Pneumatics DD321

Original instructions
92 4 en 2013-01-22
WATER AND AIR CIRCUIT

DD321/DD411/DD421/DD531/DT610/DT821
Table of Contents
1. WATER CIRCUIT ........................................................................................................................... 5

1.1. General ................................................................................................................................................................ 5
1.2. Safety instructions ........................................................................................................................................... 5
1.3. Water circuit diagram (DD321/DD411/DD421/DT610) .............................................................................. 6
1.3.1. Components (DD321/DD411/DD421/DT610) ........................................................................................... 7
1.4. Water circuit diagram (DT821 THC) ............................................................................................................. 8
1.4.1. Components (DT821 / DD531) .................................................................................................................... 9
1.5. Water circuit diagram (DT821 / DD531 TPC) ............................................................................................. 11
1.5.1. Components (DT821 / DD531) .................................................................................................................... 12
1.6. Circuit operation ............................................................................................................................................... 13
1.6.1. Normal flushing .............................................................................................................................................. 13
1.6.2. Double flushing .............................................................................................................................................. 13
1.7. Mud separator (507) ......................................................................................................................................... 13
1.7.1. Cleaning the mud separator ......................................................................................................................... 14
1.8. Pressure reducing valve (506) ...................................................................................................................... 15
1.8.1. Operation of the water pressure reducing valve ....................................................................................... 15
1.8.2. Disassembly and assembly .......................................................................................................................... 16
1.8.3. Checking the operation of the pressure reducing valve .......................................................................... 16
1.8.4. Adjusting the pressure .................................................................................................................................. 17
1.9. Water booster pump (501) .............................................................................................................................. 17
1.9.1. General ............................................................................................................................................................ 17
1.9.2. Components ................................................................................................................................................... 18
1.9.3. Connections .................................................................................................................................................... 18
1.9.4. Venting and filling of pump ........................................................................................................................... 18
1.9.5. Operation and maintenance ......................................................................................................................... 19
1.10. Oil cooler (315) .................................................................................................................................................. 19
1.10.1. Function of oil cooler ..................................................................................................................................... 19
1.10.2. Maintenance ................................................................................................................................................... 20
1.10.3. Checking the operation of the oil cooler ..................................................................................................... 20
1.10.4. Cooler's dissipation figures .......................................................................................................................... 21
1.11. Flushing valves (510) ....................................................................................................................................... 22
1.11.1. Hydraulically controlled water valve FV-70 ............................................................................................... 22
1.11.2. Hydraulically controlled water valve FV-100 ............................................................................................. 24
1.12. Pressure switch (S422) ................................................................................................................................... 25
1.12.1. Checking the operation of the pressure switch (S422) ............................................................................ 26
1.13. Flow control switches S9 and S10, series 5010 (optional) .................................................................... 26
1.13.1. Electrical connection ..................................................................................................................................... 26
1.13.2. Operating and display elements .................................................................................................................. 27
1.13.3. Setting up for water and air media .............................................................................................................. 29
1.13.4. Maintenance ................................................................................................................................................... 32
1.13.5. Scale drawing ................................................................................................................................................. 33
1.13.6. Technical data ................................................................................................................................................ 33
1.14. Anti-freeze blowing (option) .......................................................................................................................... 34
1.14.1. Draining the water circuit and adding anti-freeze agent .......................................................................... 35
Copyright © Sandvik Mining and Construction 3 (54)

ID: 92 4 en 2013-01-22
1.15. Checking the water system for leaks .......................................................................................................... 36
1.16. Troubleshooting ............................................................................................................................................... 36
2. AIR CIRCUIT .................................................................................................................................. 37

2.1. General ................................................................................................................................................................ 37
2.2. Safety ................................................................................................................................................................... 38
2.3. Air circuit diagram (DD321/DD411/DD421/DT610) ................................................................................... 39
2.3.1. Components (DD321/DD411/DD421/DT610) ........................................................................................... 40
2.4. Air circuit diagram (DT821 / DD531) ............................................................................................................ 41
2.4.1. Components (DT821 / DD531) .................................................................................................................... 43
2.5. Circuit operation ............................................................................................................................................... 43
2.5.1. Pressurized air from compressor ................................................................................................................ 43
2.5.2. Pressurized air from the air network ........................................................................................................... 43
2.6. Air cleaner IP5 (609) (option) ......................................................................................................................... 44
2.6.1. Draining the air cleaner ................................................................................................................................. 44
2.7. Air receiver (604) (option) ............................................................................................................................... 45
2.7.1. Bleeding the air receivers (option) .............................................................................................................. 45
2.8. Flushing valves (510) ....................................................................................................................................... 46
2.8.1. Hydraulically controlled air valve ................................................................................................................. 46
2.9. Compressor (608) ............................................................................................................................................. 47
2.9.1. Use of compressor ........................................................................................................................................ 48
2.9.2. Procedures prior to compressor maintenance .......................................................................................... 48
2.9.3. Checking the compressor oil level .............................................................................................................. 49
2.9.4. Changing the compressor oil ....................................................................................................................... 49
2.9.5. Changing the compressor oil filter .............................................................................................................. 50
2.9.6. Replacing the compressor oil separator element ..................................................................................... 50
2.9.7. Cleaning the compressor oil return pipe strainer ...................................................................................... 51
2.9.8. Cleaning the outside of the compressor radiator ...................................................................................... 51
2.9.9. Checking the compressor safety valve operation ..................................................................................... 51
2.9.10. Checking the condition of the compressor hoses ..................................................................................... 51
2.9.11. Checking the tightness and condition of the compressor connections and screws ............................ 51
2.9.12. Cleaning the inside of the compressor ....................................................................................................... 51
2.9.13. Replacing the compressor belts .................................................................................................................. 52
2.9.14. Replacing the compressor intake valve seals ........................................................................................... 52
2.9.15. Replacing the compressor discharge valve seals .................................................................................... 52
2.9.16. Checking and tightening the contactors and engine connections ......................................................... 52
2.9.17. Checking the operating temperature of the compressor ......................................................................... 52
2.9.18. Checking the operation of the compressor thermometer safety measures ......................................... 52
2.9.19. Changing the compressor air filter .............................................................................................................. 52
2.9.20. Capacity control ............................................................................................................................................. 53
2.9.21. Temperature gauge ....................................................................................................................................... 53
2.10. Pressure relief valve Y446 (617) ................................................................................................................... 54
4 (54) Copyright © Sandvik Mining and Construction

ID: 92 4 en 2013-01-22
DD321/DD411/DD421/DD531/DT610/DT821
1. WATER CIRCUIT
1.1. General
Water is used in the drill rig for two main purposes: for flushing the drill hole and for various cooling
operations. The water is conveyed to the bottom of the hole through the aperture in the drill rod. As
it flows upwards, the flushing water conveys with it the cuttings while simultaneously cooling the
drilling equipment. Before flowing to the drill rod, the water runs through the oil cooler, thus cooling
the drilling oil.
1.2. Safety instructions
DANGER
ELECTRICAL HAZARD!
Failure to strictly follow instructions will lead to severe injury
and/or death and/or property damage.
Work on electrical equipment or devices is to be performed only
by persons with the expertise and qualifications required by the
authorities, or under the supervision of a person meeting these
requirements.
PROPERTY DAMAGE RISK!

Never drill without sufficient flushing. Do not reuse water that
has been used for flushing.
Keep the pressure limiters and switches in good condition and

correctly set.

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1.3. Water circuit diagram (DD321/DD411/DD421/DT610)
510.03
510.01
510.02 510.02
510.06
510.03
510.01 510.06
704 511
511
521.01 521
510.05
522
702
510.06
701
615
509 315.01 315.01
520
705 315 315
508
501
501.01 512
604
506
514
507
601 609
609.02
507.01
515
609.03 515.01 507.02
609.01 617 503
608
502
Figure: Water circuit diagram DD321 / DD411 / DD421 / DT610

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1.3.1. Components (DD321/DD411/DD421/DT610)
315 Oil cooler

.01 Drain valve
501 Water booster pump
.01 Water drain valve for water booster pump
502 Water supply terminal
503 Water hose reel
506 Pressure reducing valve
507 Mud separator
.01 Drain valve
.02 Shut-off valve
508 Collecting piece (water)
509 Collecting piece (air)
510 Flushing valves
.01 Air flushing valve
.02 Water flushing valve
.03 Check valve
.05 Pressure switch (S422)
.06 Pressure gauge
511 Flow meter (option)
512 Pressure relief valve
515 Three-way valve (antifreeze filling)
.01 Check valve
520 Washing hose with reel (option)
521 Washing hose (option)
.01 Water stop
522 Cabin front window washer (option)
601 Air in terminal (when using external compressor)
604 Air receiver (option)
608 Compressor
609 Air cleaner IP5 (option)
.01 Drain valve
.02 Non-return valve
615 Pressure switch (S421)
617 Pressure relief valve Y446 (electrical)
701 Shank lubricator unit (SLU) pump block
702 Water separator
704 Air valves (SLU)
705 SLU

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1.4. Water circuit diagram (DT821 THC)
510.03
510.01
510.02 510.02
616 510.06
510.03
510.01 510.06
704 511
511
521.01 521
510.05
522
702
1S127
616 510.06
701
S421
615
509 315.01 315.01
520
705 315 315
605
508 572
604 501
501.01
512
506
DRAIN 617 514 507
507.01
601
609.02 507.02
609.03 609
515
515.01
609.01 503
608
502
Figure: Water circuit diagram DT821 THC

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1.4.1. Components (DT821 / DD531)
315 Oil cooler

.01 Drain valve
503 Water hose reel
507 Mud separator
.01 Drain valve
.02 Shut-off valve
510 Flushing valves
.03 Check valve
.06 Pressure gauge
511 Flow meter (optional)
.01 Check valve
520 Washing hose with reel (optional)
521 Washing hose (optional)
.01 Water stop
522 Cabin front window washer (optional)
572 High pressure washer (optional)
604 Air receiver (optional)
605 Air receiver 2 (optional)
608 Compressor
609 Air cleaner IP5 (optional)
.01 Drain valve
616 Pressure switch (xS127)

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702 Water separator

705 SLU

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1.5. Water circuit diagram (DT821 / DD531 TPC)
510.03 510.03 510.03

LEFT A B MIDDLE RIGHT 510.02 A B 510.02 A B 510.02 A B
A B A B
1Y10 2Y10 2Y10 1Y9 2Y9 3Y9

XP XT WPM P XP XT WPM P XP XT WPM P XP XT WPM P XP XT WPM P XP XT WPM P
510.01 510.01 510.01
511 511
3Y127
704 511
OUT A P IN 702
521
616 521.01
2Y127
3S127
2.8bar
OUT A P IN 522
616 1Y127
S421
2S127 615
2.8bar
OUT A P IN
510.06
616
1S127
2.8bar
510.05
705
L G
CT7
S L G
701 CT6
L G
CT6
3.5bar 0.2bar 3.5bar 0.2bar 3.5bar 0.2bar

SC SG SC SG SC
CT2 CT1 CT2
315.01
CT1 CT2 CT1
315.01
CT4 CT4
CT3
CT4
315.01
CT3 CT3
CT5
D DG D DG D
315 315 520
Y277 PC PG PC PG PC
509 315
CT5 CT5
CT6
0.5bar 0.5bar 0.5bar
T P P P
X16 508 572

604 605
501
501.01
512
506
DRAIN 617 514 507
507.01
601
609.02 507.02
609.03 609
515
515.01
609.01 503
608
502
Figure: Water circuit diagram DT821 / DD531 TPC

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315 Oil cooler

.01 Drain valve
503 Water hose reel
507 Mud separator
.01 Drain valve
.02 Shut-off valve
510 Flushing valves
.03 Check valve
.06 Pressure gauge
511 Flow meter (optional)
.01 Check valve
520 Washing hose with reel (optional)
521 Washing hose (optional)
.01 Water stop
522 Cabin front window washer (optional)
572 High pressure washer (optional)
608 Compressor
.01 Drain valve

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702 Water separator

705 SLU
1.6. Circuit operation
1.6.1. Normal flushing
Before opening the shut-off valve (507.02), make sure that the mud separator strainer of the shut-off
valve has been cleaned. By opening the shut-off valve (507.02), you are able to feed flushing water
to the rig.
Make sure that the control switch of the water booster pump (501) is in the I position, which means
that the water pump starts automatically at almost the same time as the powerpack is started.
Select the desired flushing pressure using the pressure reducing valve (506). The pressure can be
read from the pressure gauge (510.06). The pressure switch (510.05) and the pressure gauge
(510.06) are connected after the pressure reducing valve (506). From the pressure reducing valve
(506) the pressure is directed to the oil coolers (315).
From the coolers the water flows to the pressure-controlled water-flushing valves (510.02). The
flushing valves engage water flushing automatically when percussion is started.
An optional flow switch (511) for the flushing system is available for each drilling unit. When the flow
falls below the value set for the switch, the anti-jamming automatics engage.
1.6.2. Double flushing
A system with double flushing has two flushing valves, a water flushing valve (510.02) connected to
the water circuit and an air flushing valve (510.01) connected to the pneumatic circuit. Water flushing
operates as in the circuit described above, but after the hole is finished it can also be blown clean
with compressed air.
1.7. Mud separator (507)
1 Shut-off valve (.02)

2 Mud separator 1
3 Drain valve (.01)
4 Strainer
4
2
3

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1.7.1. Cleaning the mud separator
The mud separator operates uneffectively if it reuses water

NOTE!
already used for flushing.
Restricted water flow causes flushing and cooling problems. The most common reason for the drop
of pressure is a blocked mud separator. This is why the separator must be cleaned at least once a
week. If the conditions change, start by cleaning the separator more often and determine the correct
cleaning interval based on experience.
Cleaning procedure:
1. Open the shut--off valve (1).
1
2. Open the drain valve (3) of the mud separator
(2) enough to allow the dirt in the strainer (4)
to come out.
3. Close the drain valve (3) of the mud separator.
4. If no dirt comes out, change or clean the 4
strainer (4). 2
3

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1.8. Pressure reducing valve (506)
1 Spring chamber
2
2 Spring 12
3 Valve spool 11
4
4 Pressure adjustment valve
6
5 Bottom cover
21
6 Locking ring
1
7 High pressure O-ring
20
8 High pressure seal ring
13
8
9 Valve disc
10 Valve frame 14 7
11 End ring
C
12 Spring chamber ball 22
13 Piston 15 A
14 Fastening screw
15 Seal B 9
16 Washer
17 Valve disc retaining nut
18 Seal 16 17
19 Bottom cover seal 3 10
20 Piston seal 5
19 18
21 Large piston
22 Disc valve frame
1.8.1. Operation of the water pressure reducing valve
Water flows to the shut-off valve through a hose. When the shut-off valve is opened, the water flows
through the mud separator to the pressure reducing valve and on to the water pump.
The pressure reducing valve is used to lower the feed pressure to the pump to approximately 1-7 bar
if the pressure in the mine water system is higher.
The pressure reducing valve operates as follows: The pressure to be adjusted is applied to the valve
inlet side both on the upper surface (A) and lower surface (B) of the disc valve. These two surfaces
are in balance, so the pressure applied to them does not cause the spool (3) to move in either
direction. The spring (2) force causes the spool movement downward. The disc valve opens, allowing
the pressure into the outlet side channel. However, through the internal gate, the same pressure is
also applied to the bottom surface (C) of the larger upper piston, thus creating the force that pushes
the piston upward. The flow continues until the force pushing the piston upward, caused by the
pressure, exceeds the spring force, and the disc valve closes.
As the pressure on the outlet side drops, the spring force becomes dominant again, and the disc
valve opens, thus opening the flow route, and the pressure below the larger piston becomes dominant,
and so on. The pressure is thus increased by tightening the spring (2) and decreased by loosening
it.

