Components

410 0 en 2009-05-13
Air Conditioner
Operation and Maintenance
Table of Contents
1. COMPONENTS OF AIR CONDITIONING ............................................................................. 3
2. OPERATION OF AIR CONDITIONER ................................................................................... 6
3. COMPONENT FUNCTIONS .................................................................................................. 7
4. INSTRUCTIONS FOR USE ................................................................................................... 8
5. HOW TO MAKE THE MOST OF THE AIR CONDITIONER .................................................. 9
6. PERIODIC MAINTENANCE .................................................................................................. 10

6.1. Interpreting the Sight Glass .................................................................................................................. 11
6.2. Checks During Periodic Maintenance ................................................................................................ 11
6.3. Cold and Dry Spells, When the Unit Is Rarely Used ....................................................................... 12
7. ELECTRIC SYSTEM .............................................................................................................. 13
8. AIR CONDITIONER TROUBLESHOOTING ......................................................................... 14
Copyright © Sandvik Mining and Construction 1 (18)

ID: 410 0 en 2009-05-13
2 (18) Copyright © Sandvik Mining and Construction
ID: 410 0 en 2009-05-13
Air Conditioner
1. COMPONENTS OF AIR CONDITIONING ID: 34032
777
A 3 10 9
1 5 11 8
12
7 6
4
10 9 13
10
6 11
ID: 34052

ID: 410 0 en 2009-05-13
Air Conditioner
1 Compressor • Pressurizes refrigerant and makes it circulate.

• Mounted to front end of diesel engine and driven by it,
using a V-belt drive.
2 Magnetic clutch of compressor • When dead, the clutch lets the compressor idle; when
live, it engages the compressor drive.
• The magnetic clutch is controlled by the thermostat, the
pressostat, and the air conditioning fan switch.
3 Condenser • Transfers heat to outside air, changing refrigerant vapor
into liquid.
• The condenser unit comprises a cell and a fan.
• The condenser is located on the side of the hydraulic oil
receiver.
4 Drier • The purpose of the drier is to remove moisture from the
system (danger of freezing).
• Refrigerant flows through a particle filter and moisture
absorbing medium. The drier is provided with a sight
glass in the top cover for checking refrigerant flow.
• The drier must always be replaced if it has been empty
longer than 30 minutes; long exposure to air destroys the
drier.
5 Pressostat • Functions as a pressure switch, cutting off electricity to
the compressor’s magnetic clutch if the system pressure
drops too low or rises too high.
• Located with the drier in the condenser housing.
6 Evaporator cell • Absorbs heat and condenses humidity from the ambient
air.
• Turns liquid refrigerant into vapor.
• Located in the cabin.
7 Expansion valve • Regulates the refrigerant flow into the evaporator.
• Located in the evaporator cabin, connected to the line
from the drier.
• The valve has a spindle, controlled by a membrane, that
regulates the flow to the evaporator according to a
sensor.
• The liquid-filled sensor is connected to the line coming
from the evaporator.
• If too much refrigerant flows through the evaporator, the
liquid in the sensor cools down (volume decreases), and
the valve closes -- the operation is reversed if too little
refrigerant flows through.
8 Fan • Blows air through the evaporator into the cabin.
• Located in the evaporator housing in the cabin.
• The fan switch controls the magnetic clutch of the air
conditioner compressor; air conditioning operates only if
the fan is in operation.

ID: 410 0 en 2009-05-13
Air Conditioner
9 Thermostat • Controls cabin temperature when air conditioning is on.

• The regulating switch is located on the evaporator
housing.
• Controls the operation of compressor magnetic clutch:
turns compressor to idle when the set temperature is
reached (cuts off current to magnetic clutch).
10 Heater valve • The valve is used for regulating the amount of water
flowing through the heater cell.
• Located on the heater.
11 Heater cell • Transfers heat to the cabin air from the hot engine
coolant flowing through the cell.
• Located in the evaporator housing in the cabin.
12 Air filter • Removes dust from the incoming air.
• Located in the evaporator housing outside the cabin.
• The air cleaner should be cleaned with pressurized air
and replaced regularly; the service interval greatly
depends on the quality of the surrounding air.
13 Control switch • The air conditioning system is turned on and off with the
control switch located in the control panel in the cabin.

ID: 410 0 en 2009-05-13
Air Conditioner
2. OPERATION OF AIR CONDITIONER ID: 34047
The compressor circulates refrigerant R134a in a closed circuit system.

• Refrigerant vapor pressurized by the compressor is led through the condenser (3). As the
temperature of the vapor is higher than the ambient temperature, it loses heat to the outside air.
This loss of heat condenses the vapor to liquid form. The condenser has a fan (a) to provide
necessary cooling.
• The liquid refrigerant flows through the drier (4). Moisture is the severest problem in air conditioners,
and thus it must be removed as completely as possible. Water will freeze in the circuit!
• Next, the liquid refrigerant flows through the expansion valve (7) to the evaporator (6). The
expansion valve controls the amount of refrigerant entering the evaporator cell by choking the flow.
• The refrigerant entering the evaporator absorbs heat from the surrounding air. Air from the cabin is
circulated through the evaporator by a fan (8), whereby heat is absorbed and moisture condenses
from the air to the cold surfaces of the evaporator. Due to its low boiling point, the refrigerant again
changes into vapor in the evaporator.
• Then the refrigerant vapor enters the intake side of the compressor, and the circulation continues
as described above.

