immediately.
Do not use the machine and inform a responsible person immediately.

172
SERVICE BRAKE TESTS

1. SERVICE BRAKE TEST

• Perform the brake test in a safe, horizontal, flat and opened zone.
• Ensure the machine is in tramming position with normal oil temperature and operating conditions.
• Ensure tramming speed selector switch (3) is in slow speed range position (turtle).
• Release the emergency/parking brake by pulling the button (1).
• Select one tramming direction(2), push the brake pedal (5), and at the same time, accelerate slowly (4),
until the engine reaches full RPM.
=> THE MACHINE MUST NOT MOVE.
NOTE: Both tramming directions must be tested.

DANGER
Uncontrolled movements hazard using a drill rig with faulty brakes will cause death or
severe injury.
If the machine doesn’t fulfil the emergency/parking brake test and service brake test,
have the brakes repaired immediately.
Do not use the machine and inform a responsible person immediately.

2. SERVICE BRAKE DYNAMIC TEST

Sandvik recommends to test the service brake additionally by dynamic way.

WARNING
This test must only be made by service team on test track or similar safe place after
periodic maintenance operations or when the brakes are replaced.

• This test requires 50 meters long and straight test track. The test track must be horizontal and flat. Do
not arrange the dynamic test on inclined test track. The machine should be in tramming position with
normal oil temperature and operating conditions. Seat belt must be fastened all the time during the
test. The test procedure is as follows:
• Turn the tramming speed selector switch (3) to fast speed range (rabbit).
• Select a safe tramming direction (2).
• Accelerate (5) the machine 10 - 20 meters until the full speed, release the accelerator pedal (5) and
push on the service brake pedal (6).
=> THE MACHINE MUST STOP IMMEDIATELY.
• If the machine doesn’t stop, push the emergency/parking brake push button (1) immediately.
NOTE: Both tramming directions must be tested.

DANGER
Uncontrolled movements hazard using a drill rig with faulty brakes will cause death or
severe injury. If the machine doesn’t fulfil the emergency/parking brake test and service
brake test, have the brakes repaired immediately. Do not use the machine and inform a
responsible person immediately.

173
4.7. BRAKES TESTS (PREVIOUS VERSION)

EMERGENCY/PARKING BRAKE TEST

WARNING
Whenever an operator takes charge of the machine, he must perform the electrical
emergency/parking brake test and service brake test before any other operation.

DANGER
Brake test shall not be done by pressing emergency/parking brake push button from full
speed! The tramming wheel motors braking technology only enables 10 emergency
Stops at full speed. After 10 emergency braking, all wheel motors brake discs must be
replaced in order to ensure safe operating of the machine. Emergency braking events
must be counted and immediately reported. Sandvik also recommends to always get
wheel motors brake discs kits in stock. This test procedure must be performed in static
mode and it is not counted as one of these maximum 10 emergency brake stops from full
speed.
DANGER
Mobile machinery hazard! Unexpected movement of the drill rig during the brake test
could cause death or severe injury. Ensure there is nobody in the hazard zone indicated
below during brake test. Always sound the horn before starting the engine in order to
perform the test.

• 5m zone toward the front end of the feed and 5m zone backward the rear end of the machine.
• 5m zones from right and left sides of the machine.

WARNING
Use only 0-600 bar gauge due to the high pressure.

174
 1. Emergency/parking brake push button.
2. Tramming direction switch
3. Speed selector switch
4. Accelerator pedal.
5. Service brake pedal.
T. Tramming pressure test point.

1. TEST PREPARATION
• Brake test must be performed in a safe, horizontal, flat and opened zone.
• Ensure the machine is in tramming position with normal oil temperature and operating conditions.
• Apply the emergency/parking brakes by pressing the push button (1).
• Install a 600 bar gauge at the tramming pressure test point (T).
• Turn the tramming speed selector switch (3) to slow speed range (turtle).

2. EMERGENCY/PARKING BRAKE TEST

• Select one tramming direction (2) and accelerate slowly (4) until the engine reaches full RPM.
=> The tramming pressure must reach 440 bar AND THE MACHINE MUST NOT MOVE.
NOTE: Both tramming directions MUST BE TESTED TWICE.
Before testing the emergency/parking brake for the second time, release the brakes by pulling the parking
brake push button in order to release the pressure in the wheel motor. Follow the complete procedure for the
second test.

DANGER
Uncontrolled movements hazard using a drill rig with faulty brakes will cause death or
severe injury.
If the machine doesn’t fulfil the emergency/parking brake test and service brake test,
have the brakes repaired immediately.
Do not use the machine and inform a responsible person immediately.

175
SERVICE BRAKE TESTS

1. SERVICE BRAKE TEST

• Brake test must be done in a safe, horizontal, flat and opened zone.
• Machine must be in tramming position with normal oil temperature and operating conditions.
• Ensure tramming speed selector switch (3) is in slow speed range position (turtle).
• Release the emergency/parking brake by pulling the button (1).
• Select one tramming direction(2), push the brake pedal (5), and at the same time, accelerate slowly (4),
until the engine reaches full RPM.
=> THE MACHINE MUST NOT MOVE.
NOTE: Both tramming directions must be tested.

DANGER
Uncontrolled movements hazard using a drill rig with faulty brakes will cause death or
severe injury. If the machine doesn’t fulfil the emergency/parking brake test and service
brake test, have the brakes repaired immediately.
Do not use the machine and inform a responsible person immediately.

2. SERVICE BRAKE DYNAMIC TEST

Sandvik recommends to test the service brake additionally by dynamic way.

WARNING
This test must only be made by service team on one test track or similar safe place after
periodic maintenance operations or when the brakes are replaced.

• This test requires 50 meters long and straight test track. The test track must be horizontal and flat. Do
not arrange the dynamic test on inclined test track. The machine should be in tramming position with
normal oil temperature and operating conditions. Seat belt must be fastened all the time during the
test. The test procedure is as follows:
• Turn the tramming speed selector switch (3) to fast speed range (rabbit).
• Select a safe tramming direction (2).
• Accelerate (5) the machine 10 - 20 meters until the full speed, release the accelerator pedal (5) and
push on the service brake pedal (6).
=> THE MACHINE MUST STOP IMMEDIATELY.
• If the machine doesn’t stop, push the emergency/parking brake push button (1) immediately.
NOTE: Both tramming directions must be tested.

DANGER
Uncontrolled movements hazard using a drill rig with faulty brakes will cause death or
severe injury. If the machine doesn’t fulfil the emergency/parking brake test and service
brake test, have the brakes repaired immediately.
Do not use the machine and inform a responsible person immediately.

176
4.8. TRAMMING ACCUMULATORS

Check the pressure on the tramming accumulator, It must be to 12 bar at 20°C.

4.9. DIESEL ENGINE AND HYDRAULIC PUMP

For DIESEL ENGINE and HYDRAULIC PUMP maintenance, refer to supplier documentations included in this
manual.

5. PERIODIC MAINTENANCE OPERATIONS

All hours frequency expressed in tramming hours, except for the diesel engine and its components (diesel
engine hours).

5.1. FIRST ENTRY INTO SERVICE

After 20 working hours or 1 week of service, check all the screws and tighten the expendable pins.