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1.8.2. Disassembly and assembly
If the pressure on the output side of the pressure limiter fluctuates substantially or changes
significantly in either direction, the likely cause is leakage from the valve seals. Replace the seals.
Disassembling the valve is started by loosening the locking ring (6) and screwing the spring
adjustment screw (4) off the spring chamber (1). Be careful when removing the adjustment screw as
the spring (2) is under stress. Remove the spring chamber ball (12), the end ring (11), and the spring
(2). Unfasten the fastening screws (14) and remove the spring chamber (1), piston (13), piston seal
(20) and large piston (21). Next, remove the bottom cover (5) below the valve. The cover is attached
to the valve frame with threads. Remove the spool (3), disc retaining nut (17), washer (16), valve disc
(9), disc valve frame (22), O-ring (7), and seal (8).
Replace the O-ring (7), seal (8), and valve disc (9). Also replace the piston seal (20).
Reassemble in reverse order. Replace seals 12, 18 and 19, or use a suitable sealant glue to seal the
bottom cover (19) and spring chamber (3).
When disassembling the valve, take care not to lose the spring
NOTE!
chamber ball.
NOTE! Remember to adjust the valve before use.
1.8.3. Checking the operation of the pressure reducing valve
Check that the pressure reducing valve operates

properly.

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1.8.4. Adjusting the pressure
Flushing pressure = inlet pressure + pump pressure.

Adjust the pressure with the adjustment screw (A) while the water pump is running. Increase the
pressure by turning the screw clockwise and decrease by turning it anticlockwise. The value must
never exceed 25 bar. To ensure adequate flushing, the minimum inlet pressure to the drilling rig is 5
bar. An optional 15 bar relief valve (514) can be installed before the flushing circuit, in case high-
pressure peaks occur in the working site’s water supply system.
514
The adjusting range of the pressure reducing valve is 2-7 bar.
1.9. Water booster pump (501)
1.9.1. General
The water booster pump is used when the pressure of the water supply network is not sufficient to
ensure proper flushing.

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1.9.2. Components
1 Motor
2 Pump
3 Primer- / vent plug 3 1
4 Primer valve- / drain plug
1.9.3. Connections
The arrows on the base of the pump indicate the direction of flow of the water. If protective caps are
installed to the pump’s hose connectors for transport or storage, remove them before connecting the
hoses. Always check that the hoses are clean on the inside.
1.9.4. Venting and filling of pump
RISK OF WATER PUMP DAMAGE!

The pump will be damaged if it is used in dry.
Do not start the pump until it has been vented and filled with
water.
1. Close the pump isolating valve(s).

2. Open the venting valve (A) (pumps with the
venting valve) or remove the primer plug (B)
(pumps without the venting valve) from the
pump head.
3. Gradually open the isolating valve in the
suction pipe until a steady stream of water runs
of primer port. A B
4. Close the venting valve (A) (pumps with the
venting valve) or assemble the primer plug (B)
(pumps without the venting valve) and tighten
securely.

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1.9.5. Operation and maintenance
Before starting the pump, refer to manual Water booster pump; Operation and maintenance.
1.10. Oil cooler (315)
The OW21, OW30, OW45 and OW60 hydraulic oil coolers are used with Sandvik Mining and
Construction Oy’s hydraulic powerpacks. The oil coolers differ from each other only in size and
efficiency.
The working principle of the cooler is ”from oil to water”. The cooling water flows inside the cooler in
three stages so that it changes direction twice at the cooler’s end flange. Because of this arrangement,
the cooler does not drain completely through the bottom plug but pressured air blown through the
flow--circuit is needed for assistance.
4 3
1
5
1 Water in
2 Water out
3 Oil in
4 Oil out
5 By-pass valve
1.10.1. Function of oil cooler
The flow path of the water that takes care of the oil cooling opens normally automatically when the
drilling hydraulics’ percussion circuit is actuated. In certain cases cooling may be needed also during
drilling pauses, but the valve that is responsible for the automatic flushing is closed. Cooling can be
enhanced by opening the by-pass valve (5) connected to the oil cooler, in which case a nonstop water
flow (= cooling flow) is produced.
In this case the volume flow is not as great as when using the normal course of flow, but this only
serves the purpose of additional cooling. However, it must be noted that if the available water flow is
limited, the by--pass running can cause deficiency in the flushing flow. This manifests itself as a large
decrease in the pressure of the flushing valve, depending on whether the drilling is going on or not.
Fitting the water hoses the other way around results in a less
NOTE!
efficient cooling.

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1.10.2. Maintenance
If the oil temperature increases or the pressure of the flushing valves falls, itmay be a sign that the
oil cooler needs cleaning. There may also be other reasons for a decrease in the pressure, so the
cause for it must always be clarified.
If it has been ascertained that the cooler is blocked and if the cooler model is dismountable, drain
both the water and the oil from the cooler unit and detach the hoses before cleaning.
The best way to clean the water circuit--side surfaces of the tubing (the inner surfaces of the tubes)
is pushing a 3 mm steel rod into the tube in the opposite direction of the water flow during cooling.
After cleaning, remove all impurities carefully from both surfaces of the tubing. This can be done for
example by first washing the unit carefully and then blowing any loose materials and the water off the
tube surfaces with compressed air.
Be careful not to over-tighten the bolts. The tightening torque
(37 Nm) of the cooler end fastening bolts should be complied
with so that the ends do not bend and get damaged by excessive
tightness.
If the cooler hoses are detached,make sure that they are

reconnected in the correct order. The inflowing oil must be
directed through the upper way, for the reason that then the
running direction of the oil is natural with respect to the cooling.
For the same reason the water must be directed into the cooler
through the bottom way.
Observe the given pressure limits! For example, if the pressure

in the water circuit exceeds the specified limit, the oil cooler is
in danger of getting damaged. The damaged cooler may let
water into the hydraulic oil and the damages can be very
serious.
New seals should be used when assembling the cooler.
1.10.3. Checking the operation of the oil cooler
Check that oil cooler operates properly.

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1.10.4. Cooler's dissipation figures
The cooler’s nominal dissipation:

• OW21..........21 kW
• OW30..........30 kW
• OW45..........45 kW
• OW60..........60 kW
kW Dissipated when the oil outlet temperature exceeds the water inlet temperature by 25 °C.
The heat dissipation figures are based on a When the oil outlet temperature exceeds
water flow rate which is 50 % of the oil flow. the water inlet temperature by other than 25
For the other water flow rates, multiply the °C, multiply the dissipation figure by the fol-
dissipation figure by the following correc- lowing correction factor.
tion factor.
25 % 50 % 100 % 15 °C 20 °C 25 °C 30 °C 35 °C
0,8 1 1,2 0,6 0,8 1 1,2 1,4

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1.11. Flushing valves (510)
1.11.1. Hydraulically controlled water valve FV-70
The flushing valve switches on the water flushing automatically when the percussion is started. The
return automatics closes the flushing valve automatically when the rock drill carriage reaches the
front impulse cylinder and the return movement starts.
1 2 5
4 3
1 Valve body
2 Spool
3 Return spring
4 Cover
5 Overflow duct

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Function
When water (or air) pressure is present in the input side of the valve but drilling is not on, the water
flow passages are closed. The cooling water for the oil coolers also circulates through this valve and,
thus, cooling also operates only during drilling.
When percussion is switched on from the control panel, the pressure affects not only the actual
percussion circuit but also the control side of the flushing valve. The control pressure pushes the
valve spool (2) so that the flow passage through the valve opens.
When percussion is switched off, the pressure in the control side of the flushing valve also drops, the
spring (3) pushes the spool back into the resting position, and the flow passage is closed.
With regards to water pressure, make sure that the pressure level is sufficient and also that the
amount of pressure fluctuation remains reasonably small. Large pressure fluctuations usually indicate
that there is an unnecessary restriction in the line, such as an excessively narrow input hose or a
clogged oil filter.
Checking the operation of the water valve
The valve needs attention only if water or oil

comes out of the overflow duct (arrow), or if the
flushing water flow does not stop although the
valve is closed.
All seals that affect the operation of the valve are
sealing rings on the spool. They all come out with
the spool when it is pulled out of the valve block.
Disassembly and assembly
1. Disconnect hoses.
2. Plug control pressure oil hose.
3. Remove nipple (4) with adapter, and pull out spring (3) and spool (2).
4. Blow passages of the valve block clean with compressed air.
5. Clean spool and install new sealing rings.
6. Push spool and spring back into place.
7. Install a new seal on nipple (4) and reinstall the nipple.
8. Reconnect hoses.

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1.11.2. Hydraulically controlled water valve FV-100
The flushing valve switches on the water flushing automatically when the percussion is started. The
return automatics closes the flushing valve automatically when the rock drill carriage reaches the
front impulse cylinder and the return movement starts.
PP WPM
1 2 5 3
1 Valve body 2 Spool

3 Return spring 4 Cover
5 Overflow duct
Function
When water (or air) pressure is present in the input side of the valve but drilling is not on, the water
flow passages are closed. The cooling water for the oil coolers also circulates through this valve and,
thus, cooling also operates only during drilling.
When percussion is switched on from the control panel, the pressure affects not only the actual
percussion circuit but also the control side of the flushing valve. The control pressure pushes the
valve spool (2) so that the flow passage through the valve opens.
When percussion is switched off, the pressure in the control side of the flushing valve also drops, the
spring (3) pushes the spool back into the resting position, and the flow passage is closed.
With regards to water pressure, make sure that the pressure level is sufficient and also that the
amount of pressure fluctuation remains reasonably small. Large pressure fluctuations usually indicate
that there is an unnecessary restriction in the line, such as an excessively narrow input hose or a
clogged oil filter.

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Checking the operation of the water valve
The valve needs attention only if water or oil

comes out of the overflow duct (arrow), or if the
flushing water flow does not stop although the
valve is closed.
All seals that affect the operation of the valve are
8. Reconnect hoses.
1.12. Pressure switch (S422)
The water pressure switch (S422) is set to 2.8 bar, with a time delay of four seconds. If the pressure
remains below 2.8 bar for more than four seconds, the water pump and drilling will cease
automatically.

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1.12.1. Checking the operation of the pressure switch (S422)
Close the water circuit using the shut-off valve. When the water pressure drops below 2.8 bar, the
pressure switch engages and lights the warning indicator H601 (water pressure low) on the QN panel.
Now press button S505. The pressure switch is operating properly if the warning indicator does not
go off. Open the shut-off valve. The pressure switch is operating properly if the warning indicator
H601 goes off as the pressure exceeds 2.8 bar.
H601
S505
1.13. Flow control switches S9 and S10, series 5010 (optional)
1.13.1. Electrical connection
The unit must be connected by a qualified electrician.

The national and international regulations for the installation of electrical equipment must be adhered
to.
• Disconnect power.
• Connect the unit as follows:
BN BN
L+ L+
2 BK BK
3 1 A BU B BU
L-- L--
4 WH WH
P P
Normally open (NO) TAS CONTROL SYSTEM

A: SI5010 (positive switching ); B: SI5010 (negative switching)
Core colours of ifm sockets:
P: programming wire (for remote adjustment) -> 7.5)
1 = BN (brown), 2 = WH (white), 3 = BU (blue), 4 = BK (black)
Note! Use 4-wire connection cables without a link between pins 2 and 4. With 3-wire sockets with a
link between pin 2 and pin 4 switching of the output stage triggers the remote adjustment.
NOTE! See section 10.2.3. (configure the switching output) for normally closed (NC) operation
for RELAY CONTROLLED SYSTEM.

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1.13.2. Operating and display elements
Flow
Low High
1
0 1 2 3 4 5 6 7 8 9
Setpoint
2 3
1: Operation display
• The green LEDs indicate the current flow (the LEDs 0 to 9 represent the range between no flow
and maximum flow).
• A lighting LED indicates the position of the switch point (orange = output closed, red = output open).
2, 3: Setting buttons for adjustment and configuration
Operation
After every power on all LEDs light and go out again step by step (during this time the output is closed
if configured as normally open). The unit is then ready for operation.
In case of power failure or interruption all settings remain.
Operating indicators
Green LED bar: Current flow within the represen-

tation range.
Indication of the switch point (SP): 0 1 2 3 4 5 6 7 8 9
• LED orange: output closed.
• LED red: output open.
LED 9 flashes: current flow above the represen-
tation range.
0 1 2 3 4 5 6 7 8 9
LED 0 flashes: current flow far below the repre-

sentation range.
0 1 2 3 4 5 6 7 8 9
Interference indicators

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Short circuit at the switching output:

The operating indicator and red LEDs light alter-
0 1 2 3 4 5 6 7 8 9
nately.
If the short circuit has been rectified, the unit im-
mediately passes into the normal operating state.
The current operating state is displayed. 0 1 2 3 4 5 6 7 8 9
Operating voltage too low (< 19 V) or failed. En- Display OFF (no LED lights ) :
sure a correct voltage supply.
Basic functionality of set-up
• Switch on the supply voltage.

- All LEDs light and go out again step by step. During this time the output is open (Normally closed
operation) (if configured as normally open). The unit is in the operating mode.
• Let the normal flow circulate in the installation.
• Check the display and determine further actions.
1 The factory setting is suitable for the ap- Low

Flow
High
plication.
• No further settings are required.
0 1 2 3 4 5 6 7 8 9
2 Your normal flow is below the represen- Flow

Low High
tation range of the display. 2 setting op-
tions:
• Change the switch point. 0 1 2 3 4 5 6 7 8 9
• Carry out high flow adjustment.

3 Your normal flow exceeds the represen- Flow
Low High
tation range of the display (LED 9 flash-
es).
• Carry out high flow adjustment. 0 1 2 3 4 5 6 7 8 9
You can restore the factory setting any time.

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1.13.3. Setting up for water and air media
DL-rigs: high flow adjustment for water flow sensor S9 and air flow sensor S10
The unit determines the existing flow as normal flow and adapts the display representation (all LEDs
except the switch point LED light green).
• Let the normal flow circulate in the installation. Note that different kind of drill steel (tubes/rods and
drill bits) effects the flow. As well as the maximum drilling hole length.
• Press the push button and keep it pressed.
- LED 9 lights, after approx. 5 s it flashes.
• Release the push button.
The unit is now adapted to your flow conditions. It passes into the operating mode, the display should
now show example 1.
1 The factory setting is suitable for the ap- Flow

Low High
plication.
• No further settings are required.
0 1 2 3 4 5 6 7 8 9
Note: The switch point (LED 7) is now set to 70% of the normal flow.
Switch point can be adjusted in case of switch point differs from 70%. See section “Change the switch
point”.
Note: The adjustment affects the switch point: It is increased proportionally (maximum up to LED 7).
DL-rigs: low flow adjustment for air flow sensor S10
Note: When using other media than water, it is highly recommended that you should additionally adapt
the unit to the minimum flow (flow as 0 %).
Note: The following adjustment must only be carried out after the high flow adjustment.
• Let the minimum flow circulate in the installation or ensure flow standstill.
• Release the push button. The unit adopts the new value and passes into the operating mode.

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DT-rigs: adjustment for air flow sensor S83, S10
1. Restore the factory settings:

• Press the unit’s pushbutton for at least 15 s.
- After approx. 15 s LEDs 0...9 flash orange.
• Release the pushbutton.
2. The unit determines the existing flow as normal flow and adapts the display representation (all
LEDs except the switch point LED light green).
• Let the normal flow circulate in the installation. Note that different kind of drill steel (tubes/rods
and drill bits) effects the flow. As well as the maximum drilling hole length.
• Release the push button.
3. Throttle the blowing to the drifter e.g. with ball valve, so that the green LED bar lowers to point 5.
Set the measuring range zero point to this point. Push the button approx. 5s until it flashes.
4. Move the red switch point to point 7.
• Briefly press the pushbutton or
- The switch point LED flashes.
• Press the pushbutton or as often as required. Each press of the pushbutton shifts
the LED by one position in the indicated direction.
• Note: The switch point (LED 7) is now set to 70% of the normal flow.
5. Check the operation and adequate speed of the flushing control by throttle the flushing line from
the drifter. Switch point can be adjusted during the test drill to be more appropriate to the
equipment.
Q
l/ min
3

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1 Zero point
2 Switch point
3 ≥ Normal point
Change the switch point (optional)
For the factory setting the switch point is at LED 7. A change makes sense if:
1. The display shows example 2.
2 Your normal flow is below the represen- Flow

High
Low
tation range of the display. 2 setting op-
tions:
• Change the switch point. 0 1 2 3 4 5 6 7 8 9
• Carry out high flow adjustment.

