s10 water circuit general

7/23/2019 S10 Water Circuit General

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WATER CIRCUIT

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



A-22-02-2006 ER-RL-FLWATER CIRCUIT


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



A-22-02-2006 ER-RL-FL WATER CIRCUIT


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





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





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.





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.





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)





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





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





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





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




SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 LYON cedex, FRANCET l 33 (0)4 72 45 22 00 F 33 (0)4 78 31 79 80

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

s10 water circuit general

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