ID: 410 0 en 2009-05-13
Air Conditioner
3. COMPONENT FUNCTIONS ID: 34035
10 2 9 4 3 1
10
5
8
ID: 34053
1 Air conditioner control switch • locates on the main switch panel

2 Fan switch • three fan speeds are available
• the same fan is used for air conditioner and heater
• air conditioning works only when fan is on (switch
positions 1 to 3)
3 Air conditioner thermostat • used for setting desired cabin temperature (cooling
regulator knob power)
4 Air circulation selector knob • the fan can either take fresh air through the air cleaner
from outside or recirculate the cabin air
5 Air flaps • flap control air circulation in the cabin (selector 4)
6 Air vents • the vents can be turned to direct warm/cool air from the
fan to desired directions
7 Air cleaner • on the wall of the cabin
• removes impurities from air taken in from outside
• air cleaner must be regularly blown clean with
pressurized air and replaced when necessary; the
required service interval greatly depends on the quality
of the outside air (check cleaner element at least every
six months)
8 Heater control valve the valve is used for regulating heating power by
increasing/reducing the liquid flow through the heater cell
9 Control switch of heater control
valve
10 Fuse

ID: 410 0 en 2009-05-13
Air Conditioner
4. INSTRUCTIONS FOR USE ID: 34036
Warm weather, normal humidity
Close the air recirculation valve and the temperature regulator. Turn the cooling system on and adjust
the thermostat as required.
Very warm weather, high humidity
Open the air recirculation valve, close the temperature regulator, and switch the cooling system on.
Adjust the thermostat as required.
Fall or early winter, high humidity, windows tend to get foggy
Turn the cooling system on and open a window slightly to allow air circulation in cabin. Adjust cabin
temperature as required.
Cold winter weather
Close the air recirculation valve. Do not turn cooling system on. Adjust cabin temperature as required.
Very cold weather, low humidity
Open the air recirculation valve. Adjust cabin temperature as required.

ID: 410 0 en 2009-05-13
Air Conditioner
5. HOW TO MAKE THE MOST OF THE AIR CONDITIONER ID: 3224
The fan speed and the air temperature are easily adjustable.
Do not use a higher fan speed than necessary. Always reduce the fan speed first, if you feel that the
cabin temperature is too low and then the temperature of the incoming air with the heater control
switch.
Adjust the air vents so that the air flow in the cabin feels comfortable.
Never direct the air flow against yourself.
Set the air circulation rotary switch in the position 0 (recirculation) and open the air vents. In this way
the air conditioner works best and you can avoid outside noise, exhaust fumes, dust etc..
Do not keep the cabin temperature too low. Remember your body does not like great changes in
temperature. Adjust the temperature to find the temperature difference that suits you best. The cabin
temperature schould not be adjusted more than 5-70C lower than the ambient temperature. Adjust
the temperature pleasent for yourself.
Using the air conditioner simultancously with the heater prevents the windows from becoming foggy,
as the air conditioner removes humidity from the air.
Humid air is heavy to breathe. The air conditioner reduces the air humidity in the cabin and you feel
more comfortable.

ID: 410 0 en 2009-05-13
Air Conditioner
6. PERIODIC MAINTENANCE ID: 34037
The system should be checked once a week.

Points to check:
1 Sight glass
2 Fluid container 1 2
3 Pressure switch
ID: 34054
1. Set the engine speed to 1500 rpm.

2. Turn the air conditioner on.
3. Turn the fan and the thermostat to maximum.

ID: 410 0 en 2009-05-13
Air Conditioner
6.1. Interpreting the Sight Glass ID: 34062
Sight Description Explanations and notes

glass
Continuous flow of bubbles or foamy flow VERY LITTLE REFRIGERANT
(filling required). Small temperature difference between in-
take and output side.
Pressure in high-pressure side unusually
low.
STOP THE COMPRESSOR AT ONCE, and
call in a mechanic to check the system.
A few bubbles every few seconds (filling INSUFFICIENT AMOUNT OF REFRIGER-
required). ANT
High-pressure side warm and low-pressure
side cool.
Check the system for leaks, and repair pos-
sible leaks at once.
Add refrigerant to the system.
Clear fluid, with a few bubbles when rotation CORRECT AMOUNT OF REFRIGERANT
speed is changed. Normal pressure values in both high and
low--pressure side. Pressure side hot and
intake side cold.
No bubbles at all (remove refrigerant from TOO MUCH REFRIGERANT
the system). P
ressure side very hot. Unusually high pres-
sures in both intake and pressure side. Re-
move refrigerant from the pressure side of
the system.
6.2. Checks During Periodic Maintenance ID: 34042
Check the following points during periodic maintenance:

1. Check the sight glass
Bubbles should be visible only when the compressor is started and shut off.
2. Check that the connection between the compressor pressure plate and the pulley is not slipping,
and that it is clean.
3. Check that the lead between the thermostat and the electromagnetic clutch is in good condition.
4. Check the V-belt tightness and compressor mounting.
5. Clean or replace the fresh air and recirculation filter.
6. Remove condensate water from the bottom of the air conditioner.
7. Check all hose connections.
If refrigerant level is low, refrigerant is leaking, or some other fault exists, the system must
not be used before the fault(s) have been repaired. Otherwise, the compressor may become
damaged.

ID: 410 0 en 2009-05-13
Air Conditioner
6.3. Cold and Dry Spells, When the Unit Is Rarely Used ID: 34044
Start the cooling system, and allow the compressor to run a few minutes once a week, to keep the
connections, sealings, etc. lubricated. If a low--pressure switch is connected to the system, it must
be bypassed if the ambient temperature drops below -1°C. Otherwise, the compressor will not start.

ID: 410 0 en 2009-05-13
Air Conditioner
7. ELECTRIC SYSTEM ID: 34045
+ 1
10
2
M 6 8
ID: 34077
Operation
Air conditioning is switched on with the control switch (1) (located on the top of the device), provided
with an indicator light (2). However, the current to this switch comes through the fan control switch
(3); if the fan is on, the switch (1) also receives current. When the fan switch (3) is in the 0--position,
the air conditioning system does not work, because the switch (1) gets no current.
The fan switch (3) has three positions for different speeds. In position 1, the current to the fan motor
(5) goes through the resistor (4), whereas in position 2 only part of the current goes through the
resistor (4), and the fan speed is higher. In position 3, the current flows directly to the fan motor (5).
When air conditioning is switched on, current flows from switch (1) to the thermostat (6). The ther-
mostat is used for selecting the desired temperature of the air. If the temperature rises above the set
value, the thermostat closes. The current coming from the thermostat (6) flows to the pressostat (8).
If the system has the required amount of refrigerant (pressure is sufficient), the pressostat keeps the
electric circuit closed, and current flows to the magnetic clutch (10) of the air conditioner compressor.
When live, the clutch engages the compressor drive; the compressor drive pulley revolves always
when the engine is running, but the compressor will rotate only when the magnetic clutch (in the
pulley) becomes live and engages the drive. When the drive is engaged, the magnetic clutch in the
pulley rotates with it; when the clutch is dead, only the pulley rotates.