2. The flow fluctuates much or pulsates.
3. If a faster response time of the unit is requested (low switch point = fast response with rising flow,
high switch point = fast response with falling flow).
• Briefly press the pushbutton or
- The switch point LED flashes.
• Press the pushbutton or as often as required. Each press of the pushbutton shifts
the LED by one position in the indicated direction.
Note: If no pushbutton is pressed for 2 s, the unit returns to the operating mode with the newly set
value.
Note: The typical response time of the unit is 1...10 s. It can be influenced by the setting of the switch
point:
• Low switch point = quick reaction with rising flow
• High switch point = quick reaction with falling flow
Configure the switching output
The unit is delivered as normally open. In case of need you can change the output to normally closed:
- After 10 s the current setting is displayed: LEDs 5...9 light orange (= output normally open).
• Release the pushbutton. The output is changed to normally closed operation.
For a new changeover repeat the operation.

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Restore the factory setting (reset)
If the unit is not working properly or connecting the settings failed, the unit can be reset to factory
settings. After this continue connecting the settings, see section 10.2.3.
• Release the pushbutton. All settings are reset to the factory setting:
- Operating area: 5 ...100 cm/s for water
- Switch point: LED 7
- Output function: NO
- Unlocked.
Lock / unlock the unit
The unit can be locked electronically to prevent unintentional settings.

• Press both setting pushbuttons simultaneously for at least 10 s in the operating mode.
- The indication goes out, the unit locks or unlocks.
On delivery: unlocked.
Error during adjustment
If no adjustment is possible, all LEDs flash red. The unit then passes into the operating mode with
unchanged values.
Possible cause / aid:
Error during installation. Check whether all requirements have been met.
The difference between maximum flow and min- Increase the flow difference and carry out the ad-
imum flow is too small. justment once again.
The sequence high flow / low flow adjustment Carry out the two adjustment operations again in
was not adhered to. the right sequence.
1.13.4. Maintenance
Recommended maintenance:
• Check the sensor tip for build-up from time to time.
• Clean it using a soft cloth. Stubborn build-up (e.g. lime) can be removed using a common vinegar
cleaning agent.

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1.13.5. Scale drawing
1 2
50 63
27
M12x1
113
14
65
22
60
45
7,7
1 LED bar display

2 set button
1.13.6. Technical data
Application area Liquids and gases

Operating voltage [V] 19 ... 36 DC
Current rating [mA] 250
Short-circuit protection, pulsed; reverse polarity / < 2.5
overload protection Voltage drop [V] < 60
Current consumption [mA] 10, optically indicated
Power-on delay time [s]

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1.14. Anti-freeze blowing (option)
7 6
5
9
AIR
X2
2/30
WATER
1 Mud separator (507) 2 Water pump (501)

3 Pressure reducing valve (506) 4 T-valve (515)
5 Non-return valve (515.01) 6 Filling cap
7 Filling adapter 8 Shut-off valve (507.02)
9 Drain valve (507.01)

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1.14.1. Draining the water circuit and adding anti-freeze agent
DANGER
Before the flushing/blowing procedure, make sure that nobody
is in front of the rock drill or the drill rod.
The capacity of the compressor is sufficient if the flushing

valves are opened one at a time.
Remember to fill the water pump before starting to drill.
It is important to ensure that the three-way valve is not left in

the position where pressurized air can enter the water circuit.
In cold conditions always remember to drain the water circuit

for the duration of a longer shut-down.
If there is a danger of the temperature dropping below 0°C, the

water circuit must be emptied using compressed air, so that the
entire water circuit, including the coolers, is empty.
1. Disconnect the rig's water hose from the supply line and open the rig's main valve (8).
2. Turn the three-way valve (4) into the position where air can enter the flushing circuit (handle turned
towards pressurized air inlet) and start the compressor. Water is now expelled from the pump's
inlet line.
3. Close the rig's main valve (8) and open the drain valves of the oil coolers. Water is now drained
from the coolers.
4. Perform following procedure for each boom separately:
TPC controlled rigs
• Close the cooler drain valve, and select the reaming operation by turning the selector (S72) to
the right. The flushing valve opens when you engage rotation (joystick S74 to the left). Select
flushing (flushing selector (S73) to the middle position). Continue blowing until only air flows
out of the rock drill.
THC controlled rigs
• Close the oil cooler drain valves. The flushing switch shall be in the water flushing position (pull
lever backwards). Water flushing is on. Continue draining until plain air comes out of the rock
drill. Powerpacks must be running in order to provide control pressure to the valves.
5. Perform following procedure:
TPC controlled rigs
• Blow water out of the line between the air and water valves by turning air flushing on for a
moment (S73 to the right).
THC controlled rigs
• Turn the air flushing valves on for a while (push the lever forward) to expel water from the line
between the air and water valves. Powerpacks must be running in order to provide control
pressure to the valves.
6. Stop the compressor and turn the three-way valve (4) to the position where the filling line is
connected to the flushing line (handle toward the filling cap).

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7. Open the filling cap (6), and pour 100% -antifreeze agent into the line. Close the filling cap (6).
8. Open the main shut-off valve (8). Turn the three-way valve (4) to the position where compressed
air is in connection to the flushing line, and start the compressor.
9. Repeat steps 6-8 until the mixture of air and antifreeze comes out of the rock drill or the end of
the drill rod.
1.15. Checking the water system for leaks
Check the water system for possible leaks.
1.16. Troubleshooting
Problem Possible cause

Pump does not start. • No current.
• Water pump switch (at electric cabinet) in posi-
tion 0.
• Motor protector switch triggered.
• Motor protector switch contact points or elec-
tromagnet faulty.
• Control voltage circuit faulty.
Motor protector switch triggered (triggered right • Motor protector switch contact points faulty.
after starting). • Loose or faulty cable connection.
• Motor winding faulty.
• Pump mechanically blocked.
• Set value too low.
Motor protector switch triggered erratically. • Set value too low.
• Fluctuation in voltage.
• Mains voltage too low.
Motor protector switch not triggered but pump still • No current.
not running. • Water pump switch (at electric cabinet) in posi-
tion 0.
• Control voltage circuit faulty.
Pump output varying. • Too small supply hose for pump output.
• Water supply capacity too small for pump out-
put.
• Water inlet pressure too low with respect to
temperature, flow disturbances, and flow vol-
ume.
• Supply line partly blocked.
• Mud separator partly blocked.

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2. AIR CIRCUIT
2.1. General
Pressurized air on the DT/DD rigs is mainly used for:

1. Rock drill shank lubrication.
2. To blow the hole clean after drilling.
3. Water mist flushing with a certain amount of water added into the air flow.
Pressurized air is taken from the compressor mounted on the rig or from the air line of the drilling site.
Shank lubrication is very important for the operation of the rock drill. Insufficient lubrication causes
damages to the rotation mechanism and the shank of the rock drill. This is why the drilling is
automatically prevented if the shank lubrication is insufficient; a pressure switch detects low air
pressure and stops drilling.
Neglecting the shank lubrication is certain to damage the
machine.

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2.2. Safety
WARNING
PERSONAL INJURY HAZARD!
Moving machine could cause death or severe injury.
Maintenance and repairwork should only be done when the rig
is out of operation. Make sure that it cannot be accidentally
started (open the main power switch, for instance) during the
repairwork. Unauthorized persons are not allowed near the rig
during the repair work.
WARNING
SKIN INJECTION HAZARD!
High-pressure hydraulic fluid can penetrate the skin, causing
severe injury.
Do not try to locate a leak on a hydraulic hose with your hand!
Use a piece of cardboard or equivalent. If hydraulic fluid
penetrates your skin, seek medical advice immediately!
RISK OF EQUIPMENT DAMAGE!

If the water is allowed to freeze it can damage the cleaner.
In cold weather any water in the air cleaner must be carefully
drained.
WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and obey
following instructions before operating the equipment.
Service and adjustment procedures must be carried out by
personnel with specialized operation and service training.
Carefully plan your work beforehand to minimise risk of damage
or injury.

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2.3. Air circuit diagram (DD321/DD411/DD421/DT610)
510 510.03
510.01
510.02
704 510.03
510.02
510.01
702
702.01
615
509
601 609.02 609
609.03 611
617
609.01
604
608
Figure: Air circuit diagram DD321 / DD411 / DD421 / DT610

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2.3.1. Components (DD321/DD411/DD421/DT610)

510 Flushing valves
.03 Check valve
601 Air supply terminal
604 Air receiver (option)
608 Compressor
609 Air cleaner IP5 (option)
.01 Water drain valve
611 Flow control valve
702 Water separator
.01 Drain valve

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2.4. Air circuit diagram (DT821 / DD531)
510 510.03
510.01
510.02
616
510.03
704 510.02
510.01
702
1S127
702.01
616
S421
615
509
605
604
DRAIN 617
601
609.02
609.03 609
609.01
608
Figure: Air circuit diagram DT821 / DD531

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Components (DT821 / DD531)

510 Flushing valves
.03 Check valve
608 Compressor
702 Water separator
.01 Drain valve

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510 Flushing valves
.03 Check valve
608 Compressor
702 Water separator
.01 Drain valve
2.5. Circuit operation
2.5.1. Pressurized air from compressor
The filtered and pressurized air flows either straight or through the air cleaner (609) into the air circuit.
The pressurized air for shank lubrication flows through the water separator (702). The separator has
a drain valve (702.01) to let the water out. The valve can be left slightly open to blow continuously
the water out.
From the water separator (702) the pressurized air flows to the central lubricator SLU. The purpose
of the shank lubricator is to provide sufficient lubrication for the rock drill shank. The lubricating oil is
mixed with the air that carries it to the rock drill. For removal of the water the shank lubricator is
provided with the drain valve.
The air can be taken through the air flushing valve (510.01) to blow the drilled hole clean or to flush
the hole if the air mist flushing (option) is used. To function properly, the air mist flushing usually
requires extra pressurized air from the mine air network.
2.5.2. Pressurized air from the air network
The pressurized air can also be taken into the circuit from the mine own air lines. The air flows through
shut-off valve to the separate air cleaner IP5 (609) which cleans the air and removes the possible
water content before the air enters into the circuit. The IP5 is equipped with a water drain valve
(609.01). Otherwise the circuit operates as described in chapter ”Pressurized air from compressor”.

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2.6. Air cleaner IP5 (609) (option)
The shank lubrication is one of the most important functions affecting the operating condition of the
rock drill. Therefore, the air used in the shank lubrication system must be sufficiently clean. When the
rig’s own compressor is used the pressurized air is filtered. If, however, the air comes from an air
network at the drilling site, a separate air cleaner (IP 5) must be used. It is installed in the line before
the central lubricator. The IP 5 not only cleans the air from impurities but also separates water from
the air.
The IP 5 operates with the cyclone principle. All of the air that flows through the cleaner is cleaned.
The impurities and the water separated by the cleaner remain in the bottom of the cleaner. The
manually operated valve at the bottom is opened to drain the cleaner.
1 Tap
2.6.1. Draining the air cleaner
All air flowing through the cleaner is purified. The

impurities and water are collected at the bottom
of the air cleaner and drained through the valve.
The valve is manipulated via a manual tap (1).

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2.7. Air receiver (604) (option)
Some machines are possible to equip with an extra air receiver (604). This receiver is then mainly
used for hole blowing. The loading speed of the receiver can be regulated using a restrictor (611).
Using a pressure relief valve (604.01), the maximum receiver pressure has been restricted to 8 bar.
604 Air receiver

.01 Pressure relief valve
611
.02 Draining valve
.03 Pressure gauge
611 Flow control valve
604.03 604
604.01
604.02
2.7.1. Bleeding the air receivers (option)
Bleed the condensed water from the air receivers

by using the drain valve (1).

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2.8. Flushing valves (510)
2.8.1. Hydraulically controlled air valve
1 Valve body
1 2 5
2 Spool
3 Return spring
4 Nipple
5 Overflow duct
6 Non-return valve
4 3
8. Reconnect hoses.
Function
Air is activated on by pushing the control lever of the flushing control valve to the forward position.
Now the pilot pressure is able to reach the end of the air valve (1) spool (2). The spool (2) moves to
the left and allows the air flow through the air valve (1) and through the non-return valve (6) ahead
to the rock drill.
The air flow is closed by centralizing the control lever of the flushing control valve. Now the pilot
pressure drops on the end of the spool (2) and the spring (3) pushes the spool (2) to the right
preventing the air flow through the air valve.

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Checking the operation of the air valve
The valve needs attention only if air or oil comes

out of the overflow duct (arrow), or if flushing air
flow is not stopped although the valve is closed.
All seals affecting the operation of the valve are
2.9. Compressor (608)
The screw compressor is used to produce the compressed air required for drilling, unless an external
compressed air network is used. Inside the compressor, an electric motor rotates rotors that are
geared together and which compress the air to the desired pressure.
1 Compressor
12 5
2 Air filter
3 Filling hole cap 8 7
4 Oil separator filter
3 2
5 Electric motor
6 Oil level sight glass 9 13
7 Oil separator
16 14
8 Inlet valve
9 Oil cooler 10 11
10 Oil filter
11 Oil vortex cleaner
12 Air filter condition indicator 1
13 Pressure gauge 15 6 4
14 Temperature gauge
15 Outlet tube
16 Air pressure releasing valve

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2.9.1. Use of compressor
The operating switch (S502) has three positions (S502, located in the SW panel of the cabin/safety
canopy).
Position 0
Compressor not running. Pressure monitoring is activated also then when compressor is not running.
Position 0 is used when the required air is taken from the mine network so that no compressor is
needed.
Position 1
Normal position, compressor running. As the first powerpack starts, compressor will start 1 second
after that, and pressure monitoring is activated. With powerpack already running, the turning of the
switch to position 1 will start the compressor. The compressor is switched off when the powerpacks
are stopped.
Position S (non-locking)
If no powerpacks are running, turning the switch to the non-locking S position will start the compressor
alone (manual control for production of compressed air).
Air pressure control is NOT activated when the compressor is
running alone.
Turn the switch to position 0 for stopping the compressor. When the compressor is in manual control,
the starting of powerpacks is not possible. For starting powerpacks you must first switch off the
manual control of the compressor. In case of power failure, or if the emergency stop button is
depressed, the compressor will not start again automatically but needs to be restarted.
The QN panel has the following indicator lights for the compressor: green “compressor running”
indicator light H618, red “compressor overload” indicator light H605, and red “compressor overheat”
indicator light H604. Activation of the overload and temperature controls of the compressor will stop
the powerpacks, the water pump, and the compressor.
2.9.2. Procedures prior to compressor maintenance
WARNING! BURN HAZARD!

Hot surfaces of the equipment could cause burns.
Let the compressor cool down before starting any maintenance
work!
- Stop the compressor and check that the oil separator unit is not pressurised. After the compressor
is stopped, the oil separator unit is drained by the out-blow unit – wait approximately 2 minutes.
- Turn the power off and make sure the compressor cannot be started.
- Close the shut-off valve between the network and the compressor.
- Open the safety valve cap 4–5 turns.