5.2. OPERATIONS AT EACH SHIFT

Before starting up:

• Check the overall condition of the equipment, the tyres condition and grease all points.
• Check the tramming hydraulic tank oil level and filling filter clogging.
• Check the optional HP tramming filter condition (clogging).
• Check the diesel engine oil & coolant level.
• Check that the brakes (park and service) are correctly working.
• Look for leaks.

5.3. 50 HOURS OR WEEKLY OPERATIONS

• Carry out the each shift operations again.

• Check all tightening torques.
• Check the central articulation expandable pins.
• Check the condition of hydraulic components (cylinders, hoses, fittings, etc...)

5.4. 50 HOURS OR MONTHLY OPERATION

• Check the tramming accumulators pressure.

5.5. 125 HOURS OR ANNUAL OPERATIONS

• Replace the diesel engine oil and filters elements.

177
5.6. 500 HOURS OR ANNUAL OPERATIONS
• Replace the tramming circuit oil and filter elements.
• Check the diesel engine coolant additive concentration, replace the coolant if needed.

5.7. 2000 HOURS OR ANNUAL OPERATIONS

• Replace the diesel engine coolant.

5.8. 3600 HOURS OPERATIONS OVERALL INSPECTION AND RECONDITIONING

• Check the wheel motors condition.
• Test for correct operation.
Note: You can recover all these operations in the periodic maintenance table (next and last page of this
manual) we invite you to use this document.

6. PERIODIC MAINTENANCE TABLE

For all lubrication

operations, see the
machine lubrication
schedule and the
lubricant and coolant
recommendation
manual in section 2
of this manual. The
same for operations
concerning the diesel
engine, with also
the diesel engine
maintenance manual in
section 8 of this manual.

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MODULE 8 - EMR 2

1. IMPORTANT NOTES

1.1 OPERATING INSTRUCTIONS

• IMPORTANT
The purpose of this document is the explanation and clarification of the design and functions of
engines, engine components and systems. The information contained herein always corresponds
to the technical conditions valid at the time of going into print and are not subject to any immediate
alteration service.

• IMPORTANT
Applicable for the operation, maintenance and start-up are exclusively the information of the published
and currently valid technical documentation, corresponding to the scope of delivery and function (such
as operating instructions, switching diagrams, workshop manual, repair and adjustment instructions,
technical circulars, service information, etc)

1.2 INSTALLATION GUIDELINES

• IMPORTANT
For the mechanical installation of the apparatus, reference should be made to the applicable issue of
the “Installation Guidelines for electronic systems of DEUTZ diesel engines”. More information can be
obtained from the DEUTZ AG, dept. technical operation support.

• REMARKS!
Sufficient ventilation of control unit and actuator must be ensured in order to prevent limitations of
function and damage.

1.3 DAMAGE

• REMARKS!
Sensors and actuators may not be fitted individually to, or between, power sources for either inspection
or testing purposes but only in connection with the EMR 2, as there is a danger of destruction!

• REMARKS!
Despite polarity reversal protection in the control apparatus, it is necessary to prevent incorrect
polarity. Incorrect polarity can damage control units!

• REMARKS!
The plug connections of the control units are only dust and watertight when plugged into mating
connection! Until the mating connector has been plugged in, the control units must be protected
against spray water!

179
1.4 CUSTOMER SIDE WIRING, PLUG CONNECTION

• IMPORTANT!
In order to attain the required protection class (IP 66) at the control unit, the individual wire seals, plugs
and sealing rings provided must be used.

• IMPORTANT!
The connection between pins and individual wires must only be carried out with the proper pinching
tools.

• REMARKS!
The voltage supply for inputs and outputs for the users must be able to be switched in a de-energized
manner via the key switch (terminal 15) - not via continuous positive.

1.5 REMOVE PLUG

• REMARKS!
Removing the 25-pole equipment plug and engine plug when the control unit is on, i.e. when the
voltage supply is on (terminal 15 on) is not permitted.
1. Voltage supply off
- Only then -
2. Pull out equipment plug and engine plug

1.6 ELECTRICAL WELDING

• REMARKS!
In order to prevent damage when carrying out ELECTRIC welding of the installation, the plug
connections at the control unit must first be pulled out.

• REMARKS!
The ignition (terminal 15) must be switched off when working at the EMR 2.

2. SYSTEM DESCRIPTION

2.1 UTILIZATION OF THE EMR 2

The purpose of the electronic engine governor (EMR 2) is the regulation of the speed of revolution of DEUTZ
Diesel engines of the model series 1012/1013/2012/2013/1015 for applications in agricultural and
construction machinery as well as in generating sets. It is designed for heavy duty also under difficult
environmental conditions and possesses the corresponding protection classes.

The governor fulfils all the functions of the mechanical governor (variable speed governing, torque limitations,
LDA function) and makes further functions available.

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2.2 SYSTEM OVERVIEW

Basically, the EMR 2 consists of the sensors, the control unit and the actuator. Engine-side as well as vehicle-
side or plant-side installation are connected by means of separate cable harnesses to the EMR control unit.
The cabling on the plant side is carried out by the vehicle or plant manufacturer. For arrangement on the
engine and plant/vehicle side, see the following figure.

* With atmospheric pressure sensor (optional)

2.3 DESCRIPTION OF FUNCTIONS

The sensors attached to the engine provide the electronics in the control unit with all the relevant physical
Parameters. In accordance with the information of the current condition of the engine and the preconditions
(accelerator pedal etc.), the EMR 2 controls an actuator that operates the control rod of the injection pump
and thus doses the fuel quantity in accordance with the performance requirements.

The exact position of the regulating rod is reported back and, if necessary, is corrected, by means of the
control rod travel sensor, situated together with the rotation magnets in a housing of the “actuator”.

181
The EMR 2 is equipped with safety devices and measures in the hardware and software in order to ensure
emergency running (Limp home) functions (see Chapter 7.1).

In order to switch the engine off, the EMR 2 is switched in a de-energized fashion over the ignition switch. A
strong spring in the actuator presses the control rod in the de-energized condition into the zero position. As
a redundancy measure, an additional solenoid serves for switching off and this, independently of the actuator,
also moves the control rod in the de-energized condition into the zero position.

After the programming, that is carried out over the ISO 9141 interface, the EMR 2 is possesses a motor
specific data set and this is then fixedly assigned to the engine. Included in this are the various application
cases as well as the customer’s wishes regarding a particular scope of function. The result of this is that any
later alteration must be reported back to the DEUTZ AG so that, in case of replacement anywhere in the world,
the new control unit can be programmed with the current data set.

2.4 BASIC EQUIPMENT

Besides the control unit, the following components are required as minimum equipment for the operation of
the engine:

Vehicle side:
• Energy supply (battery)
• Diagnostic interface (ISO 9141)
• Fault lamp/diagnostic lamp
• Diagnostic button
• Set point selection
• Key operated switch
• Function change-over switch
• Cable harness

Engine side:
• Actuator (contains control rod travel sensor and positioning magnet)
• Speed sensor (camshaft)
• Coolant temperature sensor (NTC)
• Cable harness

Further components and installation are possible depending on the application case or the desired functions
(see chapters 4 and 6). The combination can be selected from the DEUTZ pocket handbook.

182
3. SYSTEM FUNCTIONS

The EMR 2 makes a broad range of functions available and these can be activated by the application dependent
configuration and the allocation of the inputs and outputs. It makes possible signal exchange between the
engine (via the engine plug) and the EMR 2, as well as between the vehicle (via the vehicle plug) and the EMR
2. The signals can be transmitted as analogue, digital, impulse modulated (PWM signals) and as CAN-Bus
messages.
Which functions are used, depends on the application conditions of the engine. Correspondingly, there are
Different variations of the functions and the pin assignments of the plugs.