ID: 410 0 en 2009-05-13
Air Conditioner
8. AIR CONDITIONER TROUBLESHOOTING ID: 34046
Poor cooling
Trouble Probable cause Procedure

Fan not working. Faulty fan or electric circuit.
Faulty thermostat.
Cabin air alternates between Expansion valve frozen. Replace filter drier.
cold and hot.
Unit provides cool air at start but System overcharged. Discharge excess refrigerant.
later blows warm air. Condenser fans are not working. Check electric system.
Condenser coil dirty and clog- Replace or repair fan motor.
ged. Clean condenser cooling fins.
Unit freezes up occasionally. Moisture in system. Replace filter drier.
Thermostat adjusted too low. Adjust thermostat.
Air flow

Cool air at outlet but not enough Evaporator coil clogged. Clean evaporator coil.
air to keep the cabin cool. Faulty evaporator fan. Replace or repair.
Air filters clogged. Check and replace.
Low refrigerant level. Check refrigerant level.
Recharge.
No cooling

No electric power Fuse blown. Replace fuse.
Broken wire or incorrect wiring. Check wiring and connections.
Repair.
Cabin fan not working. Faulty motor or incorrect wiring. Check that the motor receives
power.
Repair or replace motor.
No change in the pressure Faulty compressor (valves leak- Replace or repair compressor
readings at start. ing). (valves).
Change filter drier.
Discharge pressure normal, Faulty expansion valve. Replace expansion valve.
high suction pressure. Expansion valve frozen to open Replace filter drier.
position. Check and repair.
Sensing bulb of expansion valve
makes no contact.
Discharge pressure high, Expansion valve or filter drier Repair if needed and replace fil-
suction pressure gauge shows clogged. ter drier.
vacuum.
Magnetic valve does not Electric switch in thermostat Check current flow to magnetic
function. burned or faulty sensing ele- valve.
ment. Replace thermostat if needed.

ID: 410 0 en 2009-05-13
Air Conditioner

Compressor will not run. Compressor partially or com- Replace or repair compressor.
plete frozen.
Compressor fails shortly after Careless charging / overcharg-
replacement or after system is ing.
charged.
Complete refrigerant loss in Broken refrigerant line. Check all lines for leaks.
system.
Discharge and suction pressure System leaking. Check system for leaks.
gauges show that there is no Fusible plug blown. Repair.
pressure in system. Replace filter drier.
Excessive noise

Magnetic valve vibrates Not enough refrigerant in the Check system for leaks.
(engages and disengages), system. Repair and recharge.
expansion valve whistles, Faulty thermostat. Change thermostat.
bubbles in sight glass, discharge Low suction pressure. Check wiring.
pressure low. Check system for leaks.
Compressor noisy and hot. Compressor oil level too low. Add specified oil.
Expansion valve noisy, suction Excessive moisture in the sys- Replace filter dryer, purge and
pressure low. tem. charge.
Rumbling noise or vibration in System overcharged. Discharge excess refrigerant
high pressure line thumbing until pressure is within specifica-
noise in compressor, high tions.
discharge and suction
pressures.
Note!
Always when system is opened it must be purged (to get all moisture out) and charged. Often the
filter drier must be replaced.
Use the air conditioning unit weekly at least for 5 minutes. The compressor will be lubricated and
moving parts will stay clean and won’t oxidize.
Abnormal pressure gauge readings
Trouble Probable cause

Low suction pressure, head pressure high. Faulty thermostat.
Clogged line.
Moisture in system.
Expansion valve closed (if suction pressure
gauge shows vacuum).
High suction pressure, head pressure normal. Faulty expansion valve.
Sensing element of expansion valve not touching
the suction line.
Faulty compressor.
High suction pressure, head pressure low. Faulty compressor or compressor valves.

ID: 410 0 en 2009-05-13
Air Conditioner
Trouble Probable cause

Very high head pressure. Air in system or system overcharged.
Condenser air passages clogged.
Condenser, filter drier, or high pressure line clog-
ged.
High suction pressure, high head pressure. Condenser air passages clogged.
Excessive oil in system.
Condenser fan(s) not operating.
System is overcharged.
Normal Pressures:
Suction pressure: 0,1 - 2,0 bar

High (head) pressure: 6,0 - 18,0 bar

ID: 410 0 en 2009-05-13
Air Conditioner

ID: 410 0 en 2009-05-13
www.sandvik.com
326 1 en 2009-04-03
ROD GREASING DEVICE

Operation and maintenance
Table of Contents
1. OPERATION .......................................................................................................................... 3
2. FILLING OF PUMP UNIT CONTAINER ................................................................................ 5
3. ADJUSTMENT OF DISPENSERS ......................................................................................... 7
4. TROUBLESHOOTING ........................................................................................................... 8

ID: 326 1 en 2009-04-03
ID: 326 1 en 2009-04-03
ROD GREASING DEVICE
1. OPERATION ID: 14201
When the start button (4) is pressed, the hydraulic valve (7) and the pneumatic valve (5) open. A
hydraulic pressure of 100 bar is now reaching the pump unit (1). Through the dispensers (3), the
pressurized grease is led to the injector (2). Pressurized air is used for injecting the pressurized
grease onto the drill rod thread.
The dispensers (3) are adjustable; factory setting is 1000 mm 3. Refer to adjusting instructions.
6 Pressure relief valve
8 Flushing valve
9 Cassette valve
ID: 19094
Figure: DX / DP
ID: 18428
Figure: DX_R

ID: 326 1 en 2009-04-03
ROD GREASING DEVICE
1
4
ID: 19093
Figure: DP
4
9
6
7
ID: 18426
Figure: DX / DX_R

ID: 326 1 en 2009-04-03
ROD GREASING DEVICE
2. FILLING OF PUMP UNIT CONTAINER ID: 14202
The capacity of the pump unit tank is 2 kg.