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2.9.3. Checking the compressor oil level
Check the oil level when the compressor is stop-

ped (wait for the air and oil to separate). Make
sure that the oil level remains between the min.
and max. levels of the sight glass. Only add rec-
ommended oil types, when necessary.
2.9.4. Changing the compressor oil
1. Run the compressor until the oil temperature

is approximately +40–50 °C.
2. Stop the compressor.
3. Loosen the safety valve (2) 4–5 turns.
2
4. Open the oil filler plug (1) and drain valve (3)
and let the oil drain into the recovery tank.
5. Close the drain plug (3).
6. Replace the oil filter (see “Replacing the oil
filter”).
7. Fill with fresh oil up to the max. indicator.
8. Close the oil filler plug (1).
9. Close the safety valve (2).
1
Note! Follow the local regulations for oil disposal.

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2.9.5. Changing the compressor oil filter
1. Place a protective cloth under the filter. While

the filter is being replaced, oil runs from the
filter housing.
2. Remove the filter by turning it counterclock-
wise using a tightening belt.
3. Apply oil to the seal of the new filter.
4. Fasten the new filter by manually turning it
clockwise.
NOTE! Dispose of the oil in accordance with local regulations.
2.9.6. Replacing the compressor oil separator element
1. Close the shut-off valve between the network

and the compressor.
2. Open the safety valve cap 4–5 turns.
3. Remove the output valve (1).
6
4. Remove the separator element (2).
5. Clean the surfaces and output valve (1) of the 1
oil separator unit.
5
6. Clean the orifices (3) at the ends of the hose.
7. Clean the strainer (4) and, if necessary, the oil
separator unit.
8. Grease the separator O-ring and install the 2
new separator element.
9. Replace the O-ring (5) between the oil sepa-
rator unit and the output valve.
10. Replace the output valve seals. After the out-
put valve assembly, leave the nut (6) on the
cover approximately 2 mm free of the cover.
11. Install the output valve (1).
12. Tighten the screws alternately. 3
3 4
13. Close the safety valve.
14. Open the shut-off valve between the network
and the compressor.
Dispose of the used separator element in accordance with local

NOTE!
regulations.

ID: 92 4 en 2013-01-22
DD321/DD411/DD421/DD531/DT610/DT821
2.9.7. Cleaning the compressor oil return pipe strainer
Refer to the manufacturer's instructions.
2.9.8. Cleaning the outside of the compressor radiator
2.9.9. Checking the compressor safety valve operation
The operation must be checked at least once a year, as recommended by the manufacturer.
All safety valve adjustment and repair tasks must be performed
NOTE! by trained professionals (take into consideration local
regulations).
The opening pressure of the safety valve must be

tested in a separate compressed air circuit.
The valve operation can be tested by turning the 1
safety valve cap (1) 1–2 turns counterclockwise.
2.9.10. Checking the condition of the compressor hoses
Visually check the hoses. If visible damage is detected or the hose leaks, replace it with a new one.
2.9.11. Checking the tightness and condition of the compressor connections and screws
Refer to the compressor manufacturer's instructions.
2.9.12. Cleaning the inside of the compressor

ID: 92 4 en 2013-01-22
DD321/DD411/DD421/DD531/DT610/DT821
2.9.13. Replacing the compressor belts
2.9.14. Replacing the compressor intake valve seals
2.9.15. Replacing the compressor discharge valve seals
2.9.16. Checking and tightening the contactors and engine connections
2.9.17. Checking the operating temperature of the compressor
2.9.18. Checking the operation of the compressor thermometer safety measures
2.9.19. Changing the compressor air filter
NOTE! The filter is disposable and cannot be cleaned.
1. Remove the housing cover (1).

2. Remove the old filter (2).
3. Clean the inside of the cover.
4. Install the new filter. 2
5. Attach the cover (1). (NOTE: The particle dis- 1
charge hole [4] must always point down.)
Change the inner filter (3) every two years or in

conjunction with every fourth air filter replace- 3
ment.

ID: 92 4 en 2013-01-22
DD321/DD411/DD421/DD531/DT610/DT821
2.9.20. Capacity control
Output pressure can be regulated by turning the

B
adjusting screw (B) on the control valve.
Factory setting for the compressor is 6,5 bar. A
Don't exceed the compressor's max. pressure (8
bar). Check the correct adjustment value from the
rig's flushing circuit diagram.
Locking nut (A) must be loosened before adjust-
ing: turning the screw (B) clockwise increases
pressure and turning it counterclockwise lowers
the pressure.
Tighten the locking nut (A) after adjustments!
2.9.21. Temperature gauge
For temperature measuring the compressor is

equipped with a temperature gauge. At 100°C the
temperature alarm lights and at 115°C the com-
pressor will stop.
Wiring diagram to the temperature gauge is
shown in the figure.

ID: 92 4 en 2013-01-22
DD321/DD411/DD421/DD531/DT610/DT821
2.10. Pressure relief valve Y446 (617)
Pressure relief valve Y446 operates normally as

an open-type valve, which reliefs the pressure 2
from the air circuit. When the compressor (608)
or the hydraulic powerpack is switced on, the
pressure relief valve is activated, in which case
the valve shuts down and the system is pressur-
ized by the compressor line. 1
1 Valve body
2 Solenoid
If the air circuit is equipped with air receiver (optional), the

system depressurizes longer than normally. Make sure that the
system is non-pressurized before maintenance.

ID: 92 4 en 2013-01-22
www.sandvik.com
Instrucciones originales
331 3 es 2011-09-16
SLU 1/2/3
Operación y mantenimiento
Índice de contenidos
1. INFORMACIÓN GENERAL ........................................................................................................... 5
2. COMPONENTES PRINCIPALES .................................................................................................. 6
3. PRINCIPIO DE FUNCIONAMIENTO ............................................................................................. 7

3.1. Información general ......................................................................................................................................... 7
3.2. Funcionamiento de la bomba ........................................................................................................................ 8
3.3. Unidad de control ............................................................................................................................................. 8
3.4. Datos técnicos ................................................................................................................................................... 9
3.4.1. Depósito de aceite ......................................................................................................................................... 9
3.4.2. Unidad de bomba .......................................................................................................................................... 9
3.4.3. Unidad de control del lubricador de la espiga SLCU ............................................................................... 9
3.4.4. Pares de apriete ............................................................................................................................................. 9
4. AJUSTES ....................................................................................................................................... 10
4.1. Ajustes de salida .............................................................................................................................................. 11
4.2. Purgado ............................................................................................................................................................... 12
4.3. Interruptor de cebado ...................................................................................................................................... 13
5. MANTENIMIENTO ......................................................................................................................... 14
5.1. Comprobación del nivel de aceite ............................................................................................................... 14
5.2. Drenaje del agua condensada ....................................................................................................................... 14
5.3. Limpieza del depósito ..................................................................................................................................... 15
5.4. Sustitución del respiradero ........................................................................................................................... 15
5.5. Comprobación del funcionamiento del sistema de supervisión ......................................................... 16
5.6. Sustitución de una manguera defectuosa de lubricación de la espiga ............................................. 16
5.7. Sustitución de las juntas ................................................................................................................................ 17
6. IDENTIFICACIÓN Y SOLUCIÓN DE AVERÍAS ............................................................................ 18

ID: 331 3 es 2011-09-16
ID: 331 3 es 2011-09-16
SLU 1/2/3
1. INFORMACIÓN GENERAL
El lubricador de la espiga SLU 1/2/3 es una de las unidades más importantes de los equipos de
perforación Sandvik. Su función es la de proporcionar una lubricación suficiente a los martillos
perforadores Sandvik para las distintas condiciones y situaciones de perforación. La cantidad
suficiente y precisa de lubricación es posible con la regulación de la frecuencia de trabajo de las
bombas del lubricador del adaptador.

ID: 331 3 es 2011-09-16
SLU 1/2/3
2. COMPONENTES PRINCIPALES
13 7 13
10
9 9 4
4 12
2 3
3 2
6
11
1 Interruptor de supervisión CT 1 2 Tornillo de purga hidr. CT 4

3 Válvula direccional CT 5.1 4 Tornillo de purga CT 7
5 Depósito de aceite 6 Unidad de bomba (1 bloque principal,
máx. dos bloques auxiliares)
7 Dispositivo de protección de nivel 8 Unidad de regulación SLCU
9 Interruptor de cebado 10 Tapón de la válvula de descarga/carga
11 Válvula de drenaje 12 Potenciómetros de ajuste fino
13 Varilla de medición de aceite

ID: 331 3 es 2011-09-16
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3. PRINCIPIO DE FUNCIONAMIENTO
1
7
8
3
5
11
12
6
9
10
1 Tapón de la válvula de descarga/carga 2 Depósito de aceite

3 Interruptor de empuje 4 Unidad de bomba
5 Presión de funcionamiento de la bomba 6 Conducto de presión
7 Interruptor de nivel 8 Unidad de control SLCU
9 Depósito 10 Conducto del depósito de aceite
hidráulico
11 Aire 12 Martillo perforador
3.1. Información general
La unidad de bomba suministra el aceite al martillo perforador a través de un tubo insertado. El aire
a presión se utiliza para distribuir el aceite hacia los puntos de lubricación. En un sistema de
recuperación, el aire a presión se utiliza para recoger el aceite de lubricación en un depósito
separado. El sistema dispone de un interruptor de control del nivel de aceite.

ID: 331 3 es 2011-09-16
SLU 1/2/3
3.2. Funcionamiento de la bomba
La bomba de lubricación es accionada hidráulicamente por un pistón con control eléctrico. La

regulación de la cantidad de aceite necesario se lleva a cabo alterando eléctricamente la frecuencia
de trabajo de la bomba.
La bomba de lubricación está formada por bloques. Consiste en un bloque principal con uno o dos
bloques auxiliares conectados a él (dependiendo del número de brazos). El bloque principal y cada
bloque auxiliar poseen un interruptor de control de lubricación individual. El control eléctrico es sólo
para el bloque principal. El sistema de control se activa cada vez que se enciende la tensión de
funcionamiento.
3.3. Unidad de control
La bola de cierre de la válvula de retención del puerto de salida de la bomba de lubricación funciona
como un interruptor de control con respecto a su junta. El flujo de aceite a través de la válvula de
retención eleva la bola de la superficie de apoyo, con lo que el circuito se corta. La bola en la válvula
de retención de la válvula de control está conectada eléctricamente al bastidor de la bomba (y al
equipo de perforación). La tensión está conectada a la bola por vía de un muelle que está aislado
del bastidor de la bomba.
Si la bola permanece abierta durante más de 4 ciclos de trabajo,
se encenderá la alarma. Las luces indicadoras se encienden,
la(s) palanca(s) de mando están centradas y la función de
perforación está desactivada. Del mismo modo, si la bola no se
abre durante más de 4 ciclos de trabajo, se encenderá la alarma.
La alarma se apaga cuando se vuelva a alcanzar el bombeo
normal.
Diagrama de flujo del bloque de la bomba
CT1 = interruptor de control

CT2 = lado de entrada de la válvula de retención
CT3 = pistón de trabajo
CT4 = tornillo de purga hidr.
CT5.1 = válvula direccional
CT5.2 = válvula de retención
CT6.2 = tornillo de purga
CT7 = tornillo de purga

ID: 331 3 es 2011-09-16
SLU 1/2/3
3.4. Datos técnicos
3.4.1. Depósito de aceite
ELEMENTO SLU 22 SLU 14

Capacidad de aceite total (litros) 22 14
Capacidad de aceite efectiva sin calentador de aceite (litros) 18 12
Capacidad de aceite efectiva con calentador de aceite (litros) 16 -
Respiradero (µm) 10 10
Filtro de aceite (mm) 1 1
Dispositivo de protección de nivel sí sí
3.4.2. Unidad de bomba
Cilindrada estándar 0,85 cm³ (carrera de 7,5 mm) (máx.

1,25 cm³, carrera de 11 mm)
Gama de salida 80–1200 g/h (con carrera estándar)
Presión hidr. máxima (control de pilotaje) 210 bares
Presión hidr. mínima (control de pilotaje) 25 bares
Presión de lubricación máx. 25 bares
3.4.3. Unidad de control del lubricador de la espiga SLCU
- EMC autorizado
- 3 salidas de alarma
- Función de cebado
- Voltaje de funcionamiento 24 V CC
3.4.4. Pares de apriete
Interruptor de control 7 Nm
Tornillos de montaje de la unidad de bomba 20 Nm

ID: 331 3 es 2011-09-16
SLU 1/2/3
4. AJUSTES
Es posible ajustar la frecuencia de trabajo de la

bomba de lubricación entre 2 y 30 carreras por
minuto mediante dos interruptores giratorios ubi-
cados en la unidad SLCU. Las 16 posiciones de
los interruptores están señalizadas mediante los
números del 0 al 9 y las letras de la A hasta la F.
Uno de los interruptores selecciona la gama y
viene predeterminado y precintado de fábrica. El
otro interruptor es para el ajuste fino. En la tabla
y gráfico del ccapítulo "Ajustes de salida" se in-
dican los valores medidos con distintos ajustes
de los interruptores.

ID: 331 3 es 2011-09-16
SLU 1/2/3
4.1. Ajustes de salida
Gama Fino [ g / h ] Tipo de martillo perforador

0 80–150 HE 122, HEX1, HLX1, HSX1
1 100–200 HL 300
2 150-300 serie HLX5, HFX5, serie RD300, serie RD500
3 200-400 HL 510
4 300-600 HL 560, HL 600
5 400-850 HL 700, HL 1000, HL 710, HL 800, HL 1010
6-F 600-1200 HL 1500, HL 1560
Se suministra una placa del circuito como pieza de repuesto

ajustada con los valores máximos. Realice el ajuste de salida
correcto de acuerdo con la información contenida en esta
página.
Dependiendo de las condiciones de perforación (profundidad

del barreno, tipo de roca, etc.), es posible que pueda variar la
cantidad de lubricación necesaria con respecto a la gama
indicada. Para perforaciones pequeñas (para el martillo en
cuestión) y para perforaciones y fijaciones con pernos
ascendentes, se recomienda elegir ajustes finos bajos. Para
perforaciones más grandes y para aplicaciones superficiales de
temperatura alta, se recomienda elegir un ajuste fino más alto.
Ejemplo de lectura del cuadro:

Gama = 5. Ajuste preciso = 9.
La cantidad de aceite de lubricación es de aprox. 590 g/h
Figura: Curvas de medición de lubricante

ID: 331 3 es 2011-09-16
SLU 1/2/3
4.2. Purgado
La purga del DEPÓSITO SLU se basa en la gra-

vedad y se lleva acabo abriendo el tornillo de 9 8
purga (4) (CT7) 1–2 vueltas y, a continuación,
esperando hasta que el aceite no contenga bur-
bujas. Durante el purga debe apagarse el motor 4 12
diesel / unidad de alimentación. Al purgar la
BOMBA, conecte el tubo adicional (04-JIC) des- 2
de la abertura L hasta un depósito apropiado y
arranque el motor diesel / unidad de alimenta- 3
ción. Abra el tornillo de purga (4) (CT7) 1/2 vuel-
6
tas y el tornillo de purga (2) (CT4) 1 vuelta. Deje
abiertos los tornillos durante 1 minuto. Cierre el
tornillo de purga (4) (CT7). Espere hasta que el 1
aceite no contenga burbujas. Cierre el tornillo de
purga (2) (CT4) y retire el tubo adicional de la lí- 11
nea L y conecte el tubo original a la abertura L.
Arranque la unidad de alimentación y el compre-
sor. Encienda el interruptor de empuje (posición
1) durante aprox. 10 minutos para garantizar que
haya aceite de lubricación del adaptador en todos
los conductos del martillo y para garantizar que
se haya purgado el lado de la varilla de la bomba
SLU. Recuerde desconectar el interruptor de em-
puje después del purgado (posición 0).
¡No olvide purgar todos los bloques de las bombas al mismo

tiempo!
El tornillo de purga hidráulico (CT4) se utiliza únicamente para

purgar la bomba.
Diagrama de flujo del bloque de la bomba
CT1 = interruptor de control

CT2 = lado de entrada de la válvula de retención
CT3 = pistón de trabajo
CT4 = tornillo de purga hidr.
CT5.1 = válvula direccional
CT6.2 = tornillo de purga
CT7 = tornillo de purga

ID: 331 3 es 2011-09-16
SLU 1/2/3
4.3. Interruptor de cebado
El interruptor de cebado se utiliza en los siguientes casos:

• para llenar el tubo de lubricación del adaptador
• cuando sea temporalmente necesaria una mayor lubricación del adaptador
Cuando esté conectado el interruptor de cebado, la luz indicadora de la válvula de control de la(s)
bomba(s) empieza a parpadear. La salida de aceite de la(s) bomba(s) es ahora de 1200 g/h y la
frecuencia de carrera de las bombas es de 30 carreras / minuto. La función de cebado permanece
activa mientras esté encendido el interruptor de cebado.
¡Recuerde apagar el interruptor de cebado tras finalizar las
tareas de mantenimiento!