The functions of the EMR 2 refer to the speed control, quantity limitations (fuel injection), monitoring, vehicle
and apparatus functions and communication and diagnostic interfaces. The EMR 2 offer a basic equipment
on which all the optional variations can be structured, because of the numerous possibilities of combinations,
DEUTZ has defined function ranges. These can be crossed off in the DEUTZ pocket handbook. The switching
diagram for each function range should also be noted especially for the wiring required on the customers side.

183
3.1 OVERVIEW FEATURES

Feature Chapter Description

Speed control 4.3 As variable speed, idling/
end or fixed speed governor;
choice of switchable governor
features during operation,
freezing the current speed,
fixed speed governor for
network synchronization or load
distribution, overdrive speed
Set point input 4.4 By means of
• Pedal sensor and/or hand
throttle
• External voltage signal (0 - 5 V)
• CAN Bus (remote electronics)
• Fixed speed signal (gen-set
operation)
• Pulse width modulation (PWM)
• Touch control operation Up/
Down (digital) Optimal adaptation
to different applications
Torque limitation 4.5 Up to three performance curves
can be set independently of each
other within the framework of the
engine limits
Governor behaviour (speed 4.6 Constant, variable or switchable
droop) speed droop from 0 - 80 % for
adaptation to the application
Engine Start/Stop 4.7 Engine switch-off by means of
EMR actuator (additional safety
using switch-off solenoid possible
Monitoring and signal output 4.8 Coolant temperature and level, oil
functions pressure, charge air temperature,
fuel temperature fault display
and/or performance reduction
or engine switch-off for engine
protection
LDA function 4.9 Smoke limitation through charge
air pressure and/or temperature-
dependent limitation of the
adjustment speed of the injection
Temperature-dependent start 4.10 Improving the starting ability,
control gentle cold start without smoke
ejection
Altitude correction 4.13 Engine protection because of
reduced air pressure

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Fuel volume correction 4.14 Compensation for loss of
performance due to fuel heating
Emergency running 4.15 Emergency running after failure
of set point signal (e.g. using
accelerator pedal), the charge
air sensor or the vehicle speed
signal
Selection of cold start help 4.16 Failure of auxiliary control units,
installations EMR 2 controls a selection of
heating flange, glow plugs or
flame starting apparatus
Data communication 5 Interfaces, diagnostics and
programming
Output of fault blink codes 7.2 Simplified fault diagnosis

3.2 FUNCTION EXTENSIONS

The EMR 2 has the same functions as the EMR but possesses extended and new functions. The new functions
in detail are:
• Improved speed control
• Third performance curve
• Smoke limitation = function of the charge air temperature
• Monitoring the charge air temperature, coolant level
• Altitude-referenced fuel quantity
• Control of an engine brake
• Special set point parameter for gen-set applications
• Special vehicle speed evaluation to DIN 11786
• New functions via the diagnostic button:
-- Fault blink codes
-- Clearing the fault memory 1
• 2 Independent fault memories (mirroring the first fault memory)
• Acquisition of a load collective
• Baud rate alteration for ISO communication possible
• Possibility of a software update for the operating software via the ISO interface
• Newly introduced or changed commands in ISO communication
• CAN Bus protocol to SAE J1939 has been greatly extended, but is upwards compatible to the present
EMR applications.

Caution!
EMR and EMR 2 are separate systems. An exchange of control units and actuators is not possible

185
3.3 SPEED CONTROL

Provision is made for various variations of speed control that must be programmed in advance (at the end
of the programming) depending on the application case (power generation, building or agricultural machines)
and usage conditions. The variations depend on the type of programmed and the selected functions.

The following types of speed regulation (switches) are optional and are programmed at the works depending
on the variant.

Function Variant Description Remarks

Variable speed Variable speed Pure variable speed Only one variant can be
control governor1) governor without selected
addition and switch-over
functions
Fixed speed Variable speed governor
governor with fixed, predefined
speed for gen-sets
(1,500 or 1,800 rpm),
desired speed of rotation
is defined in the scope
of customer supply
(KLU).
Change-over switching Variable speed governor
speed 1 / 22) with change-over
switching possibility
between two speeds.
Change-over Variable speed governor
switching speed fixed/ with change-over
variable2) switching possibility
between a fixed
programmed and
a variable speed of
revolution.
Speed variable / Variable speed governor
freeze2) with change-over
switching possibility
between: freezing a
current desired speed as
set point independent of
the pedal setting, and a
variable revolution.
Speed memory Customer-specific
function solution for storing and
calling up two speeds of
revolution.

186
 Function Variant Description Remarks
Gen-set applications Power generation As for change-over See also system
governor with adjustable switching fixed/variable description EMR Gen-
speed range speed. Without Load the set, TN 0297 9939
speed can be adjusted in
the speed range.
Power generation for As for change-over
network synchronisation switching fixed/variable
or Load distribution speed. The variable
revolutions can be
adjusted in the revolution
range for network
synchronization or load
distribution.
Power generation As for change-over
governor with adjustable switching fixed/variable
speed and switchable speed the power
overdrive speed generator, in fixed speed
mode, can be used as the
overdrive speed without
loading, in variable mode
or for parallel switching.
Variable speed-, Min/ Variable speed, Min/Max Switching over between
Max-control governor2) variable speed and Min/
Max control.
Min/Max-control Min/Max governor1) Idling and end revolutions
for vehicle applications.

1) Types of speed control

Variable speed control

For this type of control the speed of the engine is governed or kept constant with reference to the desired
speed of revolution. For changes of load, the new required amount of fuel is set in accordance with a PID
control. The desired value can be determined through various variants.

Min/Max control
For this type of control, the fuel injection quantity is determined on the basis of the desired value. The result
of this is that, for this type of control, a speed of revolution depending on the load situation is set. The idling
(= Minimum) and the end revolutions (= Maximum) are controlled taking into account the control parameter
speed droop 1 and speed droop 2. The basis for this type of control is the drive characteristic field.

2) Change-over switching see point 4.3.1.

187
3.3.1 SWITCHABLE SPEED FUNCTIONS

The conditions for the switchable variants are selected by means of a switch (Input pin 18, GND pin 17 V plug).
The switch closes a contact to -UBatt.

The following is applicable for the switchable speed functions:

Switchable speed functions Switch open1) Switch closed

(For a selectable) (1/HIGH) (0/LOW)
Speed 1/ speed 2 Speed 1 Speed 2
Fixed / variable speed Variable Fixed
Speed variable / freeze Variable Freeze
Variable speed governor / Min/ Variable speed governor Min/Max regulator
Max governor

1) With an open switch, the underlined conditions above are activated as pre-set values (default values).

The switching condition can be displayed with the aid of the SERDIA diagnostic software

3.3.2 SECOND SPEED INPUT (OPTIONAL)

This input can be used as a redundant speed input. If a second speed sensor has been installed, then the
engine will not be switched off on failure of the first speed sensor but will switch over to the second one. The
failure of a speed sensor is indicated by the continuous burning of the fault lamp. The operation of the engine
can be limited by defining a lower desired speed.