The filling pump (Cf. Fig.) is suitable for greases of NLGI 0-2 grade. The container size can be 10 –
20 kg. The output of the filling pump is 0.1 kg / pumping stroke.
Filling of pumping unit:
1. Place intermediate cover (10) into tank (18).
2. Fasten tank cover (11) with screws.
3. Install pump unit (12) through tank cover to intermediate cover (10).
4. Fasten filling hose (13) to pump.
5. Let air flow out of pump by holding quick coupling (14) open (e.g. with a screw driver) while
pumping in grease.
6. Connect quick coupling (14) to male coupling (15) on pump unit (1).
7. Operate pump with calm movements (~90°), until pumping resistance increases.
8. Turn filling pump lever up (~30°) to free the pump.
9. Disconnect quick coupling (14) and fit protective plugs to both parts of quick coupling.
10. After filling, let pressure out of pump unit (1) by opening bleed screw (16). This is to ensure the
operation of the dispensers.
If excessive power is required to operate the filling pump, check

and clean the filling pump filter. The filter should be cleaned at
least once a year.
The filtering screen (17) of the pump is located in the filling line of the tank. To clean the filtering
screen, remove the quick coupling part (15).

ID: 326 1 en 2009-04-03
ROD GREASING DEVICE
~30°
~90°
13
X TE
S 52
0 0X3X
11X6XYRP.EN O .
14 12
15
17
11
10
16
18
ID: 19095

ID: 326 1 en 2009-04-03
ROD GREASING DEVICE
3. ADJUSTMENT OF DISPENSERS ID: 14203
The dispensers (3) are adjustable, each dispenser can be set to give 200-500 mm 3 , i.e. to give a
total amount of 400-1000 mm 3. The factory setting is 1000 mm 3.
One full turn of the dispenser nut A corresponds to one millimetre in length L.
L max. 5 mm
1 r = 1 mm
L / mm
4
3
2
1
250
300
350
200
400
450
500
mm3
ID: 19092

ID: 326 1 en 2009-04-03
ROD GREASING DEVICE
4. TROUBLESHOOTING ID: 14204
FAULT / PROBLEM CAUSE / REMEDY

No grease or air coming Check operation and wiring of valve coils; replace coil if necessary.
out through injector If coils are working, check valve spool. If spool is sticking, clean /
nozzle replace valve.
Check operation of start switch.
If necessary, repair or replace switch.
Grease coming out of Check operation of air valve and air circuit pressure.
injector slowly or in an If valve is not working, check coil and spool.
insufficient amount. Check dispensers of pump (2 pcs.) for correct adjustment (Cf.
Adjusting instructions).
Check hydraulic pressure at pump (100 bar); adjust if necessary.
Plain air coming out of Check the amount of grease in tank.
injector nozzle. After filling the tank, let air out of the pump unit by opening the bleed
screw.
Check the pump dispensers (2 pcs.) for correct adjustment (Cf.
Adjusting instructions).
Check operation of hydraulics control valve (7).
Check hydraulic pressure at pump (100 bar); adjust as necessary.
Filling of pump tank Check pump filtering screen (17); clean as necessary.
impossible or extremely Clean filtering screen at least once a year.
laborious.

ID: 326 1 en 2009-04-03
ROD GREASING DEVICE

ID: 326 1 en 2009-04-03
www.sandvik.com
327 2 en 2009-04-14
Flushing control automatics

Table of Contents
1. GENERAL .............................................................................................................................. 3
2. COMPONENTS ...................................................................................................................... 4
3. OPERATING PRINCIPLE ...................................................................................................... 7
4. FLUSHING CONTROL ADJUSTMENT ................................................................................. 9
5. ELECTRIC CIRCUIT DIAGRAM ............................................................................................ 11

ID: 327 2 en 2009-04-14
ID: 327 2 en 2009-04-14
1. GENERAL ID: 14206
The flushing control automatics enables drilling in areas where rock contains soft and fragmented
layers ormud and clay pockets. When drilling in such a place the drill bit easily gets blocked. The
blocked bit prevents flushing air from cleaning the hole and this leads to jammed drill steels.
The flushing control automatics constantly monitors flushing; if air flow is insufficient because of a
clogged bit or blocked hole, the drill steels are automatically lifted up until air flow is normal again and
drilling will continue normally. Usually by lifting the steels a little, the flushing holes in the bit will open
and drilling starts again.
1 1 1
2 2 2
3 3 3
ID: 19104
1. Rotation
2. Flushing
3. Feed
4. Sticky layer in the rock

ID: 327 2 en 2009-04-14
2. COMPONENTS ID: 14207
28
S65
1
34
3
240
4 d
23
c
5 6
YA10
ID: 19096
1 Rock drill 2 Flushing Control

3 Feed pilot pressure 4 Rotation pressure
5 Flushing valve 6 Feed pressure
7 Compressor

ID: 327 2 en 2009-04-14
YA10 Flushing valve

• This valve turns on / off the air flow to the drill bit
1 Venturi
S18 S18 Flushing controls selector switch
S65 Pressure difference switch
• This switch monitors pressure difference over the restriction plate
• The switch is adjustable according to the drilling needs (more/less sensitive)
• Contact points are open in normal drilling but when pressure difference is less
than 0,1 bar they close and connect voltage to the solenoid of valve (240)
240 Flushing control valve

• Controls feed pilot pressure to feed directional valve or to antijamming valve.
23 Feed directional valve

• Controls feed
• Changes the direction of oil flow to the feed motor (instead of turning downwards
the motor turns upwards)
28 Feed motor
34 Anti -jamming valve
S17 Flushing control automatics selector switch
2. Blow-down automatics (when dust collector

(S46) on), max. flushing 2
S18
3. Blow-down automatics off and flushing off
4. Blow down automatics, (when dust collector
3
(S46) on), half flushing
5. Flushing control automatics on
6. Flushing control automatics off 4
7. Power extractor on, indicator light goes on
S243 S24 S17 S18

S17
5
ID: 19097

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240
34 23
ID: 19098
240 Flushing control valve

23 Feed directional valve
34 Anti-jamming valve
YA10
S65
ID: 19099
1 Venturi
S65 Pressure difference switch
YA1 Flushing valve
0

ID: 327 2 en 2009-04-14
3. OPERATING PRINCIPLE ID: 14208
28
S65
1
3 34
240
4 d
23
c
5
6
YA10
ID: 19105
1 Rock drill 2 Flushing control

7 Compressor
Flushing air flows through the venturi tube (1) on its way to the rock drill. The restriction creates
pressure difference for the air flow. The pressure difference switch (S65) is connected to the venturi
tube by hoses. When the drill bit starts to get blocked, the pressure difference drops and contacts of
pressure difference switch will close (switch setting is 0.1 bar). Now voltage is connected through the
closed contact of the switch (S65) to the coil of the flushing control valve (240) and the spool moves.
The feed pilot pressure gets to feed direction valve (23) port (c) and feed return starts.