ID: 331 3 es 2011-09-16
SLU 1/2/3
5. MANTENIMIENTO
5.1. Comprobación del nivel de aceite
1. Compruebe el nivel de aceite desde la varilla

de medición (1). Llene el depósito según sea
1
necesario.
5.2. Drenaje del agua condensada
1. Usando la válvula de drenaje (1), drene el

agua condensada del depósito de aceite al
contenedor de recogida.

ID: 331 3 es 2011-09-16
SLU 1/2/3
5.3. Limpieza del depósito
1. Vacíe el depósito de aceite en el recipiente

usando la válvula de drenaje (1).
2. Limpie el contendor de recogida desde dentro.
5.4. Sustitución del respiradero
1. Sustituya el respiradero (1).

Sustituya el respiradero siguiendo los
intervalos especificados en las instrucciones 1
de mantenimiento, o en intervalos más
reducidos si resulta necesario, por ejemplo, si
el respiradero está húmedo.

ID: 331 3 es 2011-09-16
SLU 1/2/3
5.5. Comprobación del funcionamiento del sistema de supervisión
• Desconecte el conector de la válvula direccional, la alarma se conecta (espere 4 impulsos), o bien

• desconecte el cable de supervisión de caudal, la alarma se conecta (espere 4 impulsos), o bien
• cortocircuite el cable de supervisión de cadual al cuerpo de la bomba, la alarma se conecta (espere
4 impulsos).
5.6. Sustitución de una manguera defectuosa de lubricación de la espiga
Al reemplazar el tubo de lubricación del adaptador defectuoso por uno nuevo, proceda del siguiente
modo:
1. Sustituya la manguera defectuosa.
2. Desconecte del martillo el extremo de la manguera correspondiente de lubricación de la espiga.
3. Arranque la unidad de alimentación (motor eléctrico o diesel) y conecte el aire.
4. Encienda el interruptor de cebado.
5. Mantenga encendido el interruptor del cebado hasta salga aceite por la manguera (drénelo en el
depósito de derrame).
6. Una vez purgado el sistema, apague el interruptor de cebado y pare la unidad de alimentación.
7. Vuelva a conectar la manguera de lubricación de la espiga al martillo perforador.

ID: 331 3 es 2011-09-16
SLU 1/2/3
5.7. Sustitución de las juntas
1 Unidad de bomba SLU

2 Tapón del pistón
3
3 Pistón
4 Juntas del pistón 2 1
4
¡Antes de montar el pistón SLU en el cilindro! - Tras instalar las

juntas en el pistón, las juntas situadas en los dos extremos del
NOTA: mismo deberán calibrarse utilizando la siguiente herramienta y
debería aplicarse preferentemente un lubricante (aceite o grasa)
para evitar cualquier daño en las juntas durante dicho proceso.
1 Pistón SLU
2 Junta del pistón
1
3 Herramienta de calibrado

ID: 331 3 es 2011-09-16
SLU 1/2/3
6. IDENTIFICACIÓN Y SOLUCIÓN DE AVERÍAS
Problema: No se detecta salida de aceite; indicador encendido en la cabina
POSIBLE RAZÓN: SOLUCIÓN:

Nivel de aceite demasiado bajo Añada aceite y elimine el aire la bomba a través
del tornillo de purga (4)
Entrada de la bomba obturada Compruebe y limpie el depósito
Tubería de entrega obturada Retire y limpie o bien sustituya la tubería de en-
trega
Viscosidad del aceite demasiado alta Seleccione el tipo de grado de aceite correcto
No existe presión de funcionamiento de la bomba Problemas en el sistema hidráulico del equipo
Válvula de solenoide de la bomba defectuosa Compruebe / sustituya la válvula
Temporizador de la bomba defectuoso Compruebe (mida) / sustituya el temporizador
Cableado del solenoide de la válvula defectuoso Compruebe / sustituya el cableado
Tubo de presión de la lubricación del adaptador Cambie o repare el tubo
dañado
Problema: Cantidad insuficiente de aceite

Frecuencia del temporizador establecida inco- Compruebe los ajustes
rrecta (13)
Aire en la bomba Compruebe el nivel de aceite y purgue la bomba
Suciedad en el lado de entrada de la válvula de Limpie la bola de la válvula de retención
retención
Suciedad en el tapón de control de la válvula de Limpie el tapón de control / depósito
retención
Respiradero obstruido (presión insuficiente) Limpie el respiradero
Tubo de retorno hacia el depósito de recogida Elimine la obstrucción
obstruido
Problema: Cantidad excesiva de aceite

Tornillos de purga hidráulicos abiertos Cierre el tornillo de purga (2)
Temporizador de frecuencia ajustado incorrecta- Compruebe el ajuste
mente
Juntas del pistón dañadas Compruebe el pistón y sustituya las juntas
Interruptor de EMPUJE activado Compruebe y desconecte

ID: 331 3 es 2011-09-16
SLU 1/2/3
Problema: Fuga interna de aceite hidráulico de la bomba

Tornillos de purga hidráulicos abiertos Cierre el tornillo de purga (2)
Juntas del pistón dañadas Compruebe el pistón y sustituya las juntas
Problema: Cantidad normal de aceite (pero la alarma está activada)

Fallo en el cableado del tapón de supervisión Compruebe / sustituya el cableado
Aceite sucio, conducción de electricidad Cambie el aceite del depósito del lubricador del
adaptador
Dispositivo de supervisión de flujo deteriorado Compruebe / sustituya el conjunto del interruptor
(superficie de la bola perforada) de flujo

ID: 331 3 es 2011-09-16
SLU 1/2/3

ID: 331 3 es 2011-09-16
www.sandvik.com
Instrucciones originales
419 1 es 2009-11-18
BOMBA ELEVADORA DE PRESIÓN DE AGUA

WBP
Índice de contenidos
1. INFORMACIÓN GENERAL ........................................................................................................... 3

1.1. Designación de tipo ......................................................................................................................................... 3
2. SEGURIDAD .................................................................................................................................. 4
3. COMPONENTES ........................................................................................................................... 5
4. CONEXIONES ................................................................................................................................ 6
5. VACIADO Y LLENADO DE LA BOMBA ....................................................................................... 7
6. COMPROBACIÓN DE LA DIRECCIÓN DE ROTACIÓN .............................................................. 8
7. ARRANQUE ................................................................................................................................... 9
8. DESMONTAJE Y COLOCACIÓN DE LAS BOMBAS DE AGUA TIPO CR ................................. 10

8.1. Extracción del soporte de transporte y cambio de la posición del motor ........................................ 10
8.2. Desmontaje y colocación (CR 3 y CR 5) ..................................................................................................... 11
8.2.1. Desmontaje ..................................................................................................................................................... 11
8.2.2. Colocación ...................................................................................................................................................... 13
8.2.3. Pares de apriete de las tuercas de los pernos ......................................................................................... 15
8.3. Desmontaje y colocación (CR 10 y CR 15) ................................................................................................ 16
8.3.1. Desmontaje ..................................................................................................................................................... 16
8.3.2. Colocación ...................................................................................................................................................... 19
8.3.3. Pares de apriete de las tuercas de los pernos ......................................................................................... 22
9. LUBRICACIÓN Y MANTENIMIENTO ............................................................................................ 23

9.1. Protección contra la congelación ................................................................................................................ 23
9.2. Inspección .......................................................................................................................................................... 23
10. IDENTIFICACIÓN Y SOLUCIÓN DE AVERÍAS ............................................................................ 24

ID: 419 1 es 2009-11-18
ID: 419 1 es 2009-11-18
BOMBA ELEVADORA DE PRESIÓN DE AGUA WBP
1. INFORMACIÓN GENERAL ID: 24363
La bomba elevadora de la presión del agua se usa en los casos en los que la presión de la red de
suministro de agua no es suficiente para realizar el barrido de forma adecuada.
1.1. Designación de tipo ID: 24364
Las siguientes claves indican el significado de las letras y cifras de la designación de tipo, p. ej. CR
10-10.
A Bomba centrífuga multietapa

B Versión en línea
C Caudal volumétrico nominal [m³/h]
A B C D
D Número de etapas
ID: 25186

ID: 419 1 es 2009-11-18
2. SEGURIDAD ID: 24365
Las conexiones eléctricas deberán llevarse a cabo por

electricistas especializados y cumpliendo con los estipulado
por las normativas locales en esta materia.

ID: 419 1 es 2009-11-18
3. COMPONENTES ID: 24366
1 Motor
2 Bomba
3 Tapón de ventilación / cebo 3 1
4 Tapón de drenaje / válvula del cebo
ID: 24810

ID: 419 1 es 2009-11-18
4. CONEXIONES ID: 24367
Las flechas situadas en la base de la bomba indican la dirección del flujo de agua. Si ha instalado
tapas protectoras en las conexiones de la manguera de la bomba para el transporte o durante el
almacenamiento, no olvide retirarlas antes de conectar las mangueras. Asegúrese siempre de que
el interior de las mangueras está limpio.

ID: 419 1 es 2009-11-18
5. VACIADO Y LLENADO DE LA BOMBA ID: 24368
No arranque la bomba hasta haberla vaciado y llenado con

agua.
1. Cierre la(s) válvula(s) de aislamiento de la

bomba.
2. Abra la válvula de vaciado (A) (bombas con
válvula de vaciado) o extraiga el tapón de
cebado (B) (bombas sin válvula de vaciado)
del cabezal de la bomba.
3. Abra gradualmente la válvula de aislamiento
en el conducto de aspiración hasta que salga A B
un chorro uniforme de agua por la abertura de
cebado.
4. Cierre la válvula de vaciado (A) (bombas con
válvula de vaciado) o coloque el tapón de
cebado (B) (bombas sin válvula de vaciado) y
apriete firmemente.
ID: 25187

ID: 419 1 es 2009-11-18
6. COMPROBACIÓN DE LA DIRECCIÓN DE ROTACIÓN ID: 24369
1. Desconecte la alimentación eléctrica.

2. Compruebe que la bomba se llena de agua sin aire.
3. Compruebe que las conexiones eléctricas siguen el diagrama del cableado que aparece en la
cubierta de la caja de bornes del motor y el proceso de arranque usado.
4. Compruebe que la bomba funciona de forma suave y adecuadamente. Para hacer girar el eje,
use un destornillador o una herramienta similar a introdúzcala a través de la cubierta del ventilador
del motor o gire el acoplamiento manualmente, tras haber retirado uno de las protecciones del
acoplamiento, que se mantienen en su posición adecuada por la tensión de un muelle.
5. Arranque la bomba y observe la dirección de rotación (mire el ventilador). La dirección adecuada
de rotación viene indicada por las flechas situadas en el cabezal de la bomba y en una etiqueta
situada en la cubierta del ventilador del motor.Vista desde arriba, la bomba debería girar en
sentido antihorario.
6. Si la dirección de rotación es incorrecta, detenga la bomba de agua y desconecte la alimentación
eléctrica con el conmutador principal; intercambie dos de los cables de entrada de suministro de
energía (esta operación sólo la deberá realizar un electricista autorizado). En los motores
monofásicos, compruebe los detalles dentro de la cubierta de la caja de bornes del motor.
7. Vuelva a conectar la alimentación eléctrica y asegúrese de que la dirección del motor es
adecuada.

ID: 419 1 es 2009-11-18
7. ARRANQUE ID: 24370
Antes de arrancar la bomba, compruebe que:

• La bomba está completamente llena de agua.
• La bomba funciona adecuadamente y sin impedimentos.
• La dirección de la rotación es adecuada.
• Todos los conectores de las mangueras están bien tensados y las mangueras están bien apoyadas.
1. Abra la válvula de aislamiento del conducto de aspiración.

2. Si es posible, mida el consumo de energía del motor. En caso necesario, ajuste el interruptor de
sobrecarga del motor.
3. Compruebe las presiones de funcionamiento.
4. Compruebe que los controles funcionan adecuadamente.

ID: 419 1 es 2009-11-18
8. DESMONTAJE Y COLOCACIÓN DE LAS BOMBAS DE AGUA TIPO CR

ID: 24371
8.1. Extracción del soporte de transporte y cambio de la posición del motor

ID: 24372
Lea detenidamente estas instrucciones antes de extraer el

soporte de transporte o colocar el motor en una posición
diferente.
Para extraer el soporte de transporte, o para colocar el motor

en una posición distinta, es OBLIGATORIO seguir estas
instrucciones. Si el soporte de transporte no se retira
correctamente, o el motor no se gira correctamente para
cambiarlo de posición, la junta del eje y / o el cojinete de la
bomba podrían resultar dañados.
1. Extraiga las protecciones del acoplamiento (1)

y los tornillos (2) (si existen). 1
25
2. Extraiga tres de los tornillos (4) de las mitades
de acoplamiento (3) y el pasador del eje (13). 12
2
3. Afloje el último tornillo (4), pero no lo
desatornille completamente. 3
4. Golpee suavemente el extremo de la llave 13
hexagonal con la palma de la mano para 4
aflojar una de las mitades de acoplamiento (3).
5. Extraiga el último tornillo (4) y retire la primera
mitad de acoplamiento (3).
6. Golpee suavemente la parte plana de la
segunda mitad de acoplamiento (3) con
mucho cuidado contra el extremo del eje de la
bomba.
7. Extraiga la segunda mitad del acoplamiento ID: 24811
(3).
8. Extraiga los tornillos y tuercas del soporte de
transporte (25) y retire el soporte de
transporte. Si va a girar el motor a otra
posición, retire los tornillos (12).