3.3.3 EXCESS SPEED PROTECTION

When the speed limit is exceeded, the EMR 2 moves the control rod into the Stop position. The output, engine
switch off (Digital 3, M 2) is activated (if it is programmed) and a fault message is generated. With applications
in mobile machines the thrust mode is programmed as a safety measure. Exceeding of the revolution limit can
occur in thrust mode. In this case the control rod is moved to the zero position and the fault lamp lights up. The
engine is protected against excess revolutions also in this type of operation.

After falling below the programmed recovery limit, the governing is again taken up and the fault lamp is
extinguished. The parameters “Above speed limit” and “Recovery limit” are adjustable.

188
3.4 SET POINT SETTINGS

The following variants for the set point settings of the governor can be configured:

Function Variant Description Remarks

Set point setting Accelerator Setting with potentiometer (5 V
value sensor reference voltage, max. 30 mA1)), typ.
(SWG 1) 1 kΩ linear, pin 25, input pin 24, GND
pin 23, V-plug2))
Voltage Setting by means of external voltage Replacement for
(0.5 - pedal value sensor
4.5 V, input pin 24, GND pin 23,
V-plug)

Hand throttle Setting with hand throttle. The set

(SWG 2) point in the EMR 2 is determined by
means of a maximum
function (5 V reference voltage, max.
30 mA1),
typ. 1 kΩ linear, pin 25, input pin 20,
GND pin 23 V-plug)
Memory function Freezing the current engine speed Only possible in
connection
with the
pedal value sensor
(SWG 1)
CAN Setting via the CAN interface CAN = Controller
Area Network
Internal (fixed Setting via internal parameters. For gen-sets
speed) The parameter is determined in the
customer scope of supply (KLU).
PWM signal 1 The desired value is set by means of Auxiliary for pedal
PWM signal 2 an external value sensor
PWM signal (frequency=100 Hz)
with a modulation of 5 % to 95
%Input pin 18 or 20, GND pin
17 V-plug

1) PIN 25: Imax=30 mA (Pedal value sensor and hand throttle combined).
2) V*plug = Vehicle plug / GND = Ground.

189
3.5 FUEL QUANTITY LIMITATION (PERFORMANCE CURVE)

In order to set the engine performance and the desired torque course, the maximum injection quantity/thrust
must be limited in accordance with the settings.

Provision is made in the EMR 2 for three performance curves. The performance curve is created as a
characteristic curve with 13 freely selectable speed support points. The sampling points must be support
points, whereby the sample of the engine is carried out with performance curve 1. The performance curve 2
is correspondingly corrected with the correction data of performance curve 1.

Function Variant Description Remarks

Performance curve Performance Quantity limitation with a performance Only 1 variant
curve 1 curve (performance curve 1) can be selected
Performance Switching between two performance
curve 1/2 curves
Performance Change-over switching only via CAN
curve 1/2/3

Performance curve change-over switching Switch open Switch closed

(Input) (1/HIGH)1) (0/LOW)
pin 19, GND pin17 V-plug

Performance curve 1/ performance curve 2 Performance curve 1 Performance curve 2

1) With open switches, the underlined conditions above are activated as default values.

3.6 DROOP CONTROL

One of the features of the electronic governing is that, in contrast to mechanical governors, the P-Gradient
can be set to 0 % and switched over between two defined P-gradients. The maximum value lies at 80 %. For
limiting the P-gradient relationship of the mechanical governor, provision is made for a speed-dependent
P-gradient function by means of a characteristic curve with eight speed support points.

Function Variant Description Remarks

P-gradient Constant P-gradient is constant within the whole Only 1 variant
P-gradient speed range. can be selected
V a r i a b l e Speed-dependent P-gradient
P-gradient
P-gradients 1/2 Switching between two fixed P-gradients
Constant/ Switching between constant and variable
variable P-gradients

190
 Switchable variant Switch open Switch closed
pin 21, GND pin 17 V-plug (1/HIGH)1) (0/LOW)

P-Gradient 1/ P-Gradient 2 P-gradient 1 P-gradient 2

Constant / variable P-gradient Constant Variable

1) With open switches, the underlined conditions above are activated as default values..

3.7 ENGINE START/STOP

As soon as the control apparatus recognizes the start-speed, the control rod is freed for the start. For
switching the engine off, the EMR 2 must be switched via the key-operated switch in a de-energized manner.
With this setting, the controlling rod is moved to the stop position by the spring action of the actuator and/or
the redundancy solenoid. The switching off of the engine can also be triggered by a fault in the EMR 2.

Function Variant Description

Engine start/stop Switching off with the In a de-energized condition, the EMR 2 actuator moves
EMR 2 actuator the control rod into the stop position and switches the
engine off
Redundant switching In addition, the engine is switched off by means of a
off with the solenoid solenoid (must be programmed in the control unit)
(pin M 21) and M 1)
1) M 2: Engine plug, pin 2

3.8 DISPLAYS / OUTPUTS (MONITORING FUNCTION)

By means of the digital PWM outputs and depending on the configuration, various signals can be displayed
and output.

Fault lamp (Pin 4 vehicle plug)

A red fault lamp must be placed where it is easily visible at the customer apparatus side. The fault lamp serves
as a rough estimate of the fault that has occurred; here the following means:
• Lamp 2 s on: Self diagnosis with switched on the voltage supply. Result: There are no faults.
• Continuous light: There is a fault message; however the system is operational (possibly limited).
• Flashing: Serious malfunction - engine will be switched off or engine cannot be started.
• Blink code: Query malfunction locality by means of diagnostic button.

191
Output signals (maximum of 4 output signals possible)

Function Variant Description

Display functions Speed 1 (pin 16, Corresponding to the (No. of teeth on gear wheel)
vehicle plug) symmetrical square signal (Voltage level from 0 V to +UBatt)
Torque (pin 5, vehicle PWM signal (100 Hz) with button relationship from 5 to
plug) 95 %. Reference value: performance curve in the working
point or MdMax
Warning signal Overstepping limiting value
coolant temperature High/Low change-over switching
(pin 3, vehicle plug)
Warning signal oil Speed-dependent oil pressure control High/Low change-
pressure (pin 15, over switching
vehicle plug)
Warning signal General display for overstepping or falling below the
charge air monitor limiting values
(pin variable)
Freely selectable By arrangement
digital output signal
Freely selectable
measuring
or calculation value
(PWM- signal)

3.9 LDA FUNCTION

For mobile applications, the injection quantity for acceleration and dynamic load increase is limited with
reference to the charge air pressure (smoke quantity-characteristic field). Usage: protection of the exhaust
turbo supercharger and prevention of smoke ejection.

3.10 TEMPERATURE-DEPENDENT START CONTROL

In order to prevent smoke ejection and for optimizing the governing relationship, the start quantity, the speed
ramp and the governor parameters are controlled with reference to the temperature (required basic function).

3.11 SPEED THROTTLING (INPUT F 7)

This function is designed for a driving speed evaluation is accordance with DIN 11786.

3.12 ENGINE PROTECTION FUNCTIONS

All monitoring functions can be provided with a message lamp on the plant side (dependent on the scope of
the function and the pins that can be assigned).

192
Oil pressure monitoring
The user is warned by means of the message lamp when
• the oil pressure has overstepped the warning limit and/or
• after a pre-warning period, the performance has been reduced by the EMR 2, or
• the oil pressure falls below the switch-off limit and, after a pre-warning period, the engine is switched off.

