s10 water circuit general
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WATER CIRCUIT
Page 1
MAINTENANCE MANUAL
SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
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Page 2 A-22-02-2006 ER-RL-FLWATER CIRCUIT
SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
1 PRELIMINARY REMARKS 3
1/1 SAFETY 3
1/2 ABOUT THIS BOOKLET 5
2 EXPLANATION PLAN 6
3 REPAIR DIAGNOSIS 8
4 CHECK OPERATIONS ON MAIN COMPONENTS 9
4/1 ROCK DRILL WATER HOSES 9
4/2 DRILLING ROD 9
4/3 CONTROL VALVE 9
4/4 PRESSURE SWITCHES 9
4/5 WATER SUPPLY 10
4/6 FILTER 10
4/7 PRESSURE REDUCER 10
4/8 WATER PUMP 11
4/9 COOLER 12
4/10 SAFETY RELIEF VALVE 12
5 PERIODICAL MAINTENANCE TABLE 13
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SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
1 PRELIMINARY REMARKS
1/1 SAFETY
The informations contained in this manual must be studied and thoroughly assimilated before
undertaking any maintenance work on the equipment.
WARNING: Operation, maintenance and adjustments are only allowed to persons withspecific training in operation and maintenance of the equipment. Read the operatingand maintenance instructions before using or servicing the equipment.
WARNING: Before starting any maintenance operation ensure that the machine is in a
safe location with good safety, ventilation and lighting conditions. Ensure that liftingequipments and pedestals are compatible with elements’ weight. Follow all the safetyinstructions and ware safety protections as gloves, goggles, helmet, safety boots, earprotectors.
WARNING: Before any operation stabilize and fix steadily all the elements on suitablepedestals. Stop the power packs, switch the general power breaker. Place a tag or aboard to warn other members of the personnel that maintenance work on the machineis in progress.
WARNING: Pressurized oil jets could cause severe injuries. Before any operation onhydraulic circuit, STOP the power packs and release remaining pressure incomponents by operating hydraulic control levers several times. Always release thestatic pressure in cylinders before disassemble them.NEVER WORK ON AN OPERATING CIRCUIT.
WARNING: While tests are in progress, do not allow any other member of thepersonnel to stand in the area surrounding the machine. Stay at the control station tobe able to stop the movement and switch off the power pack.
WARNING: Maintenance, adjustment and repairs are restricted to qualified personnelwith special training for the particular equipment. Always read the instructions carefullybefore starting any maintenance work.
CAUTION: Always use suitable tools and work in a clean place when dismantling andassembling hydraulic components. After removing cylinders the hydraulic inlet/outletports must be plugged to prevent dirt and air intrusion during operation.
WARNING: The operator must always wear required personal protection, such as safetyhelmet, protective overall, safety boots, hearing protectors, safety goggles etc.
WARNING: Danger of high pressure oil jets.High pressure oil jets can cause serious personal injuries.
Release the pressure in the hydraulic circuits before opening caps or connections.(Accumulator, Cylinder and Hydraulic circuit)
Remember: SAFETY FIRST! Always observe the warnings accompanied by the following symbols.
WARNING
WARNING
WARNING
WARNING
WARNING
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SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
WARNING: Danger of hot surface.Hot surface can cause serious injuries.Components rod, shank or hydraulic component can be hot and beforestarting a maintenance work, please let them cool off.The operator must have adequate wears as gloves.
WARNING: Crushing hazard : do not stay in dangerous area, for instance: centralarticulation, front chassis and rear chassis.
SAFETY
Always follow the marked safety instructions, and observe caution while working.
The following safety instructions are general rules.
Keep tools and drilling equipment clean.
Do not attempt any such repairs or adjustments that you do not fully understand.
ABOUT THE SAFETY OF REPAIRS
Certain workstages require the use of the feed mechanism during the repair. Make
sure then that:
- no danger is caused to anybody.
- the machine can be immediately stopped when necessary.
- the powerpack is stopped again before the repair-work is continued.
Before starting any repair-work move away from the area where you have just
drilled.
Use proper tools.
Always wear protective clothing, eye protection, earmuffs, safety footwear, and
other safety equipment required by the work.
WARNING
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SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
1/2 ABOUT THIS BOOKLET
The present manual is destined for the use of personnel in charge of carrying out, servicing and
maintenance operations on Jumbos.
It contains maintenance operations schedule and operating methods concerning the main elements of
the WATER CIRCUIT.
Note that servicing and maintenance operations must be carried out by personnel with the required
qualifications, technical knowledge, and proper training on the machine.
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SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
Explanation :
Mine’s water is connected to the water supply (2 bar needed at least), and flows to the water
pump (3) through the filter (1) and the a pressure reducer (2).
NOTE : The water pump is a multi-cellular type. It runs as a pressure booster. Therefore the
outlet pressure depends on the inlet pressure. We recommend to adjust the pressure reducer to
4 bar as a standard pressure.
• At the outlet of the water pump from the main line are connected the safety relief valve (4) which
keep the pressure to a maximum of 15 bar to protect the rock drill and the cooler against over-
pressures. The surplus of water get outside of the circuit.