ID: 419 1 es 2009-11-18
8.2. Desmontaje y colocación (CR 3 y CR 5) ID: 24374
8.2.1. Desmontaje ID: 24373
1. Extraiga las protecciones de acoplamiento (1)

junto con los tornillos (2).
de acoplamiento (3) y el pasador del eje (13).
10
desatornille completamente.
hexagonal con la palma de la mano para
11
5. Extraiga el último tornillo (4) y retire la primera 2
mitad de acoplamiento (3). 12
segunda mitad de acoplamiento (3) con 4
13
bomba.
7. Extraiga la segunda mitad del acoplamiento
(3). 3
8. Retire los tornillos (12).
9. Eleve el motor (10) para sacarlo del cabezal ID: 24812
de la bomba (11).
10. Afloje los tres tornillos (5) aprox. 1/4 de vuelta

de forma que la junta del eje quede libre del
eje.
ID: 24813

ID: 419 1 es 2009-11-18
11. Afloje la junta del eje (6) usando la llave de

tubo (7) (o una herramienta similar) hasta que 7
la rosca salga completamente del cabezal de 6
la bomba.
12. Tire de la junta del eje (6) para sacarla del eje
de la bomba.
ID: 24814
13. Extraiga las tuercas (8) junto con las arandelas

(9). 11
14. Afloje el cabezal de la bomba (11) golpeándolo
8
suavemente en el borde y elévelo para sacarlo
de los pernos de puntal (14).
9
20
14
ID: 24815
15. Afloje las paletas guiadoras superiores /

descarga (17) golpeando suavemente con un
mazo de goma (si no se ha realizado la 18
extracción con el cabezal de la bomba).
16. Retire el manguito exterior (18). 17
17. Eleve la chimenea de la cámara (15) para
15
sacarla de la base (16). Si la cámara inferior
(19) se extrae con la chimenea de la cámara
19
(15), aflójela de la chimenea de la cámara (o
bien de la base (16)). 20
16
ID: 24816

ID: 419 1 es 2009-11-18
8.2.2. Colocación ID: 24375
1. Lubrique el anillo tórico (20) con Rocol 22 (o

equivalente).
2. Coloque la chimenea de la cámara (15) en la 18
base (16).
El extremo del eje liso debe quedar hacia 17
arriba.
15
3. Coloque el manguito exterior (18) en la base y
presiónelo hasta el fondo en la base.
19
4. Presione las paletas guiadoras superiores /
descarga (17) en la ranura de la cámara 20
superior (15).
16
ID: 25130

equivalente). 11
6. Coloque el cabezal de la bomba (11).
8
7. Lubrique las roscas de los pernos de puntal
(14) con Thread-Eze (o similar).
9
8. Coloque las arandelas (9) y las tuercas (8).
9. Apriete las tuercas (8) diagonalmente a un par
de 50 Nm.
20
14
ID: 25131
10. Humedezca el extremo del eje con agua

jabonosa.
ID: 25132

ID: 419 1 es 2009-11-18
11. Coloque la junta del eje (6) en la llave de tubo

(21) y presiónela en el eje. 21
12. Atornille la junta del eje (6) en el cabezal de la

bomba (11) y apriétela a un par de 35 Nm.
6
11
ID: 25133
13. Ajuste el motor (10) en el cabezal de la bomba

(11).
10
14. Coloque los tornillos (12), lubríquelos y
apriételos diagonalmente (con el par que se
indica en la imagen).
12
11
ID: 25134
15. Inserte el pasador del eje (13) en el orificio del

eje y coloque las mitades de acoplamiento (3)
en el eje.
16. Lubrique los cuatro tornillos (4) con Thread-
4
Eze (o similar).
17. Coloque los tornillos (4). Sujete y déjelos
aflojados. 3
18. Compruebe que los huecos en ambos lados

de las mitades de acoplamiento son iguales. 13
ID: 25135
19. Nota: Para esta tarea se necesitan dos

operarios. Inserte un destornillador adecuado
entre la parte inferior del acoplamiento (3) y la
junta del eje (6) y eleve el acoplamiento / eje 4
de la bomba contra el tope, presionando al
mismo tiempo el eje del motor (por ejemplo,
con un destornillador) a través de la parrilla del
ventilador para colocar el eje del motor en su
posición inferior (normalmente el muelle
propulsor del extremo inferior del motor 3
mantiene el eje del motor en su posición
superior).
20. Baje el acoplamiento / eje de la bomba a la
mitad de la altura (X). 6
21. Sujete el acoplamiento / eje de la bomba en la
ID: 25136
posición del paso 19 y apriete los cuatro
tornillos (4) (al par que se indica en la imagen).

ID: 419 1 es 2009-11-18

de las mitades de acoplamiento son iguales.
23. Apriete los tres tornillos (5) a un par de 2,5 Nm.

24. Coloque las protecciones del acoplamiento (1)
y los tornillos (2). Apriete los tornillos.
1
ID: 25137
8.2.3. Pares de apriete de las tuercas de los pernos ID: 25165
Las cuatro tuercas de perno (M12) (8) deben

apretarse de vez en cuando, ya que pueden
aflojarse durante el funcionamiento. El par de 8
apriete requerido es 50 Nm.
ID: 25194

ID: 419 1 es 2009-11-18
8.3. Desmontaje y colocación (CR 10 y CR 15) ID: 25155
8.3.1. Desmontaje ID: 25213
1. Extraiga las protecciones de acoplamiento (1)

junto con los tornillos (2).
de acoplamiento (3) y el pasador del eje (13).
10
desatornille completamente.
hexagonal con la palma de la mano para
11
5. Extraiga el último tornillo (4) y retire la primera 2
mitad de acoplamiento (3). 12
segunda mitad de acoplamiento (3) con 4
13
bomba.
7. Extraiga la segunda mitad del acoplamiento
(3). 3
8. Retire los tornillos (12).
9. Eleve el motor (10) para sacarlo del cabezal ID: 24812
de la bomba (11).
10. Afloje los tres tornillos (5) aprox. 1/4 de vuelta

de forma que la junta del eje quede libre del
eje.
ID: 24813

ID: 419 1 es 2009-11-18
11. Afloje la junta del eje (6) usando la herramienta

de inserción del anillo (22) (o una herramienta
similar) hasta que la rosca salga
completamente del cabezal de la bomba.
12. Tire de la junta del eje (6) para sacarla del eje.
6
22
ID: 25252
13. Extraiga las tuercas (8) junto con las arandelas

(9). 11 8
14. Afloje el cabezal de la bomba (11) golpeándolo
suavemente en el borde y elévelo para sacarlo 9
de los pernos de puntal (14).
20
14
ID: 25253

ID: 419 1 es 2009-11-18
15. Retire el manguito exterior (18).

18
16. Eleve la chimenea de la cámara (15) para
sacarla de la base (16).
15
20
16
ID: 25254

ID: 419 1 es 2009-11-18
8.3.2. Colocación ID: 25157

equivalente). 18
2. Coloque la chimenea de la cámara (15) en la

base (16), con cuidado de que las cabezas de 15
los tornillos apra las bandas no toquen el
conducto de entrada en la base.
3. Coloque el manguito exterior (18) en la base y
presiónelo hasta el fondo en la base. 20
16
ID: 25265

equivalente). 11 8
5. Compruebe que los muelles de goma (23)

están en el cabezal de la bomba (11). 9
6. Coloque el cabezal de la bomba (11).
23
7. Lubrique las roscas de los pernos de puntal
(14) con Thread-Eze (o similar).
8. Coloque las arandelas (9) y las tuercas (8). 20
9. Apriete las tuercas (8) diagonalmente a un par
de 80 Nm. 14
ID: 25266
10. Humedezca el extremo del eje con agua

jabonosa.
ID: 25132

ID: 419 1 es 2009-11-18
11. Presione la junta del eje (6) en el eje de la

bomba.
6
12. Atornille la junta del eje (6) en el cabezal de la
bomba (11) y apriétela a un par de 35 Nm 11
usando la herramienta de inserción del anillo
(22) (o una herramienta similar). 22
ID: 25267
13. Apriete los tres tornillos (5) a un par de 2,5 Nm.
ID: 25268
14. Eleve la chimenea de la cámara insertando un

destornillador (o una herramienta similar) en el
orificio para el pasador en el eje de la bomba
y coloque la horquilla de ajuste (24), que está 24
colocada en una de las protecciones del
acoplamiento (1).
ID: 25269
15. Ajuste el motor (10) en el cabezal de la bomba

(11).
10
16. Coloque los tornillos (12), lubríquelos y
apriételos diagonalmente (con el par que se
indica en la imagen).
12
11
ID: 25134

ID: 419 1 es 2009-11-18
17. coloque el pasador del eje (13) y las dos

mitades de acoplamiento (3).
18. Lubrique los cuatro tornillos (4) con Thread-
Eze (o similar).
19. Coloque los tornillos (4). Sujete y déjelos
aflojados. 4
de las mitades de acoplamiento (3) son 3
iguales.
13
21. Empuje el eje del motor (usando, por ejemplo,
un destornillador) a través de la parrilla del
ventilador para presionar el eje del motor
hasta su posición inferior (normalmente el
ID: 25270
muelle propulsor del extremo inferior del motor
mantiene el eje del motor en su posición
superior).
22. Apriete los tornillos (4) (al par que se indica en
la imagen).
de las mitades de acoplamiento (3) son
iguales.
24. Extraiga la horquilla de ajuste (24).
24
ID: 25271
25. Compruebe que el eje de la bomba gira sin obstáculos y sin generar ruidos anómalos.

ID: 419 1 es 2009-11-18
26. Posicione correctamente la horquilla de ajuste

(24) dentro de una de las protecciones del 24
acoplamiento (1).
27. Coloque las protecciones del acoplamiento (1) 2
y los tornillos (2).
ID: 25272
8.3.3. Pares de apriete de las tuercas de los pernos ID: 25164
Las cuatro tuercas de perno (M16) (8) deben

apretarse de vez en cuando, ya que pueden
aflojarse durante el funcionamiento. El par de 8
apriete requerido es 80 Nm.
ID: 25194

ID: 419 1 es 2009-11-18
9. LUBRICACIÓN Y MANTENIMIENTO ID: 25158
Si instala las bombas siguiendo lo estipulado por estas instrucciones, funcionarán adecuadamente
y no necesitarán demasiadas atenciones en cuento a su mantenimiento. La junta del eje mecánico
se ajusta automáticamente y está provista de superficies resistentes al desgaste, lubricadas y
refrigeradas mediante el agua bombeada. El agua bombeada también se encarga de lubricar los
cojinetes de la bomba.
Los motores sin boquillas de engrase están equipados con cojinetes de bola, que están lubricados
de por vida gracias con grasa resistente al calor. Por ello, no será necesario ningún tipo de lubricación
adicional.
Los motores con tapas de engrase (boquillas) se pueden lubricar con grasa con base de litio.
TIPO: ESSO BEACON 3 o similar.
El engrasado adicional sólo se recomienda bajo ciertas condiciones de funcionamiento, muy
específicas. Un exceso de grasa podría dañar el motor. En caso de funcionamiento estacional (es
decir, que el equipo permanece fuera de funcionamiento durante más de 6 meses al año), se
recomienda engrasar el motor antes de ponerlo fuera de funcionamiento.
9.1. Protección contra la congelación ID: 25159
En situaciones de funcionamiento en las que la temperatura pueda ser inferior a 0 °C, proteja el
sistema de barrido y evite que se congele el agua de barrido. Para ello, rocíe un poco de fluido
anticongelante a través del conducto de barrido.
9.2. Inspección ID: 25160
Realice las siguientes comprobaciones regularmente y dependiendo del tiempo y las condiciones de
funcionamiento:
• Posibles fugas.
• Extraiga y limpie los filtros acoplados a la instalación.
• Período de desconexión de la unidad de sobrecarga del motor.

ID: 419 1 es 2009-11-18
10. IDENTIFICACIÓN Y SOLUCIÓN DE AVERÍAS ID: 25161
Problema Causa posible

La bomba no arranca No hay corriente. El interruptor de la bomba (en
el armario eléctrico) está en la posición “0”.
Ha saltado el interruptor de protección del motor.
Avería en el electroimán o los puntos de contacto
del interruptor de protección del motor.
Se ha producido una avería en el circuito de
tensión de control.
Ha saltado el interruptor de protección del motor Se ha producido una avería en los puntos de
junto tras el arranque contacto del interruptor de protección del motor.
La conexión del cable está suelta o averiada.
Se ha producido una avería en el devanado del
motor.
La bomba se ha bloqueado mecánicamente.
El valor establecido es demasiado bajo.
Ha saltado por accidente el interruptor de El valor establecido es demasiado bajo.
protección del motor se ha producido una fluctuación en al tensión.
La tensión de alimentación es demasiado baja.
El interruptor de protección del motor no ha No hay corriente.
saltado, pero la bomba sigue sin funcionar El interruptor de la bomba (en el armario
eléctrico) está en la posición “0”.
Se ha producido una avería en el circuito de
tensión de control.
Se producen variaciones en la salida de la bomba La capacidad de suministro de agua es
demasiado baja para la salida de la bomba.
La presión de entrada de agua es demasiado
pequeña en comparación con la temperatura, las
alteraciones en el flujo y el volumen de flujo.
El conducto de suministro está parcialmente
bloqueado.

ID: 419 1 es 2009-11-18
www.sandvik.com
V64107-4en1211
OPERATING INSTRUCTIONS
CT10-16
Screw compressor
Version 1.00
F016635 Y
EN © 2011 Gardner Denver Oy

Table of Contents
1. Introduction ............................................................................................................................ 1
1.1 Storing the books ......................................................................................................... 1
1.2 Warranty terms............................................................................................................. 1
1.3 Log book....................................................................................................................... 1
1.4 Inquiries........................................................................................................................ 1
2. Safety ...................................................................................................................................... 2
2.1 Safety during installation and preparations for use ...................................................... 2
2.2 Safety during operation ................................................................................................ 3
2.3 Safety during maintenance........................................................................................... 3
2.4 Safety signs.................................................................................................................. 4
3. Main components .................................................................................................................. 5
4. Installing instructions ........................................................................................................... 7

4.1 Connection of WEG wide voltage motors..................................................................... 7
5. Handling instructions ............................................................................................................ 9

5.1 Storing the compressor ................................................................................................ 9
5.2 Lifting instructions (diagram) ........................................................................................ 9
5.2.1 Lifting the compressor with lifting wire.................................................................. 9
5.2.2 Lifting the compressor using forklift truck ........................................................... 10
5.3 Decommissioning ....................................................................................................... 10
5.3.1 WEEE (Waste Electrical and Electronic Equipment Directive) label .................. 10
6. Operating instructions ........................................................................................................ 11

6.1 First start-up of the compressor ................................................................................. 11
7. Operating principles ............................................................................................................ 12

7.1 Screw unit................................................................................................................... 12
7.2 Air compressing process ............................................................................................ 12
7.3 Oil circulation and the compressed air circuit............................................................. 13
7.3.1 Oil circulation...................................................................................................... 13
7.3.2 Compressed air circuit........................................................................................ 14
7.4 Compressor control system........................................................................................ 14
7.5 Capacity control.......................................................................................................... 15
7.6 Temperature gauge.................................................................................................... 15
8. Maintenance instructions ................................................................................................... 17

8.1 Before maintenance ................................................................................................... 17
8.2 After maintenance ...................................................................................................... 17
8.3 Service chart .............................................................................................................. 18
8.4 Adding and changing oil ............................................................................................. 19
8.4.1 Adding oil ........................................................................................................... 19
8.4.2 Changing oil ....................................................................................................... 20
8.5 Replacing the oil filter ................................................................................................. 20
8.5.1 Removing the oil filter......................................................................................... 21
8.5.2 Installing the oil filter........................................................................................... 21
8.6 Replacing the air filter................................................................................................. 21
8.7 Replacing the oil separator cartridge and the seals of the discharge valve ............... 22
8.8 Checking for oil leaks ................................................................................................. 23
8.9 Checking the condition of hoses ................................................................................ 24
8.10 Checking the solenoid valve for condensate removal (optional) .............................. 24
8.11 Cleaning the cooler .................................................................................................. 24
8.12 Replacing the belts................................................................................................... 25
8.13 Replacing the pulley and the conical sleeve ............................................................ 26
8.13.1 Removing the pulley of the motor..................................................................... 26
8.13.2 Removing the pulley of the air end................................................................... 26
8.13.3 Installing the pulley and the conical sleeve of the motor .................................. 27
8.13.4 Installing the pulley of the air end..................................................................... 28
8.14 Testing the pressure relief valve .............................................................................. 29
8.15 Oil recommendations ............................................................................................... 29
8.15.1 Recommended lubricants................................................................................. 29
8.15.2 Oil specifications .............................................................................................. 30
8.15.3 General guidelines for oil change intervals for mobile use............................... 30
9. Troubleshooting .................................................................................................................. 31
10. Technical Appendixes ....................................................................................................... 34

Declaration of conformity of machinery
(Directive 2006/42/EC)
Manufacturer’s name: Gardner Denver Oy
Manufacturer’s address: Etu-Hankkionkatu 9