Coolant temperature monitoring

The user is warned by means of the message lamp when
• the temperature exceeds the warning limit and/or
• after a pre-warning period, the performance has been reduced by the EMR 2, or
• the temperature exceeds the switch-off limit and, after a pre-warning period, the engine is switched off

Charge air monitoring

The user is warned by means of the message lamp when
• the temperature exceeds the warning limit and/or
• after a pre-warning period, the performance has been reduced by the EMR 2, or
• The temperature exceeds the switch-off limit and after a pre-warning period, the engine is switched
off.

Coolant monitoring
The user is warned by means of the message lamp when
• the coolant level falls below the warning limit and/or
• after a pre-warning period, the performance has been reduced by the EMR 2, or
• the coolant level falls below the switch-off limit and, after a pre-warning period, the engine is switched
off.

3.13 ALTITUDE CORRECTION

The altitude correction is carried out by means of an Atmospheric pressure sensor in the control unit. Two
different control unit variants are offered (with and without atmospheric pressure sensor).

3.14 FUEL VOLUME CONTROL

Compensation for loss of performance due to fuel heating. Necessary variant with fuel temperature sensor.

3.15 EMERGENCY RUNNING (LIMP HOME)

The EMR 2 provides comprehensive emergency running functions that are configured depending on the field
of application. These functions are necessary in order that, in an emergency, the operation can be continued
with auxiliary speed. In detail, this function can be activated by
a) set point default
b) charge air pressure
c) vehicle speed signal and/or
d) speed acquisition
It is also possible by the failure of the set point default to switch over via CAN Bus
a) on the accelerator pedal and
b) on auxiliary speed
The respective type of malfunction is defined in the fault memory.

193
3.16 COLD START INSTALLATION

Failure of additional control units; if desired EMR 2 controls heating flange, glow plugs or flame start installation.

4. INTERFACES

The EMR 2 is equipped with various interfaces. The wiring is carried out on the customers side and must be
Integrated in the vehicle plug. For pin assignment see the application-dependent switch diagrams.

4.1 DIAGNOSTIC INTERFACE (BASIC FUNCTION)

The end programming of the EMR 2 is carried out via the serial diagnostic interface (according to ISO 9141).

With the aid of a PC connected to an interface and the SERDIA diagnostic software -measuring values, error
messages and other parameters can be displayed and set - depending on access authorization. Furthermore,
new control units can be programmed. Communication is only possible with the electric power switched on.

4.2 CAN-BUS INTERFACE

The CAN-Bus interface (Controller Area Network) is increasingly being used in vehicles and is suitable for
measuring values and data exchange with one or more apparatus-side control units (hydraulics, drive control,
etc.). The SAE J1939 protocol is utilized for communication.

The following is an aid to utilization of the respective scope of functions:

• Selection according to the DEUTZ pocket handbook
• Definition before supply of engine
• Connection in accordance with connection diagram (see Chapter 12.1 to 12.3)
Subsequent changes to the configuration is only possible in conjunction with the DEUTZ operating partner
and the aid of SERDIA.

5. CONFIGURATION AND PARAMETER SETTING

The EMR 2 is specially programmed and configured for each individual engine, which means that the EMR
2 contains a specially engine-specific data set. Configuration is carried out via the externally accessible
diagnostic interface (ISO 9141) and is strongly dependent on the customer’s wishes, from the application
cases and from the behaviour of a vehicle in operation.

Access to the various parameters is protected (by password) by means of access authorizations organized
on four levels and can only be carried out by authorized personnel.

More than 1200 different parameters are available. Access to these parameters, as well as to other data,
can be carried out by means of the special SERDIA diagnostic software installed on a PC.

• Important!
Rebuilding, as well as alteration to the parameters can only be carried out in conjunction with the corresponding
DEUTZ operating partners. For this purpose SERDIA Level III is required. In connection with the above-
mentioned possibilities, the changed data sets must be reported back to DEUTZ.

194
195
5.1 FUNCTION OVERVIEW, PIN ASSIGNMENT AND CONFIGURATION EXAMPLE

Summarized function overview with examples of function selection

The user-referenced selection is carried out using the DEUTZ pocket handbook

1) Above example applicable to gen-set series 1012/1013, single frequency generating sets.

196
6. DIAGNOSTIC BUTTON AND FAULT INDICATOR LAMP

Diagnostic button and fault indicator lamp must be placed in the vehicle or plant on the customer side. They
can be used for diagnosis.

6.1 SELF-DIAGNOSTIC (WITHOUT OPERATING THE DIAGNOSTIC BUTTON)

The EMR 2 possesses numerous protection functions for the engine - depending on the available measuring
points or sensors. Depending on the seriousness of the recognized fault, the engine may run on in reduced
mode (limp home), whereby the fault indicator lamp is continuously lit, or the engine is switched off, whereby
the fault indicator lamp flashes.

A lit fault indicator lamp indicates an error in the wiring (short circuit, cable break) or a defect in the displays
of the corresponding sensors. A further source of faults could be falling below or exceeding the measuring
value limits.

Faults in the electronics are registered or stored in the control unit and shown by the fault indicator lamp. The
fault indicator lamp is extinguished as soon as the fault has been removed. Only when the electronics has
been switched to emergency running (-speed), need the engine be switched off briefly with the key operated
switch in order to extinguish the fault indicator lamp. Also corrected or non-current faults remain stored in the
control unit and can be read out or deleted with the SERDIA diagnostic software.

197
198
Function control of the configured warning lamps

With the activation of the key switch (pin 15), the warning lamp is also switched on for the duration of the
self-diagnostic (2 s).

6.2 DIAGNOSTIC WITH BUTTON AND ERROR CODE

With the diagnostic button there is the possibility of reading out the existing faults as blink codes and to delete
the fault memory 1. The Diagnostic button and the fault indicator lamp are situated in the moving part of the
vehicle.

6.2.1 READING OUT A CURRENT FAULT MEMORY BLINK CODES

The fault indicator lamp shows a fault, e.g., it flashes or lights continuously. The Diagnostic button is depressed
for a time period of 1 s to 3 s. The EMR 2 recognizes the request for a read out and starts to display the faults.
(see blink code overview, Chapter 7.2.3). The read-out of the blink code is only possible after extinguishing
of fault indicator lamp or after the initialization phase of the operating program. This means that the fault
indicator lamp can also show continuous lighting after switching on if a fault has been recognized already after
switching. The EMR 2 only shows active faults as blink codes.

199
In the following the steps for reading out the first blink code are shown:
1. The fault indicator lamp indicates a fault, e.g. it flashes of lights continuously.
• Press diagnostics buttons 1 to 3:
The flashing or continuous light of the fault indicator lamp is extinguished.
2. After 2 s:
recognition by the EMR 2 (2×short flashes).
• Output of the flashing sequence of the first stored fault.
(example: fault number 01, “speed sensor 1“):
3. after 2 s: 1×long
4. after 2 s: 1×short
• After fault code output
5. 5 s pause, then display of flashing or continuous light.

Steps for reading out the next fault:

1. The fault indicator lamp indicates a fault, e.g. it flashes of lights continuously.
• Press diagnostics buttons 1 to 3:
The flashing or continuous light of the fault indicator lamp is extinguished
2. After 2 s:
recognition by the EMR 2 (2×short flashes).
• The next blink code is output (c, d)
• After fault code output
3. 5 s pause, then display of flashing or continuous light.