NOTE : In drilling condition, the minimum high pressure needed at pump outlet is 10 bar.
• The pressure switch (6) stops the pump if the outlet pressure drops down 2 bar for 1 to 10
secounds. It is a safety device in case of lack of water.
• As soon as the flow get 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.
- Optionnal air mist device :
On machines equiped with air mist option, air from compressor is mixed with water before the
flushing, thanks to a jet. In this case, the water circuit is the same, but we add an extra water
valve in parallel with a flow controller (in place of mine’s water connection).
- Optionnal auto flushing auto return device :
With this option, the flushing is automaticaly started when the rock drill return. The water circuit is
the same, exept that air and water are carried by two separated hoses to the rock drill nozzle.
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SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
3 REPAIR DIAGNOSIS
INJECTION PRESSUREDROPS
Pressure atpump outlet isabove 15bar
Bigamount
of water get outthrough therelief valve
Pressure atthe drilling panel
gauge isnear 0 bar
Relief valve (§ 4/10)Cooler (§ 4/9)
Relief valve (§4/10)
Cooler (§4/9)Control valve (§4/3)
Pressureat pump inlet
between 2 barand 4 bar
Water pump (§4/8)Control valve (§4/3)Pressure switches (§4/4)Cooler (§4/9)
Water supply (§4/5)Filter (§4/6)Pressure reducer (§4/7)
CHECK
NO
NO NO
NO
YES
YES
YES
YES
CHECK
CHECK
CH
ECK
CHECK
Rock drill water hoses (§4/1)Drilling rod (§4/2)Control v lvePressure switches (§4/4)
a (§4/3)
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SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
4 CHECK OPERATIONS ON MAIN COMPONENTS
The locating of following elements are not the same on any ranges of machines.
For locating, see machine’s OPERATOR MANUAL.
4/1 ROCK DRILL WATER HOSES
Look for leaks on the water hoses between the control valve and the rock drill. Check it is in good
condition (not weared, not bended..). check that the hoses don’t hinder rock drill movement.
Replace the hoses if damaged.
Verify there is no internal leak in the rock drill too.
4/2 DRILLING ROD
In case of water pressure lack, the drilling rod can be plugged. Check the water can get through
the drilling rod removing it and cleaning flushing hole. Replace the drilling rod if necessary.
4/3 CONTROL VALVE
Check hydraulic connections of the control valve.
Try to force the control valve openning to test the functionning.
4/4 PRESSURE SWITCHES
The pressure switches can be checked manually :
- Operate the adjusting screw (1) to the 0 bar to force the contact.
- Apply a pressure at the hydraulic inlet (2) to test the
functionning of the switch.
If the contact don’t happen, replace the pressure switch.
«Water presence» pressure switch must indicate 2 bar on the adjusting indicator (3).It is connected to a signaling light on the drilling control panel («Drilling fault»). This light must
switch off after the start-up of the pump.
«Pump start-up» pressure switch must indicate 15 bar on the adjusting indicator (3).
1 3 2
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SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
4/5 WATER SUPPLY
Check mine’s water supply pressure witch must be > 2 bar
Check the connection.
4/6 FILTER
The water filter at the inlet of the circuit must be clean each
week to not clog. The filter element (1) must be replace if
damaged.
Warning : The filter must be down positioned to function (2).
You can have a ball valve in place of the plug, to clean the filter element easier (option).
4/7 PRESSURE REDUCER
The pressure reducer must be adjusted to obtain a pump inlet
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 functionning : Pressure must vary when operating the adjusting
screw.
12
1
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SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80
4/8 WATER PUMP
Four differents 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 equiped with air mist option :
PUMP 3CP 1140 (CAT )
The pump must be vented after each operation on the water circuit : Let a small amount of water
get through the pump, and slowly open the vent valve (1).
=> Check pressure at water pump outlet : P = 15 bar
=> Look for leaks on water pump. Check motor connections and functionning.
See SUPPLIERS DOCUMENTATION included in this manual for diagnosis, repair and
maintenance instructions.
Main operations : - When replacing the pump motor, respect the space of 1.5mm between the
coupling and the pump.
- Grease regularily the coupling (grease nipple on the moto-pump group).
Note : On AXERA 5, ROBOLT 5 and SOLO 5 machines, it possible force the pump starting-up
thanks to the switch S501 (see electric shematic). It can be use to test pump functionning.
2
Water pump CR3 19 shown
1
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4/9 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.
4/10 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).
1
4
3
2
1
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5 PERIODICAL MAINTENANCE TABLE
WATER CIRCUITFREQUENCY (PERCUSSION HOURS)
When
completed
Daily 50 200 600 1200 1800 2400 3600Y
yesNno
Leakage
All equipments condition
Freedom and condition of moooving parts
Hoses / Union / Fitting
Water pump coupling : One grease nipple
Filter element : check and clean
Motor / pump coupling : Greasing
Vent the water pump
CHECKTEST
CLEANFLUSH
LUBRICATE SERVICECHANGEREPLACE
AT EACH OPERATION ON CIRCUIT