FIN-33700 Tampere
Finland
The manufacturer hereby assures that the manufactured Screw compressor type:
machine CT10-16 with the accessories
F016635
meets the EMC Directive 2004/108/EC
and the machine directive 2006/42/EC
and pressure equipment directive (PED) 97/23/EC
and the enforcing national regulations VNA 400/2008
The machine also complies with the following EC

directives and the corresponding national regulations: 2006/95/EC
The following uniformed standards have been applied in EN 1012-1

the engineering of the machine: Compressors and vacuum pumps -
safety requirements - Part 1:
Compressors
Technical information available from: Jyrki Mäkiö

Gardner Denver Oy
Etu-Hankkionkatu 9
FIN-33700 Tampere
Finland
Tampere 17.11.2011
(Place) (Date)
(Signature)
Jyrki Mäkiö, Director of Engineering

(Name, position)
1. Introduction
1. Introduction
Gardner Denver wishes you welcome among the users of Gardner Denver screw compressors!
This manual gives you instructions on correct and safe operation and maintenance of your screw
compressor.
Read these and other instructions with the compressor carefully before using your screw
compressor. This ensures correct preparations and use from the very beginning.
1.1 Storing the books
All the instructions in this manual have been provided to guarantee a long life and reliable operation of your
screw compressor.
Always keep the manual available near the compressor. Make sure that the compressor is operated and
serviced according to the instructions.
1.2 Warranty terms
Get acquainted with the Gardner Denver warranty terms, which are enclosed with the manuals for the
compressor. Fill in the warranty registration card with care and return it to the seller as instructed.
The warranty becomes void if the terms are not observed or if other than original Gardner Denver spare
parts are used. Use only the recommended AEON oil types in order to ensure undisturbed operation.
All the service and maintenance duties, which are not covered in this manual should be made only by
trained and qualified service personnel authorized by Gardner Denver or its representative.
1.3 Log book
There is a log book enclosed with the manuals for the compressor. Always fill it in after any maintenance or
repair work.
1.4 Inquiries
When making inquiries concerning your screw compressor, always quote the complete type specification
and the serial number as they are given on the data plate of the compressor.
Gardner Denver reserves the right to change the construction and manuals of the compressors without
prior notice.
1
2. Safety
2. Safety
The general safety instructions concerning the compressor are presented in this chapter.
Read also the safety instructions for transportation, installation, operation and maintenance
presented separately in each section of the manual.
Always read the safety instructions before starting to work.
The instructions concerning safety are marked with this symbol.
In addition to these instructions, the local regulations in your country may impose additional requirements
that must be observed.
2.1 Safety during installation and preparations for use
The noise level of the compressor, which is presented in the "Technical data" on page 34, is determined
according to ISO2151 and ISO3744. The noise level may rise higher if the walls surrounding the installing
location reflect sound. Take this into consideration, when choosing the best location for the compressor.
Observe the local regulations concerning the use of ear protectors.
The intake air for the compressor must be clean and cool. Prevent the used and hot cooling air
circulating back to the cooling air intake. Make sure that foreign objects cannot get into the compressor
with the intake air. The intake air must not contain any explosive or inflammable gases or harmful
substances.
Do not exceed compressor's rated maximum pressure, capacity or rotation speed. For more details see
"Technical data" on page 34.
Use pneumatic hoses that can hold the working pressure. Pay special attention to the hose mountings.
The pressure in the hoses must be removed before disconnecting. A whipping hose may cause
unpredictable damage.
The pressure vessels in the pressurized air network must be in accordance with the pressure vessel
regulations.
Only authorized and qualified personnel should make the electrical connections.
The condensate water contains oil. It should be disposed of according to the local regulations on waste oil.
2
2. Safety
2.2 Safety during operation
Do not blow pressurized air against the skin.
Use only the recommended AEON oil types. Do not mix different types of oil.
Do not use the compressor in explosive environment.
2.3 Safety during maintenance
While doing maintenance, the compressor must always be stopped and disconnected from the electrical
mains connection. The shut-off valve of the pressurized air network must also be closed. Make sure that
there is no pressure in the air/oil receiver before starting maintenance.
Use only original Gardner Denver spare parts.
Do not repair the receiver by welding.
All alterations must comply with the pressure vessel regulations PED 97/23/EC.
Do the regular checkups and maintenance of the compressor in order to ensure undisturbed operation.
Maintenance and service operations other than described in this manual must be left to service personnel
authorized by Gardner Denver.
3
2. Safety
2.4 Safety signs
Read User Manual before starting the compressor Wear ear protectors
Warning: hot surface Warning: risk of electric shock
Warning: compressor is remotely controlled and

Warning: moving parts
may start without warning
Warning: risk of hot exhaust fumes/hot air
General meaning of geometric shapes, safety colors and contrast colors for the safety signs
Graphical symbol
Geometric shape Meaning Safety color Contrast color
color
Mandatory action Blue White White

Circle
Warning Yellow Black Black

Equilateral triangle
4
3. Main components
3. Main components
The screw compressor is an oil-cooled single stage screw compressor. The pressurized air is produced
with a screw air end driven by an electric motor. Oil is separated from the compressed air in an oil
separation receiver. Oil is cooled before injecting into the air end.
10
11
2
3 6
23000383
Main components
5
3. Main components
Main components
No. Part Function
1 Motor Rotates air end
2 Thermostat valve Prevents cold oil from entering the cooler
3 Inlet valve Controls air output
4 Air filter Cleans the inlet air
5 Air end Compresses air
6 Discharge valve Maintains minimum receiver pressure, non-return valve
7 Pressure relief valve Protects the receiver against overpressure
8 Oil cooler Cools oil
9 Oil filter Purifies oil
10 Belts Transmits the power
11 Gauges Show pressure and temperature
6
4. Installing instructions
4.1 Connection of WEG wide voltage motors
Some of the motors used in CT-range compressors are so called wide-voltage motors. Correct operation
with wide voltage range is implemented with split-winding technique where each phase winding is split in
the middle and each winding end is wired to the motor conduit box. IOW, in this type of motors there are 12
leads in the conduit box instead of 6 leads in typical motors. By connecting the leads suitably according to
the present operating point (voltage vs. frequency), the magnetic flux inside the motor and thus the motor
operation is optimized.
The windings can be connected to four different arrangements:
Single wye Y
Single delta Δ
Double wye YY
Double delta ΔΔ
1. In single arrangement each split winding halves are first connected to series and thus obtained full
windings connected to either wye or delta. With these arrangements the motor is equal to wye- or delta-
connected typical motor.
2. In double arrangement each split winding halves are first connected parallel and then these paralleled
winding halves connected to either wye or delta. With these arrangements the motor operates according to
its nominal values with half of the nominal voltage level (for example, 400V/50Hz -> 200V/50Hz).
In the case of CT-range compressors, three out of four previously mentioned arrangements are being
used, those being Y, Δ ja YY. YY-connection is used in 60Hz networks when the network voltage is lower
than standard (for example 400V/60Hz)
The correct winding arrangement is stamped to the motor nameplate along with each operating point.
There are 12 connection points in the conduit block of the motor. Also, each winding lead is numbered.
Winding leads are arranged according to picture 1. because by using this arrangement all the necessary
CT-configurations can be connected by altering only the conduit block bridges, without using any extra
jumper wires etc.
7
12 10 11
1 2 3
7 8 9
4 5 6
Pic 1. Winding lead arrangement in the conduit block when viewed from the non-drive end
Bridge arrangements are presented in pictures 2, 3 and 4. Motor supply cable is always connected to the
leads 1, 2 and 3 by using the order presented in the electrical drawing to obtain the correct running
direction.
12 10 11
1 2 3
7 8 9
4 5 6
Pic 2. Single delta Δ
12 10 11
1 2 3
7 8 9
4 5 6
Pic 3. Single wye Y
12 10 11
1 2 3
7 8 9
4 5 6
Pic 4. Double wye YY
8
5. Handling instructions
5.1 Storing the compressor
If the compressor is stored for a long period of time, the stockroom must be dry and warm. Check the
functioning of the belt tightening before starting the compressor first time after the storing.
If the compressor is stored unused for over 12 months, please contact an authorised Gardner Denver
retailer before using the equipment again.
5.2 Lifting instructions (diagram)
Lifting and transporting the compressor requires caution. Check the compressor’s centre of gravity from
Dimensional drawings.
The water separator (if available) must be removed before lifting the compressor.
Do not go under the equipment when lifting the compressor.
5.2.1 Lifting the compressor with lifting wire
Lifting the compressor with lifting wire
9
5.2.2 Lifting the compressor using forklift truck
Insert the forks under the compressor in the directions shown in the following figure.
23000381
Lifting the compressor with a forklift truck
5.3 Decommissioning
When the compressor is decommissioned, the compressor oil, the oil filter and the oil separator elements
must be disposed of in accordance with local hazardous waste regulations.
Decommissioning
5.3.1 WEEE (Waste Electrical and Electronic Equipment Directive) label
The WEEE label means the product must be disposed of separately from other waste.
Appropriate recycling of the product helps to maintain a cleaner environment. For
more information about recycling the product, please contact your local authorised
Gardner Denver retailer.
10
6. Operating instructions
6. Operating instructions
6.1 First start-up of the compressor
The first start-up must be performed by qualified personnel.
1. Check for sufficient oil level in the receiver. For more information, see "Adding and changing
oil" on page 19 and "Oil recommendations" on page 29.
2. Open the shut-off valve of the compressed air network.
3. Make sure the screw elements rotate in the correct direction before starting the compressor .
Wrong rotation direction will damage the screw unit.
Correct rotation direction must always be ensured after the power supply or motor cables have been
disconnected and reconnected.
Do not control the air flow in the compressed air network using the shutter valve. Misuse of the shutter valve
may cause a rapid deflation of the system and increases oil consumption.
11
7. Operating principles
7.1 Screw unit
Main components of the screw

unit
1. Housing
2. Female rotor
3. Male rotor
4. Discharge flange
5. Shaft seal
6. Bearing cover
Screw unit
7.2 Air compressing process
Rotors
In a screw compressor the air is compressed in the air end driven by a motor.
The meshing rotors take air in between the ridges as they pass the inlet opening. When the rotors turn, the
connection to the inlet opening closes and the space between the ridges starts to decrease. At the end of
the compression phase, the desired pressure has been reached and the connection to the receiver opens.
The air in the air end is cooled by oil that is injected into it. The oil cools also the air end. In addition, the oil
lubricates the bearings and seals the clearances between the rotors and the rotor housing.
12
7.3 Oil circulation and the compressed air circuit
Oil circulation and the compressed air circuit
7.3.1 Oil circulation
From the compressor air end the mixture of pressurized air and oil mist is ducted into the oil separating
receiver, where oil is separated from the pressurized air. The separating process has two phases.
Main part of the oil is separated in the cyclone (10) in the receiver, where the centrifugal effect is utilized.
The separated oil flows to the bottom of the receiver (11). The remainder of the oil is separated from the air
by means of oil separator (1). The oil separated in the oil separator is led back into circulation through the
oil return pipe (2). The return pipe is provided with an orifice plate (3) that prevents excess air recirculation
back into the compressor air end.
The internal pressure forces the oil back to the circulation through the oil cooler (8) and the oil filter (4).The
oil circulation is controlled by an oil thermostat valve (5). The oil thermostat valve controls the oil flow to the
oil cooler and to the oil cooler by-pass.
The forced oil circulation is maintained by the pressure difference between the receiver and the
compressor air end. To quarantee oil circulation whenever the compressor produces pressurized air, the
discharge valve (6) prevents the receiver pressure from dropping below the set minimum level (3 bar).
13
7.3.2 Compressed air circuit
The compressed air is led out through the discharge valve (6). Alternatively (option) the compressed air is
led from the discharge valve to the after-cooler (7), where it´s temperature drops.
The pressure relief valve (9) protects the receiver against overpressure. It opens at a certain pressure,
preventing the receiver pressure from rising dangerously high.
7.4 Compressor control system
Air out
Compressor control system
The control system adjusts compressor output in accordance with the current air consumption and
maintains uniform pressure. It also cuts the power consumption for each cubic meter of pressurized air as
low as possible.
The output control range is continuous, and ranges from zero to full output capacity. Output is adjusted by
opening and closing the intake valve. The intake valve is controlled automatically by a control valve (1) that
measures compressor pressure and regulates it so that it remains within a set fluctuation range (normally 1
14
bar). The fluctuation range limits the allowed output pressure, which may fluctuate because of changing air
consumption.
When the motor is stopped, the blow-down valve (2) depressurises the receiver.
7.5 Capacity control
Output pressure can be regulated by turning the adjusting screw (B) on the control valve.
Locking nut (A) must be loosened before adjusting: turning the screw (B) clockwise increases pressure
and turning it counterclockwise lowers the pressure.
Tighten the locking nut after adjustments!
Don't exceed the compressor's max.pressure (cf. Technical data).
Capacity control
7.6 Temperature gauge
For temperature measuring the compressor is equipped with a temperature gauge.
At 100°C the temperature alarm lights and at 115°C the compressor will stop.
Wiring diagram for temperature gauge
15
The safety functions: the temperature alarm (Sl) and stopping (S2) are located in the temperature gauge.
Connect them accordingly to these wiring diagrams, which are also on the side of the temperature gauge.
The safety functions must absolutely be connected before taking the compressor into use.
16
8. Maintenance instructions
Maintenance and service operations other than those described in this manual must be left to service
personnel authorized by Gardner Denver.
Always wear protective clothes and gloves during the maintenance.
Use only original Gardner Denver spare parts. The use of other spare parts may cause compressor damage.
8.1 Before maintenance
Before any maintenance operations, switch off the compressor with the main switch and make sure that the
compressor cannot be accidentally started.
There are hot surfaces in the compressor immediately after stopping.
1. Stop the compressor and make sure that there is no pressure in the receiver. Wait for 2
minutes after stopping for the blow-down function to empty the receiver.
2. Turn the power off at the main switch and make sure that the compressor cannot be
accidentally started.
3. Close the shut-off valve between the compressed air network and the compressor.
4. Open the pressure relief valve’s cap with 4 to 5 turns.
The space between the discharge valve and the system shut-off valve stays under pressure when the
compressor is stopped and the shut-off valve is closed. Release the pressure for example through a water
drain.
8.2 After maintenance
1. Close the pressure relief valve.
2. Open the shut-off valve between the compressed air network and the compressor.
3. Start the compressor.
17
8.3 Service chart
Record all maintenance operations in a maintenance log.
In the case of extreme operating conditions, it is advisable to halve the service intervals. The compressor’s
rapid cycling between unloading and loading will shorten the service intervals. Please contact an authorized
distributor of Gardner Denver for more information.
The maintenance intervals below are recommended for portable equipment and correspond approximately
to the maintenance interval of the motor and other components.
Service chart
Action 1 2 3 4 5 6 7 8 9
Check the correct running temperature (70-90°C) x