The steps can be repeated until the last stored fault code is output. After that, the first fault code is shown
again.

200
6.2.2 DELETION OF THE FAULT MEMORY 1

The EMR 2 has two fault memories (1 and 2). Every fault is stored in both memories at the same time. With
the aid of the diagnostic button it is possible to delete passive faults in fault memory 1. The fault memory 2
can only be deleted with SERDIA.

The following shows the steps for deleting the fault memory 1:
1. Press, and keep depressed, the diagnostic button.
2. Switch ignition on.
3. Whilst the fault indicator lamp is lit up (duration 2 s) release diagnostic button.
4. All passive faults in faults in fault memory 1 are deleted.
5. The deletion process is confirmed by three short flash impulses.

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6.2.3 FAULT BLINK CODE OVERVIEW

202
203
204
205
206
 Anhang EMR 2
Appendix

12.4 Anschlussplan für CAN-Bus und Diagnoseleitung Connection Diagram for CAN-Bus and Diagnostic Line

emsemr2 © 06/02

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Seite/Page 118 © 06/0
208
MODULE 9 - AIR CIRCUIT

1. EXPLANATION PLAN

1.1. DIAGRAM WITH KVL OILER

209
2. AIR SUPPLY

2.1. MACHINE AIR COMPRESSOR

Different types of compressor can be mounted on the drilling machines.

FOR ALL COMPRESSOR MAINTENANCE

. OPERATIONS, SEE COMPRESSOR MAINTENANCE MANUAL
ENCLOSED IN THIS SECTION

Maintenance operations at each shift:

• Check that there is no pressure left in the circuit when motors are stopped.
• Verify that the clogging indicator is located in the green zone, if it is in red zone, all compressor filter
elements must be replace. After filters replacement, reset the clogging indicator.
• Check compressor oil level, add oil if needed. (Prior to add oil, make sure that there is no pressure
remaining in the circuit).

Maintenance operations every weeks:

• Start the compressor, check the pressure. The pressure should not exceed 2 or 2.5 bar when installing
a gauge at the inlet port of the rock drill. According to the length of the air line the pressure at the
compressor or at the oiler may be higher. Adjust the compressor pressure to get 2 bar at the rock drill
inlet port.
If a pressure reducer is installed on the machine, it is then possible to adjust the compressor pressure to 7 bar.

Maintenance operations every months:

• Replace filters elements.
• Replace cartridge element of oil separator.

Replace Compressor oil after 500 drilling hours.

210
3. LUBRICATED AIR CIRCUIT

In standard drilling operation, it is necessary to provide a flow mixed air and oil at 2.5 bar to lubricate the rock
drill shank and the bronze driver to protect them from water and dust intrusion. If the mix pressure is to low, the
pressure switch stops the drilling feed forward movement. A lack in this lubrication will result in rapid damage
or destruction of the rock drill. It is so of prime importance to permanently assure a correct functioning of the
pressurized lubricated air circuit and its main components.

3.1. WATER SEPARATOR

The water separator (reclaimer) is necessary to prevent water presence in the rock drill and avoid its destruction.
Maintenance operations at each shift:
Bleed the water separator, full by water contained in oil.

3.2. PRESSURE SWITCH

This component is an informer, when the circuit pressure is less than 1 bar a warning light is switched on and
the drilling feed forward movement stop. It is exactly the same when the pressure is higher than 2.5 bar.

3.3. PRESSURE REDUCER

The reducer is installed to protect the rock drill against over-pressure that could cause failures. The air
pressure to the rock drill must be adjusted and reduced to 2/2.5 bar.

3.4. AIR OILER

FOR ALL AIR OILER MAINTENANCE OPERATIONS, SEE AIR OILER

MAINTENANCE MANUAL ENCLOSED IN THIS SECTION.

3.4.1 KVL

Maintenance operations at each shift:

• Bleed the water separator : Slightly open the drain valve, let the condensed water get out the oiler.
Make sure that there is no remaining pressure in the circuit. The gauge should show 0bar.
• Check oil level : Remove the filling plug used as a dipstick. Add rock drill oil if the level is too low.
• Start the compressor, check that oil flows regularly by looking the sight glass.

211
Maintenance operations every weeks:
• Drain the reservoir, replace the lubrication oil.
• Check the oil flow
• Remove the oil flow adjusting device, undo the adjusting device connection.

Start the compressor. Wait a couple of minutes until the reservoir is correctly pressurized. Adjust the oil flow
to get 30 drops of oil per minute and per boom. Re-tighten the oil flow adjusting device to the manifold.

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MODULE 10 - WATER CIRCUIT
1. EXPLANATION DIAGRAM

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

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

The pressure switch (6) stops the pump if the outlet pressure drops under 2 bar for 1 to 10 seconds. It is a
safety device in case of lack of water.
As soon as the flow gets to 12l/mn, the flow controller (6a) allows the joysticks maintenance for drilling, by the
signal S71.
Mine’s water is used to cool down the drilling oil coming from the rock drill in the oil / water cooler (5).
NOTE: The cooler can be upstream or downstream of the water pump (depending on machines).

The main outlet line is connected to the control valve (8) operated by a pilot pressure from the drilling control
activating the pressure switch (7).
The solenoid valve (8a) opens and allows the water flushing by the signal Y84.
NOTE: The control can be assured by a manual ball valve to, depending on machines.

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

Optional air mist device:

On machines equipped with air mist option, air from compressor is mixed with water before the flushing,
thanks to a jet. In this case, the water circuit is the same, but we add an extra water valve in parallel with a flow
controller (in place of mine’s water connection).

Optional automatic flushing with feed automatic return device:

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

214
2. REPAIR DIAGNOSTICS

215
3. CHECK OPERATIONS ON MAIN COMPONENTS

The location of the following components is not the same for all machines range. For the components
exact locations, see the machine’s operator manual.

3.1. ROCK DRILL WATER HOSES

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

3.2. DRILLING ROD

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

3.3. CONTROL VALVE

Check hydraulic connections of the control valve.
Try to force the control valve opening to test the functioning.

3.4. PRESSURE SWITCHES

The pressure switches can be checked manually :
Operate the adjusting screw (1) to the 0 bar to force the contact.
Apply a pressure at the hydraulic inlet (2) to test the functioning of the
switch.

If the contact don’t happen, replace the pressure switch.

Water presence pressure switch must indicate 2 bar on the

adjusting indicator (3).
It is connected to a signalling light on the drilling control panel
(«Drilling fault»). This light must switch off after the start-up of the
pump.

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

3.5. Water supply

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

Check the connection.

216
3.6. FILTER

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

NOTICE
The filter (2) must be down positioned to function correctly.

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

3.7. PRESSURE REDUCER

The pressure reducer must be adjusted to obtain a pump inlet pressure

of 4 bar. Operate the adjusting screw (1) to adjust pressure.
(Unscrew to make outlet pressure decrease).

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

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

3.8. WATER PUMP

Four differences pumps can be mounted on machines:

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

The pump must be vented after each operation on the water circuit : Let a small amount of water get through
the pump, and slowly open the vent valve (1).
=> Check pressure at water pump outlet : P = 15 bar
=> Look for leaks on water pump. Check motor connections and functioning.
See the water pump SUPPLIER’S DOCUMENTATION next to this manual for diagnosis, repair and
maintenance instructions.