ID: 327 2 en 2009-04-14
28
S65
1
3 34
240
4 d
23
c
5
6
YA10
ID: 32821
1 Rock drill 2 Flushing control

7 Compressor
When the flushing holes in the bit open, the pressure difference again increases over 0,1 bar; the
pressure difference switch (S65) disconnects the voltage to the flushing control valve (240) and the
spool returns to its original position. The feed pilot pressure gets to feed direction valve (23) port (d)
and feed forwards starts.

ID: 327 2 en 2009-04-14
4. FLUSHING CONTROL ADJUSTMENT ID: 14209
1. Remove the flushing hose from the rock drill.

2. Plug the hose by a cap which has a hole drilled through. Size of the hole depends on the rig:
DX500, 680, 700, 800 Ø 6 mm

DP800 Ø 6 mm
DP900, 1100 Ø 8 mm
DP1500 Ø 9 mm
3. Open the cover of the pressure difference switch (S65).
S65
ID: 19100
4. Start the engine and let it run at full speed.

5. Select flushing control on by switch (S17).
6. Select max. flushing by switch (S18).
S18
S17
ID: 19101
7. Start percussion.
8. Start feed forwards
9. Turn adjustment nut (a) (clockwise) until feed return starts.

ID: 327 2 en 2009-04-14
10. Turn adjustment nut (a) a bit counterclockwise.

11. Install the cover of the pressure difference switch (S65) and connect the flushing hose.

ID: 327 2 en 2009-04-14
5. ELECTRIC CIRCUIT DIAGRAM ID: 14210
+24 VDC
S24
K16
S65
K15
Y57 Y240
2 3
ID: 19107
1. From percussion pressure switch

2. Anti-jamming ON/OFF valve
3. Flushing control automatics valve

ID: 327 2 en 2009-04-14
www.sandvik.com
388 0 en 2009-05-14
Water Injection System with Pressure

Table of Contents
1. WATER INJECTION SYSTEM .............................................................................................. 3

1.1. Components .............................................................................................................................................. 6
1.2. Operation and Use ................................................................................................................................... 7
1.3. Maintenance ............................................................................................................................................... 7

ID: 388 0 en 2009-05-14
ID: 388 0 en 2009-05-14
1. WATER INJECTION SYSTEM ID: 34119
The system injects water into the flushing air to make the flushing dust damp. The damp dust sticks
to the walls of the hole and forms a cement--like layer that prevents the hole from collapsing. Water
injection can be used during collaring as well as drilling.
3 4 6
ID: 34135
1 Rock Drill 2 Flushing Valve

3 Compressor 4 Water Tank
5 Water Regulating Valve 6 Solenoid Valve
Water in the tank at the rear of the rig is forced with pressurized air through the water injection solenoid
valve and regulating valve into the flushing line. Regulating valve and switch for solenoid valve are
in cabin.
Note:When water injection is on also the dust suction is on.When usingmuch water stop dust collector
motor because there is risk that water gets into the dust collector filters and blocks them. If the rig is
provided with a movable suction head, we recommend that the suction head is lifted up during col-
laring to make observing of water amount easier.
When the water amount is correct, most of the drill cuttings come out at the cyclone and only a small
amount reaches the fine separators.Using suitable amounts ofwater can also affect the usable life of
the filters.

ID: 388 0 en 2009-05-14
S16
S46 1
S18
ID: 34136
1 Water regulating valve

ID: 388 0 en 2009-05-14
S16 • Water injection or Zero dust liquid mixed with flushing air
• Off
• Water injection or Zero dust liquid mixed with flushing air during percussion on
S18 • Blow-down automatics, if dust collector (S46) is on, max. flushing

• Blow-down automatics off and flushing off
• Blow down automatics, if dust collector (S46) is on, half flushing
S46 • Suction off and dustcollector off

• Dust collector on

ID: 388 0 en 2009-05-14
1.1. Components ID: 34120
11
10
B
D 4
9
6
C
1
5
ID: 34145
1 Solenoid valve for water injection. Switch 2 Regulating valve for water amount (in
(S16) in cabin. cabin).
3 Control valve for operation and releasing 4 Check valve
pressure

ID: 388 0 en 2009-05-14
5 Draining valve 6 Safety valve

7 Pressure gauge 8 Water tank valve
9 Water tank 10 Check valve
11 Check valve A Air flow
B Flushing control C Compressor
D Flushing valve W Water flow
1.2. Operation and Use ID: 34121
Never open tank valve (8) if there is pressure in water tank. Al-
ways turn the control valve (3) to releasing position first.
1. Turn control valve (3) to releasing position.

2. Check that drain valve (5) is closed.
3. When pressure has released open valve (8) and fill water tank.
4. Close valve (8) and turn control valve (3) to operation position.
5. Water injection is now ready to start by switch (S16).
6. Adjust amount of water by water regulating valve (2) during operation.
After stopping the engine always the turn control valve (3) to
releasing position.
1.3. Maintenance ID: 34122
• Clean the water tank (9) regularly.