Check the operation of the condensate drain x x x
Check the cooling air fan x
Check the oil level* x
Check for oil leaks x x x
Replace the oil filter x x
Check and retighten main motor cables x x
Change oil, see "Oil recommendations" on page 29 x
Replace the air filter x x
Change the belts x
Clean the cooler externally x x
Clean the compressor inside x x x
Replace the oil separator cartridges x x
Clean the oil return line x x
Check the operation of the pressure relief valve x
Replace the seal kits of the inlet and the discharge valve x
Replace the oil hoses x x
Replace the blow-down valve x
Replace the oil thermostat x
Replace the motor bearings x
Replace the shaft seal kit x
Replace the air end x
1) Daily 6) As required
2) After the first 50h 7) Every 3 years / 5000h
3) Every 500h 8) Every 5 years / 10 000h
4) Every 1000h 9) Every 10 years / 20 000h
5) Once a year
* Stop the compressor before checking the oil level. Wait until the oil is separated from the air,
about 10 min.
18
8.4 Adding and changing oil
Use only recommended AEON oil types. Do not mix different oils.
Oil is hot just after the compressor has stopped.
Do not open the oil filling plug or cooler drain plug if the system is pressurized.
Dispose used oil according to the waste oil regulations.
8.4.1 Adding oil
1. See "Before maintenance" on page 17 for precautions.
2. Open the oil filling plug (1) and add new oil until two-thirds, counting from bottom of the oil-
checking glass, is reached. Note! Do not over fill.
3. Close the oil filling plug (1).
4. Close the pressure relief valve (2) and open the network shut-off valve.
3
Adding oil
19
8.4.2 Changing oil
1. Run the compressor until oil temperature is +40...+50°C.
2. See "Before maintenance" on page 17 for precautions before starting the work.
3. Open the oil filling plug (1) and the oil drain plug (3). Drain oil into a suitable receiver. Close the
oil drain plug (3).
Changing oil
4. Replace the oil filter, see "Replacing the oil filter" on page 20.
5. Add new oil and close the oil filling plug (1).
6. Close the pressure relief valve (2) and open the network shut-off valve.
7. (Start the compressor and let it run for 5 minutes. Stop the compressor and wait for a while so
that oil settles and the pressure drops. Add new oil again. Repeat this two times.
8.5 Replacing the oil filter
Allow the compressor to cool down before replacing the oil separator.
Dispose the used oil filter in accordance with local hazardous waste regulations.
Only use original Gardner Denver spare parts. The use of other spare parts may cause compressor damage.
20
8.5.1 Removing the oil filter
2. The oil filter is installed on the air end. Use a protective cloth, as some oil will drain out when
the filter is removed.
3. Remove the filter by rotating it counterclockwise.
23000385
Replacing the oil filter
8.5.2 Installing the oil filter
1. Lubricate the oil filter sealing ring with clean oil.
2. Install the filter by tightening it up clockwise by hand.
8.6 Replacing the air filter
The air filter cannot be cleaned or reused.
Remove the filter with caution. Make sure that particles do not get into the inlet air channel.
Use only original Gardner Denver spare parts. The use of other spare parts may compressor damage.
2. Remove the air filter cover (3) and the old filter (2).
21
3. Clean the air filter housing (1).
4. Install the new air filter (2) and its cover (3) back to their places.
1 2 3 4
Replacing the air filter
Note! Install particle remover (4) always downwards.
8.7 Replacing the oil separator cartridge and the seals of the discharge valve
Allow the compressor to cool down before the replacement.
Dispose the used oil separation cartridge in accordance with local hazardous waste regulations.
Use only original Gardner Denver spare parts. The use of other spare parts may cause compressor damage.
1. See "Before maintenance" on page 17 for precautions before starting to replace the oil
separator cartridge. Make sure that there is no pressure in the receiver. Note! Pressure
remains between the discharge valve and the shut-off valve. Do not open the retaining
ring in the bottom of the valve.
2. Remove the body of the discharge valve/the cover of the receiver (1) by opening the screws.
3. Remove the oil separator cartridge (2)
4. Clean the sealing surfaces on the receiver and on the discharge valve (1). Make sure that the
inside of the receiver is free of particles.
5. Clean orifices (3) in the hose ends.
6. Replace the filter strainer (4) and clean the oil separator housing.
7. Lubricate the O-ring of the separator cartridge and install new separator cartridge (2) by hand.
22
8. Replace and lubricate the O-ring (5) between the oil separator housing and the discharge
valve.
9. Replace the seals of the discharge valve with a new set if needed.
10. Install the assembled valve back in it’s place. When assembling the valve, tighten the screws
alternately to even tightness.
Replacing the oil separator cartridge
There should be about 2 mm clearance between the nut (6) and the top of the discharge valve, when there is
no pressure in the receiver or the network. Do not tighten the nut!
8.8 Checking for oil leaks
Visually check the compressor for oil leaks, in particular around the compressor unit, the oil cooler and the
oil hoses.
23
8.9 Checking the condition of hoses
Check all hoses for cracks, blisters, tears, leaks, and stiffness. Replace as required
Remove the pressure in the hoses before disconnecting.
Always use original pneumatic hoses that are rated to withstand the working pressure and temperature. Pay
particular attention to the hose installings as a lose hose can flail and cause unpredictable damage.
8.10 Checking the solenoid valve for condensate removal (optional)
The compressors which optionally include an after-cooler and water separator assy also include solenoid
valve.
1. Locate the solenoid valve.
2. Check the condensate drain when compressor is running.
8.11 Cleaning the cooler
A clogged cooler increases the output air temperature and may lead to a compressor stoppage.
Cleaning the cooler
Clean the cooler with pressurized air, see the picture. For a more effective cleaning, brush the cooler from
underneath. Note! Do not use a metal wire brush.
24
If the cooler is very dirty, remove it from the compressor and clean the outside with mild detergent.
For more information on cleaning the cooler, please contact an authorized distributor of Gardner Denver.
8.12 Replacing the belts
The weight of the motor keeps the belts correctly tensioned.
23000384
Replacing the belts
1. See "Before maintenance" on page 17 for more details.
2. Untighten the screw counterclockwise until the belts are loose enough. (The screw pushes the
motor up so that belts loosen.)
3. Change the belts.
4. Return the screw to its original position.
25
8.13 Replacing the pulley and the conical sleeve
8.13.1 Removing the pulley of the motor
Removing the pulley of the motor
Remove the two screws and insert one into the removal hole. Tighten the screw evenly until the sleeve
comes off the hub. Remove the loose pulley manually from the shaft, taking care not to damage the shaft
(do not hammer). Sleeve comes off with the pulley.
8.13.2 Removing the pulley of the air end
Removing the pulley of the air end
1. See precautions at "Before maintenance" on page 17 before removing the pulley.
2. The thread of fastening bolt (1) is left-handed. To remove the bolt, use an Allen key. Knock the
key bar sharply with a hammer, holding the pulley in place by means of Gardner Denver
clamping tool (ID = 034 769 18) or big circlip tongs.
26
3. Pull the pulley (2) from the rotor shaft with an extractor. Protect the threaded hole in the shaft
end.
4. Sleeve (3) comes off with the pulley.
5. Always replace both sleeve and shaft seal. Remove the sleeve from the pulley by knocking it
with a drift throught the three holes in the pulley.
6. Pull out shaft seal (4) with an extractor. Protect the threaded hole in the shaft end.
8.13.3 Installing the pulley and the conical sleeve of the motor
Inserting the sleeve to the pulley of the motor
1. Remove protective grease from the sleeve and the pulley hub. Fix the sleeve to the pulley and
align the holes.
2. Grease the two fixing screws (1), insert them into the holes shown in the figure, and tighten
lightly. Threads are in the pulley.
Installing the pulley of the motor
27
3. Clean the shaft, and install the pulley with the sleeve on it. Note that the sleeve fastens first,
after which the pulley can still be moved a bit in relation to the sleeve. Bear this in mind when
aligning the pulleys.
4. Tighten the screws to equal tightness with a spanner.
5. Knock the sleeve lightly with a drift, and retighten the screws. Repeat this a few times to
make sure the sleeve is firmly fixed in place.
6. Check the tightness of the screws from time to time.
7. Fill the extraction holes e.g. with grease to protect them against dirt.
Sleeve Tightening torque

1610 20
2012 31
NOTE! Sleeve type is marked on the end of the sleeve
8.13.4 Installing the pulley of the air end
Installing the pulley of the air end
1. Clean the shaft end and the seal housing carefully
2. Apply Loctite 542 on the seal housing of the shaft seal. Push the seal into the housing with a
drift.
3. Push the sleeve on the rotor shaft with a drift.
4. Apply Loctite 601 thinly on the part of the pulley that will be inserted in the sleeve. Press the
sleeve in place, and insert the pulley with help of the fixing bolt. Hold the pulley in place with
Gardner Denver clamping tool (ID = 034 769 18), and tighten the bolt 80 Nm.
28
8.14 Testing the pressure relief valve
All adjustment and repair operations of the pressure relief valve must be performed by qualified
maintenance technicians. All local regulations must be observed.
The compressor must be stopped and secured from automatic restart before attempting this procedure.
The opening pressure of the pressure relief valve must be tested in a separate pressurized air line. The
pressure relief valve has been tested at the manufacturer's site before shipping out the compressor. If the
valve has been replaced, it needs to be tested for proper operation. This procedure can be performed only
by a qualified mechanican.
The operation of the valve can be tested by turning the cap (1) counter-clockwise 1 to 2 turns. Always
tighten up the pressure relief valve cap properly to avoid damage caused by vibration.
Testing the pressure relief valve
8.15 Oil recommendations
These oil recommendations are for Gardner Denver screw compressors in industrial use.
8.15.1 Recommended lubricants
Gardner Denver compressors are factory filled with AEON lubricants. These lubricants are formulated to
the highest quality standards and are factory authorized, tested and approved for use in screw
compressors. AEON lubricants are available through your authorized Gardner Denver compressor
distributor.
29
8.15.2 Oil specifications
Recommended lubricants for the compressor:
• Gardner Denver AEON 3000 (mineral oil) factory first fill.

• Gardner Denver AEON 9000 SP (synthetic oil) by request.
Recommended lubricants for the compressor
Package size AEON 3000* order no. AEON 9000 SP order no.
3 X 5 litres pack 033 891 44 -
20 litres 033 891 42 897 560 89
209 litres 033 891 43 897 676 89

* first fill
8.15.3 General guidelines for oil change intervals for mobile use
For recommended oil change intervals, please see the table below.
Recommended oil change intervals
Running temperature of AEON 9000 SP oil change

AEON 3000 oil change interval
the compressor interval
70–87°C 500 hours 1 000 hours
88–92°C 500 hours 1 000 hours
≥ 93°C 300 hours 500 hours
Operating temperature of the compressor can be seen in temperature gauge.
Specific AEON lubricants are recommended for use in this equipment. Other lubricants will cause:
• shortened life time of oil filter, oil separating cartridges and oil
• varnishing and blockage of oil circuit
• increased oil consumption
• excessive oil carryover and compressor damage
Do not mix different types of oil
Note! If wrong oil type has been used or oil circuit is varnished, please contact an authorized distributor of Gardner
Denver for oil circuit cleaning instructions.
30
9. Troubleshooting
9. Troubleshooting
Troubleshooting table
Problem Possible cause and repair
• Check the condition and suitability of

the protection devices for the voltage
No power supply supply. Please contact an authorized
distributor of Gardner Denver for more
details.
Find out the cause of overheating:

• oil filter clogged
• wrong oil type or oil level too low
• cooler clogged, clean externally
Compressor stopped due to
• recirculation of hot cooling air
overheating.
• cooling air volume insufficient
• ambient temperature too high
COMPRESSOR IS • oil separator cartridge clogged
STOPPED AND FAILS TO • oil thermostat valve faulty
START • Check the wiring of the motor and the
Electrical fault
tightness of the cable connectors
• Check that the maximum pressure is

not exceeded
• Check the supply voltage
• Check the oil level to between min-
max
• Check the oil separator cartridge, max.
Motor overloaded.
0.7 bar over the network pressure at
load
• Check discharge valve, min. pressure
3-4 bar
• Check the temperature and volume of
the cooling air at the inlet, clean motor
31
9. Troubleshooting
Air filter clogged • Replace
Oil separator cartridge • Replace

clogged
Inlet valve faulty • Repair or replace
Discharge valve or • Repair or replace

condensate drain faulty
Leaks in the compressed • Check and repair the leaks

OUTPUT IS INSUFFICIENT air system
Incorrect pressure settings • Readjust
• Ensure sufficient cooling air circulation

Ambient temperature too
• Ensure that the inlet air is from the
high
coolest possible place
• Prevent the flow of cold cooling air to

After-cooler frozen
the compressor
Pressure relief valve open • Close the cap of the valve by hand
Oil return line clogged • Clean

faulty

clogged
• See "Oil recommendations" on page

Wrong oil type
29.
OIL CONSUMPTION IS TOO
HIGH Discharge temperature too • Find out and eliminate the cause
high.
Leakage • Check and repair
Oil level too high • Lower the oil level
• Readjust the pressure limits

• Please contact an authorized
Rapid pressure loss
distributor of Gardner Denver for more
details
• Replace the seal kit

Inlet valve seal is leaking • Inspect the check valve function of the
inlet valve and the blow-down line
INLET VALVE LEAKS OIL
AFTER STOPPING • Lower oil level, check oil quality /
Oil foaming too much
check rapid pressure loss
Check oil separation • Repair
32
9. Troubleshooting
Cooler clogged • Clean the outside
Ambient temperature too • Check cooling air circulation

high
Oil level too low • Add oil

COMPRESSOR IS Wrong oil type
29.
OVERHEATED.
Oil filter clogged. • Replace
Oil thermostat element not • Replace

functioning
Oil separation cartridge • Replace

clogged
Pressure in the receiver • Wait until pressure drops
COMPRESSOR STARTS Supply voltage too low • Check the supply voltage
TOO SLOWLY
Wrong oil type
29.
33
10. Technical Appendixes
10. Technical Appendixes
Technical data
Dimensional drawings
34

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Original instructions

WATER AND AIR CIRCUIT

1. WATER CIRCUIT ........................................................................................................................... 5

Copyright © Sandvik Mining and Construction 3 (54)

2. AIR CIRCUIT .................................................................................................................................. 37

4 (54) Copyright © Sandvik Mining and Construction

1.2. Safety instructions

PROPERTY DAMAGE RISK!

Keep the pressure limiters and switches in good condition and

Copyright © Sandvik Mining and Construction 5 (54)

1.3. Water circuit diagram (DD321/DD411/DD421/DT610)

609.01 617 503

Figure: Water circuit diagram DD321 / DD411 / DD421 / DT610

6 (54) Copyright © Sandvik Mining and Construction

1.3.1. Components (DD321/DD411/DD421/DT610)

315 Oil cooler

Copyright © Sandvik Mining and Construction 7 (54)

1.4. Water circuit diagram (DT821 THC)

DRAIN 617 514 507

Figure: Water circuit diagram DT821 THC

8 (54) Copyright © Sandvik Mining and Construction

1.4.1. Components (DT821 / DD531)

315 Oil cooler

Copyright © Sandvik Mining and Construction 9 (54)

702 Water separator

10 (54) Copyright © Sandvik Mining and Construction

1.5. Water circuit diagram (DT821 / DD531 TPC)

510.03 510.03 510.03

1Y10 2Y10 2Y10 1Y9 2Y9 3Y9

3.5bar 0.2bar 3.5bar 0.2bar 3.5bar 0.2bar

X16 508 572

DRAIN 617 514 507

Figure: Water circuit diagram DT821 / DD531 TPC

Copyright © Sandvik Mining and Construction 11 (54)

1.5.1. Components (DT821 / DD531)

315 Oil cooler

12 (54) Copyright © Sandvik Mining and Construction

702 Water separator

1.6. Circuit operation

1.6.1. Normal flushing

1.6.2. Double flushing

1.7. Mud separator (507)

1 Shut-off valve (.02)

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1.7.1. Cleaning the mud separator

The mud separator operates uneffectively if it reuses water

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1.8. Pressure reducing valve (506)

1.8.1. Operation of the water pressure reducing valve

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1.8.2. Disassembly and assembly

NOTE! Remember to adjust the valve before use.

1.8.3. Checking the operation of the pressure reducing valve

Check that the pressure reducing valve operates

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1.8.4. Adjusting the pressure

Flushing pressure = inlet pressure + pump pressure.

The adjusting range of the pressure reducing valve is 2-7 bar.

1.9. Water booster pump (501)

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4 Primer valve- / drain plug

1.9.4. Venting and filling of pump

RISK OF WATER PUMP DAMAGE!