217
Main operations:

• When replacing the pump motor, respect the space of 1.5mm between the coupling and the pump.
• Grease regularly the coupling (grease nipple on the moto-pump group).
NOTE: On DD310, DS310 and DL330 machines, it possible force the pump starting-up thanks to the switch
S501 (see electric schematic). It can be use to test pump functioning.

3.9. COOLER

(1) : Water inlet

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

In case of faults on pressure or oil temperature, without fault in the rest of the circuits, replace
the cooler.

3.10. SAFETY RELIEF VALVE

The safety relief valve must be adjusted to obtain a pressure of 15 bar

maximum in the high pressure circuit. Operate the adjusting screw (1) to
adjust pressure.
(Unscrew to make outlet pressure decrease).

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MODULE 11 - ELECTRIC SYSTEM
1. GENERAL

The main switchgear electric system consists of the main switchgear (MP), and the devices, sensors, and the
control and the indicator light panel connected to it. The electric control of the hydraulic system is dealt with
in separate instruction manuals.

The sensors, the working lights, the switches, the indicator lights, and the electric control of hydraulics use
reduced voltage (24 VDC).

Sandvik manufactures the electric system of the rig to conform to the standard EN 791.

The power supply must be dimensioned to guarantee trouble free operation at full power and when electric
motors are started. The power supply transformer or the generator, and the power supply cable must be rated
to meet the rig’s power requirements.

The rig is designed to operate in a supply network that meets the requirements of the standard EN 60204-1.
The power requirement, the frequency, and the operating voltage are given on the panel at the main switch.
The fluctuation of the rated voltage must not exceed + or -10% at the main switchgear, whether idling or
operating at full power. Sandvik defines the maximum voltage drop in the power supply cable to below 3%.

219
2. MAIN COMPONENTS OF THE MSE SYSTEM

The main switchgear electric system consists of the main switchgear (MP), and the devices, sensors and the
control and the indicator light panel connected to it.

2.1. MAIN SWITCHGEAR (MP)

Contains the main switch supply system for the electric devices.

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2.1.1. MOTOR PROTECTOR SWITCHES, ELECTRONIC MOTOR PROTECTOR RELAYS

WARNING
Reset the protective switches to position I only when the main switch is in the 0
position, if the rig is connected to the power supply network. Motor protector
switches and circuit breakers. Adjustment of protector switch for power pack
motor.

1F100 Motor protector switch of the power-pack with fixed thermal and magnetic triggering. The protective
switch must be reset by turning the control handle first to position 0 and then to position 1.

F230 Water booster pump’s motor protector switch with fixed thermal and magnetic triggering. The protective
switch must be reset by turning the control handle first to position 0 and then to position 1.

F240 Compressor’s motor protector switch with fixed thermal and magnetic triggering . The protective switch
must be reset by turning the control handle first to position 0 and then to position 1.

F290 External pump’s motor protector switch with fixed thermal and magnetic triggering. The protective
switch must be reset by turning its control handle first to position 0 and then to position 1; or motor protector
switch with fixed thermal and magnetic triggering for 3-phase socket outlet. The protective switch must be
reset by turning its control handle first to position 0 and then to position 1. (Optional)

F310 Protector switch with fixed thermal and magnetic triggering for control voltage transformer

T310. The protective switch must be reset by turning its control handle first to position 0 and then to position
1.

F320 Protector switch with fixed thermal and magnetic triggering for power supply system for control voltage.
The protective switch must be reset by turning its control handle first to position 0 and then to position 1.

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2.1.2. SWITCHES

Q100 Main switch; cuts off power supply.

WARNING
It does not cut off the voltage at the cable reel and the slip rings, nor the battery
voltage of the carrier.

It can be locked in the 0 position. The main switch also cuts the pilot conductor that monitors the supply cable
and the protective conductor. The pilot conductor is an optional device. When the main switch is turned into
the 1 position (ON), the switchgear cabinet door is locked.

2.1.3. GAUGES

1P100 Rock drill percussion hour meter.

1P101 Power pack hour meter.
(Optional)
1P102 Tramming hour meter. (Optional)
P5 Diesel Engine hour meter.
P400 Air Compressor hour meter.

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2.1.4. CIRCUIT BREAKERS

• F10.1 Circuit breaker for battery charger.

• F10.2 General circuit breaker for 24 VDC circuit.
• F311 Fault current circuit breaker for internal 220V control voltage in main switchgear.
• F312 Circuit breaker for internal 220V control voltage in main switchgear.
• F333 Circuit breaker for MTU power supply 110VAC
• F450 Circuit breaker for internal 24V control voltage in main switchgear.
• F451.1 Circuit breaker for drilling control system.
• F452.1, F452.2, F452.3 Circuit breakers for lights.
• F454.1 Circuit breaker for hydraulic oil filling pump. (Optional)
• F454.2 Circuit breaker for MTU control voltage 24V.
• F454.3 Circuit breaker for carrier supply.
• F600 Circuit breaker for TIS/TMS system. (Optional)
• FQ100 Circuit breaker for over and under voltage control supply. (Optional)
• P410 Supply voltage meter.

2.1.5. TRANSFORMERS

• A100 Multi-timer unit (MTU).

• A410 Battery charger. Charges the carrier’s batteries when the rig is connected to the supply
network and the main switch is on. The charger is equipped with charging automatics to prevent
overcharging.
• A420 Power supply system for control voltage 380-575VAC/24VDC. The power source of the rig’s
24 VDC circuit 1000 VA.
223
• T100 On board ground fault detector (only with VYK). (Optional)
• T290 Transformer for external pump earth leakage relay. (Optional)
• T310 Low voltage transformer. 2 phases 400 VA.
• T490 Transformer for external pump control circuit. (Optional)

2.1.6. CONTRACTORS, RELAYS

224
• A44 Door interlock, control safety relay. (Optional)
• F291, FK100 On board ground fault detector (only with VYK). (Optional)
• 1KS100 Power pack motor soft starter.
• 1K101 Auxiliary relay, start/stop power-pack.
• 1K112 Thermistor relay for temperature control of power pack electric motor.
• K46, K451 Relays for pressure switch on the jacks.
• K77, K78 Emergency stop auxiliary relays.
• K85 Fire suppressor relay.
• K141, K142 Relays for pressure switch rig on the front jacks. (Optional)
• K143, K144 Relays for pressure switch rig on the rear jacks. (Optional)
• K230 Starter contractor of water booster pump.
• K231 Auxiliary relay for water booster pump.
• K240 Starter contractor of compressor.
• K241 Auxiliary relay for compressor.
• K290 Starter contractor for external pump. (Optional)
• K291 Auxiliary relay for external pump. (Optional)
• K294, K295 Inhibition movements relays (drilling, boom). (Optional)
• K300 Ground fault check relay.
• K320 Phase sequence control relay.
• K330, K331 Relays for electric filling pump. (Optional)
• K400, K406 Relays for driving lights.
• K401, K402 Relays for front lights of the canopy/cabin.
• K403 Relay for rear lights of the canopy/cabin. (Optional)
• K404 Relay for rear lights of the carrier.
• K405 Relay for portable working liths. (Optional)
• K422 Relay for water pump (Safety relay for water pressure or level).
• K424 Auxiliary relay for monitoring functions.
• K425 Battery feed connector relay.
• K445 Drilling stop auxiliary relay.
• K471 Auxiliary relay for supply net ON.
• K480 Pilot interlock relay. (Optional)
• K491 Starting relay for External pump. (Optional)
• K50 Safety trip wire on feed relay. (Optional)
• 1K447 Auxiliary starter relay for power pack.
• KT3, KAT3 Door control safety relay. (Optional)
• KT4 Relay for two-hand control for door security activation. (Optional)
• QK100 Under/over voltage detection relay. (Optional)
• SH520 Air/Water by-pass test push button.