ID: 388 0 en 2009-05-14
www.sandvik.com
322 1 en 2009-04-03
DUST SUPPRESSION ADDITIVES

Table of Contents
1. DUST SUPPRESSION SYSTEM ADDITIVES ....................................................................... 3

1.1. Water injection system ........................................................................................................................... 3
1.2. The DustMizer system ............................................................................................................................. 4

ID: 322 1 en 2009-04-03
ID: 322 1 en 2009-04-03
1. DUST SUPPRESSION SYSTEM ADDITIVES ID: 14142
In dust suppression systems, the suppression agent used is water or a water/additive mixture.
1.1. Water injection system ID: 14143
In a water injection system, water or a water / foaming agent mixture is led into the rock drill’s flushing
air. The fluid led into the flushing air suppresses the formation of rock dust in drilling and vaults the
hole with a cement-like layer that prevents the hole from collapsing.
The fluid used is water or a mixture of water and 0.5 to 5% foaming agent, such as Baroid Quick-
Foam; for additional information, visit www.baroididp.com.
The amount of fluid led into the flushing air is 0.5 l/min (factory setting). The actual amount of fluid
used depends on the type of the rock and the size of hole drilled. If fluid is used excessively, the hole
tends to block; if too little is used, the dust created is visible.
ID: 19021
1. Rock drill
2. Compressor
3. Fluid container

ID: 322 1 en 2009-04-03
1.2. The DustMizer system ID: 14144
With the DustMizer system, dust suppression fluid is led into the rock drill flushing air, in like manner
to that of the water injection system. In addition, dust suppression fluid is injected into the lower part
of the dust collector. The dust suppression fluid led into the flushing air suppresses the formation of
rock dust in drilling; it instead forms a sand-like and grainy, dust-free substance.
The fluid used to suppress the dust is a mixture of water and 1 to 2% biodegradable orange oil, like
Nalco Dustfoam; for additional information, see www.nalco.com.
The amount of dust suppression fluid led into the flushing air is 0.5 l/min (factory setting). The actual
amount of fluid used depends on the type of the rock and the size of hole drilled. If fluid is used
excessively, the hole and the dust collector outlet port tend to block; if too little is used, the dust
created is visible.
The maximum time the dust suppressing fluid can remain in the fluid line is 40 minutes. After that,
the fluid lines must be blown empty.
2
3
ID: 19055
1. Rock drill
2. Compressor
3. Dust collector
4. Fluid Container

ID: 322 1 en 2009-04-03

ID: 322 1 en 2009-04-03
www.sandvik.com
321 0 en 2009-02-16
Central lubrication system

Operation and maintenance instructions
Table of Contents
1. OPERATION .......................................................................................................................... 3
2. PUMPING UNIT ..................................................................................................................... 4

2.1. Structure ..................................................................................................................................................... 4
2.2. Operation .................................................................................................................................................... 4
3. FILLING THE LUBRICANT RESERVOIR OF THE PUMPING UNIT .................................... 5
4. DOSER GROUPS .................................................................................................................. 7

4.1. Structure ..................................................................................................................................................... 7
4.2. Doser operation ........................................................................................................................................ 7
5. USER INTERFACE (RIGS WITH A CABIN) ......................................................................... 8

5.1. Lubrication button ................................................................................................................................... 8
5.2. Indicator lights .......................................................................................................................................... 8
5.3. Settings for main functions ................................................................................................................... 9
5.3.1. Setting the lubrication cycle ........................................................................................................... 9
5.3.2. Setting the maximum pressurisation time ................................................................................... 10
5.3.3. Selecting the lubrication system ................................................................................................... 10
5.3.4. General information on settings .................................................................................................... 10
6. USER INTERFACE (RIGS WITHOUT A CABIN) .................................................................. 11

6.1. Indicator lights .......................................................................................................................................... 11
6.2. Buttons ........................................................................................................................................................ 12
6.3. Display ......................................................................................................................................................... 12
6.3.1. Time display ..................................................................................................................................... 12
6.4. Operation .................................................................................................................................................... 12
6.4.1. Interval time counter ....................................................................................................................... 13
6.4.2. Pressurisation .................................................................................................................................. 13
6.4.3. Extra lubrication cycle ..................................................................................................................... 13
6.4.4. Stage codes in normal and alarm mode ...................................................................................... 13
6.4.5. Normal mode displays .................................................................................................................... 14
6.4.6. Line pressure displays .................................................................................................................... 14
6.4.7. Power failure .................................................................................................................................... 14
6.4.8. Alarms ............................................................................................................................................... 15
6.5. Settings ....................................................................................................................................................... 15
6.5.1. Entering the password .................................................................................................................... 15
6.5.2. Entering the settings ....................................................................................................................... 16
7. RECOMMENDED LUBRICANTS .......................................................................................... 17
8. PERIODIC CHECKS .............................................................................................................. 20

8.1. Checking the operation of dosers ....................................................................................................... 20
8.1.1. Check procedures ........................................................................................................................... 20

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9. TROUBLESHOOTING ........................................................................................................... 21
10. BRAIDED HOSE SOCKETS - INSTALLATION .................................................................. 22

10.1. 8/4 screw-type socket for braided hose - installation .................................................................. 22
10.2. 8/4 press-type socket for braided hose - installation ................................................................... 24

ID: 321 0 en 2009-02-16
1. OPERATION ID: 14100
The MultiLube system is a central lubrication system in which the pumping unit (1) pumps the lubricant
through piping (2) to the dosers (3). The dosers feed the pre-selected amount of lubricant to the
lubrication points. The operation of the system is controlled and monitored with a control unit (4). The
control unit controls the system by automatically starting the process at an interval chosen by the
user and monitors the pressurisation of the system and the amount of lubricant. If the pressure does
not reach a set level within the set maximum pressurisation time, or if the amount of lubricant drops
to the lower limit, the control unit indicates a malfunction with the warning lights on the button panel
(5) (rigs with a cabin) or via the user interface (6) (rigs without a cabin).
ID: 20210
Always check the function diagram in the appropriate rig's

NOTE!
spare parts manual.

ID: 321 0 en 2009-02-16
2. PUMPING UNIT ID: 14101
2.1. Structure ID: 14102
The pumping unit consists of the body (1) and lubricant reservoir (2).
The body is comprised of the pump element (3), electric motor (4), line valve (5), pressure relief valve
(6), and heating element (7). The pumping unit is controlled by the control circuit board (8). The
pumping unit is equipped with line-specific pressure sensor (9).
The lubricant reservoir is equipped with the follower piston (10), level indicator (11), and low level
switch (12). The filling connector (13) of the lubricant reservoir features a filter (14) and safety valve
(15).
10
2
11
15
6
12
3
9
13 14
7
5 1
ID: 19784
2.2. Operation ID: 14103
When the pressurisation stage begins, the control starts the pump and opens the line valve. In the
pressure switch operation, the pump stops when the pressure switch closes and restarts when it
opens. After the pre-selected pressurisation time, the control stops the pump and the pressure from
the line is discharged into the lubricant reservoir.
If the lubricant level drops to the low limit during pumping, the reservoir’s low level switch sends an
alarm signal to the control and pumping is stopped. The alarm status disappears when the lubricant
reservoir is filled and the alarm is reset.