2.1.7. OTHERS COMPONENTS

V401 Diode module. (Optional)

R490 Testing of earth leakage relay. (Optional)

225
2.2. MULTI TIMER UNIT (MTU)

1. Adjustment of delay for water pressure monitoring

2. Adjustment of delay for air pressure monitoring

Water pump and drilling functions stop after set delay if water pressure drops below 2.8 bar. Drilling functions
stop after set delay if output pressure from compressor drops below 2.8 bar. Under the cover of the timer unit
(A100) you will find the two adjusting screws that are used for setting the delays for the water pump and the
compressor.

By turning the adjusting screw clockwise you can increase the delay, and by turning the screw anti-clockwise
you decrease the delay. The factory settings for the delays are: 4 seconds for water pressure and 10 seconds
for air pressure.

2.3. EXTERNAL SENSORS

• S1A Battery master switch.

• S35H Tramming oil high level sensor switch. (Optional)
• S85 Fire suppressor system. (Optional)
• S143 Pressure switch rig on rear right jack. (Optional)
• S144 Pressure switch rig on rear left jack. (Optional)
• S420.L Oil low level switch / Oil level alarm.
• S420.H Oil max. light level sensor switch for stop the electric oil filling pump. (Optional)
• S421 Pressure switch for shank lubrication and flushing air.
• S422 Pressure switch sensor for flushing and cooling water.
• S424 Oil temperature switch and gauge. The temperature switches are incorporated in the
temperature gauge. Two switching points are provided: upper for oil temperature alarm and stopping
(75°C) and lower for bypassing oil filter monitoring (30°C).
• S425 Pressure switch of hydraulic oil return filter. (Clogged)
• S426 Pressure switch of tramming hours. (Optional)
• S441 Temperature switch for compressor’s output air.
• 1S180 Pressure sensor switch for hydraulic oil pressure filter of power-pack. (Clogged)
• 1R112 Thermistor protection of power pack motor (stator temperature 150°C).

226
3. OPERATION

WARNING
Read and observe the Sandvik Safety Instructions.

3.1. STARTING AND STOPPING OF POWER PACK

• Make sure that the electric switchgear cabinet doors are closed.
• Turn the main switch (Q100) into position (I).

• Ensure that all the control levers for the hydraulic control valves, particularly the drilling control levers,
are in the NEUTRAL POSITION. Before and after starting the power-pack, check the voltage meter
reading. The supply voltage should be within the limits given by the manufacturer (+ or - 10%).

• Turn the POWER PACK switch to the right (I) power pack is under tension, turn to the right (START)
power pack starts and switch automatically returns to position (I). Turn to the left (0) power pack stops.

NOTICE
If the starter contractor of power-pack motor is clapping, do not continue starting attempts. The
starter contractor may be damaged and may cause severe damage in the electric switchgear. Do not
use the Emergency Stop button for stopping under normal circumstances. Do not stop the power-
pack if a function is activated.
227
3.2. AUTOMATIC STARTING OF COMPRESSOR AND WATER PUMP

Turn the starting switches for the compressor (SH502) and the water pump (SH501) into middle position for
auto-start with power pack.

Turn the switch (1SH78) to the right (I), power pack is under tension, turn to the right (START), power pack
starts and switch automatically returns to position (I). Water pump will start by pushing percussion joystick or
water flushing joystick.

3.3. STARTING OF COMPRESSOR AND WATER PUMP WHEN POWER-PACK IS RUNNING

When the starting switches for the compressor (SH502) and the water pump (SH501) are in position (O) and
the power pack is running.

Start the compressor by turning the switch (SH502) into position (S). Wait at least 1 second before starting
the next motor. Start the water booster pump by turning the switch (SH501) into position (S). Wait at least 2
seconds before starting the next motor. Any starting order of the above motors can be used.

228
4. MAINTENANCE

Each shift
• Check the operation of the emergency stop button(s).
• Make sure that the electric cabinet door is properly closed and that the plugs are properly connected.
• Visually check the condition of the electric cables.

Once a month
• Check the electric boxes subjected to moisture, and dry them if necessary.
• Apply protective agent to the connections.
• Carefully check all cables for damage, cable mountings, and grommets for tightness.
• Check the operation of the fault current protector switch.
• Pull the power supply cable out and check it’s condition.
• Check the water drainage holes are open.
• Check the seal bushings condition and tightness.

Once a year
• Check the operation of the safety device sensors.
• Check the tightness of the motor terminals and other screw-mounting terminals in the main switchgear
and in the control system.

After a long period out of use

• Check the electric cabinets and boxes for condensate water. Wipe off any moisture.
• Check the insulation resistance at the supply cable end with the main switch in position I. Also check
the insulation of the electric motors.
• Check the contractors of the plug connectors for oxidation. Clean and protect with grease as necessary.

In connection to repairs
If you have to replace components in the electric control system (24 V) or remove protective agent, always
apply protective agent to the connections when you have finished the repairs: protective grease for plug-
in connections, such as multi-pole connectors and valve connectors, and protective coating for screw
connections.

• Protective grease ID-867 429 89

• Protective coating ID-867 430 49

5. TROUBLESHOOTING

5.1. POWER PACK DOES NOT START OR STOPS

• Make sure that the main switch is on.

• Check the indicator lights (Cf. 3.3).
• Water pump or compressor is running.
• If the voltage meter does not show any reading, check the protector switch F320.
• Check the fault current protector switch F311 for the 220-240 V control voltage, and the circuit
breaker F312.
• If the indicator light H617 is not lit, check the circuit breaker F450.

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5.2. POWER PACK STARTS, BUT STOPS AFTER A WHILE

• Compressor air temperature rise above 115°C or compressor - or water pump motors are overload.
In this case all motors stops and indicator light H604 goes on. Fault goes off when temperature is
under 115°C and compressor- and water pump circuit breakers are on.
• Hydraulic oil tank temperature rise above 75°C. After that power pack stops and indicator light H610
goes on. Fault goes off when temperature is again under 75°C.
• Hydraulic oil level drops (over 3 seconds) below the minimum. Indicator light H602 goes on. Press
pressure switch reset button S505 (indicator light H602 goes off), after that power pack can be
restarted (if oil level is above the minimum oil level).

5.3. POWER PACK MAIN CONTRACTOR CLAPPING

• Power supply network too weak. Check the supply voltage and the dimensioning of the supply
network, the cross-sectional area and length of the supply cable.
• Check the control voltage.

5.4. WORKING LIGHTS DO NOT WORK

• Working light bulb burnt.

• Lighting plug off.
• Check the working lights circuit breaker F452.1, F452.2 and F452.3.
• Check the protector switch F320 of the 24 VDC feed transformer, and the circuit breaker F450.
• Control circuit fault.

5.5. OIL FILLING PUMP DOES NOT WORK (OPTIONAL)

• Oil tank full.

• Check conductor protective switch F454.1.
• Check the control circuits and the wiring.

230