ID: 321 0 en 2009-02-16
3. FILLING THE LUBRICANT RESERVOIR OF THE PUMPING UNIT ID: 14104
The lubricant reservoir of the pumping unit is filled through the filling connector equipped with a filter.
1. Ensure that the area surrounding the pumping unit is clean. Impurities in the system prevent its
trouble-free operation and cause damage when they reach the lubrication point.
2. Remove the lid from the lubricant container (1) and press the follower plate (2) tightly to the
container on top of the lubricant. The follower plate is not used with fluid lubricants, as it would
not float on the surface of such lubricants.
3. Place the container lid (3) on top of the lubricant container. Fasten the container lid to the container
with the wing screws (4).
4. Insert the pump (5) through the container lid into the follower plate’s central unit (6).
5. Connect the lubricant hose (7) to the pump.
6. Fill the lubricant hose by pumping by hand.
7. Connect the quick connector (8) to the lubricant hose.
8. Connect the quick connector to the pumping unit filling connector (9).
9. Fill the lubricant reservoir of the pumping unit by pumping slowly by hand.
10. The filling of the lubricant reservoir can be monitored with the level indicator (10). To prevent
overfilling, the pumping unit is equipped with a safety valve (11).
11. Turn the pump handle (12) to a vertical orientation to discharge the pressure so it passes to the
lubricant container.
12. Disconnect the quick connector from the pumping unit filling connector.
13. Fasten the protecting cap (13) of the pumping unit filling connector.
14. Fasten the protecting cap (14) of the filling device quick connector.
The filter (15) of the filling connector must be cleaned regularly
and replaced if necessary.

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12
5
8
14 4
10 3
11
6
15 2
13 1
9
ID: 19785
The working stroke of the filling pump is about 90 degrees. The pressure is released when the handle
is turned so that it is vertical.

ID: 321 0 en 2009-02-16
4. DOSER GROUPS ID: 14105
4.1. Structure ID: 14106
A doser group consists of a mounting rail (1) and one or more dosers (2) attached to it. The mounting
rail divides the lubricant among the dosers, which feed the chosen amounts to the lubrication points.
The doser includes the charging valve (3), dosing chamber (4), dosing piston (5), and spring (6).
ID: 19786
4.2. Doser operation ID: 14107
During pressurisation, the pressure in the line increases and the doser charging valve moves to the
uppermost position. At the same time, lubricant flows past the charging valve and moves the dosing
piston to its uppermost position. From this position, the dosing piston pushes the set lubricant dosage
from the dosing chamber to the lubrication point.
After the pressurisation, the pressure in the line decreases and the charging valve moves to the
lowermost position and closes. The spring returns the dosing piston to its lowermost position; at the
same time, lubricant flows above the dosing piston to the dosing chamber.
The line can be pressurised again when the pressure in the line has decreased and the dosing pistons
of the dosers have returned to their lowermost position.
Ensure that there is no pressure in the system when replacing
the dosers.

ID: 321 0 en 2009-02-16
5. USER INTERFACE (RIGS WITH A CABIN) ID: 14108
The button panel includes a button ( SET) and three indicator lights: 1, 2, and P.
ID: 19787
5.1. Lubrication button ID: 14109
Depending on the lubrication programme’s status, the lubrication button ( SET) can be used for dif-
ferent functions:
Lubrication programme status Lubrication interval

Lubrication interval Extra lubrication status
Pressurisation Interruption of pressurisation
Alarm Alarm reset
5.2. Indicator lights ID: 14110
Whenever the lubrication pump is energised, at least one of the indicator lights, 1, 2, or P, is on.
Status Function
Light 1 is on Lubrication interval, line 1 was pressurised last
Lights 1 and P are on Pressurisation is in progress in line 1
Light 1 is flashing Pressure alarm in line 1
Light P is flashing Reservoir low level alarm
None of the lights are on The timer is turned off or there is a cable fault

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5.3. Settings for main functions ID: 14111
The SET button can be used for setting the lubrication interval, maximum pressurisation time, and
number of lines (always 1).
5.3.1. Setting the lubrication cycle ID: 14112
In normal mode, press the button for about 5 seconds, until light 1 starts flashing rapidly.
You are now in the lubrication interval setting mode.
Light P indicates the current length of the lubrication cycle. Light P flashes 1 to 10 times. Then there
is a pause of 2 seconds and light P again flashes 1 to 10 times. The current setting for the lubrication
cycle can be found in the following table.
Number of flashes Lubrication cycle (minutes)

1 5
2 10
3 15
4 20
5 30
6 45
7 60
8 80
9 100
10 120
The value proceeds from the shortest to the longest cycle, with incrementing performed by pressing
the SET button. When the longest value is reached, the rotation starts again from the shortest value.
To save the new setting and exit the setting mode, press the button for about 5 seconds, until all three
indicator lights are lit.
To exit the setting mode without saving the settings, switch off
NOTE!
the operating voltage of the lubrication system for a moment.

ID: 321 0 en 2009-02-16
5.3.2. Setting the maximum pressurisation time ID: 14113
When in normal operation mode, press the SET button for about 10 seconds, until light 2 starts
flashing rapidly.
You are now in the correct mode for setting the maximum pressurisation time. The number of flashes
of light P indicates the current maximum pressurisation time setting according to the following table.
Number of flashes Maximum pressurisation time (minutes)

1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
The pressurisation time value beings at the shortest value and is incremented by pressing the SET
button. When the longest value is reached, the rotation starts again from the shortest value.
To save the new setting and exit the setting mode, press the button for about 5 seconds, until all three
indicator lights are lit.
To exit this mode without saving the settings, switch off the op-
NOTE!
erating voltage of the lubrication system for a moment.
5.3.3. Selecting the lubrication system ID: 14114
When in normal operation mode, press the SET button for about 15 seconds, until lights 1 and 2 start
flashing rapidly.
You are now in lubrication system selection mode. A single- or dual-line lubrication system can be
selected. All Sandvik rigs feature the single-line system.
When the single-line system is selected, light P flashes once; if the dual-line system is selected, the
light flashes twice before a pause of 2 seconds. The system setting is changed with the SET button.
To save the new setting and exit lubrication system setting mode, press the button for about 5 sec-
onds, until all three indicator lights are lit.
To exit this mode without saving the settings, switch off the op-
NOTE!
erating voltage of the lubrication system for a moment.
5.3.4. General information on settings ID: 14115
In setting mode, if the button has not been pressed for 3 minutes, the system returns automatically
to normal mode and the new settings are not saved.

ID: 321 0 en 2009-02-16
6. USER INTERFACE (RIGS WITHOUT A CABIN) ID: 14116
The user interface consists of a display (1), line and pressurisation indicator lights (2), scroll buttons
(3), and setting/function button (SET) (4).
ID: 19788
6.1. Indicator lights ID: 14118
Indicator light Description

1 The green indicator light is lit when header line 1 is pressurising.
The green indicator light is lit intermittently when main line 1 is pressurised last.
The red indicator light flashes when the pressure alarm for header line 1 is on.
2 Not used in Sandvik rigs.
P The green indicator light is lit when pressurising is in progress.
The red indicator light flashes when the low level alarm for the pumping unit is
active.

ID: 321 0 en 2009-02-16
6.2. Buttons ID: 14119
Button Description
Normal mode: scrolling the displayed settings.
ID: 19789
Setting mode: changing the value displayed.
Normal mode: scrolling the line pressure displays.
Setting mode: moving to the next character displayed.
ID: 19790
When scrolling the settings: returning to normal mode.
SET Normal mode: starting an extra lubrication cycle, stopping the
pressurisation, or resetting the alarm.
Setting mode: saving the changes value.
When scrolling the settings: returning to setting mode
When a button is pressed, all green indicator lights are lit for a moment. This indicates that the signal
from the pressed button has been transmitted onwards.
6.3. Display ID: 14120
The user interface has a display of 3-character and 3 decimal points.

The display shows time and, during pressure sensor operation, also pressure.
6.3.1. Time display ID: 14121
The lubrication cycle setting and elapsed time within the interval are displayed in hours and minutes.
Hours and minutes are separated by a decimal point.
Time value to be displayed Display format Example

0 to 59 min H.MM 12 min = 0.12
1 h to 9 h 59 min H.MM 1 h 20 min = 1.20
10 h to 99 h 50 min HH.M 12 h 50 min = 12.5
100 to 999 h HHH. 120 h = 120 .
The maximum pressurisation time value and elapsed pressurisation time are displayed in seconds
without a decimal point.
6.4. Operation ID: 14122
In normal operation mode, the display switches to power save mode if no button is pressed within 3
minutes. In power save mode, only the decimal points flash on the display. Lubrication functions are
performed according to the values set. The display returns to normal mode if a button is pressed or
an alarm is activated.

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6.4.1. Interval time counter ID: 14123
In normal mode, the display shows the time elapsed, in hours and minutes, since the previous pres-
surisation. The green indicator light for line 1 or 2 indicates the line that was pressurised last.
Time elapsed in the cycle is always counted except when
• the system is in alarm mode or receives no power
• the interlock switch is closed
• the system is shut down (maximum pressurisation time = 0).
6.4.2. Pressurisation ID: 14124
The pressurisation time is displayed in seconds. The green indicator light for line 1 or 2 indicates the
line to be pressurised. Green indicator light P indicates that pressurisation is in progress.
The pressurisation can be stopped with the SET button.
6.4.3. Extra lubrication cycle ID: 14125
An extra lubrication cycle can be started if the system is not in alarm mode or shut down, or if pres-
surising is not in progress.
The extra lubrication cycle can be started from normal mode with the SET button when the display
is showing the time elapsed since the previous pressurisation.
In single-line systems, the line is pressurised once.
The extra lubrication can be stopped with the SET button.
In pressure sensor operation, the line pressure discharge is monitored. A new pressurisation is started
only when the pressure in the line has decreased below the set limit.
The stage code dC is displayed while the pressure is being discharged.
6.4.4. Stage codes in normal and alarm mode ID: 14126
In normal or alarm mode, a code corresponding to the programme stage is displayed.
Stage code Description

dC Waiting for the pressure to be discharged
( dis Charge)
Loc The interlock switch is closed
( Locked)
OFF The system has been shut down
AGr Lubricant reservoir low level alarm
( Alarm, Grease)
ALP Low pressure alarm
(the line pressure does not increase sufficiently during pressurisation)
( Alarm, Low Pressure)
AHP High pressure alarm
(the line pressure has not decreased sufficiently by the time pressurising starts)
( Alarm, High Pressure)

ID: 321 0 en 2009-02-16
6.4.5. Normal mode displays ID: 14127
The normal mode displays showing the lubrication programme settings can be scrolled with the
button.
The display codes change in the following order when the button is pressed.
Display code Description

Cou Lubrication cycle counter
(Cycle Counter)
C Lubrication cycle setting
(Lubrication Cycle)
P Maximum pressurisation time setting
(Lubrication, Pressurisation time)
PLo Low limit pressure setting
( Pressure, Low limit)
This code appears only in pressure sensor operation
PHi High limit pressure setting
( Pressure, High limit)
This code appears only in pressure sensor operation
A decimal point is used as the thousands separator in lubrication cycle counter readings. The highest
counter reading possible is 49.9 = 49999.
Depending on the basic lubrication system settings, the pressure unit used for the values displayed
is either bar or psi. A decimal point is used as the thousands separator in the readings displayed in
psi. For example, 1.02 = 1020 psi.
6.4.6. Line pressure displays ID: 14128
Pressure sensor operation

In pressure sensor operation, the line pressure display can be selected with the button. When
the button is pressed, the line pressure display is shown. The display shows alternately the code
P1 and the line pressure value. When the button is pressed again, the display returns to showing the
stage code.
If no signal is received from the pressure sensor, the display shows the code _ _ _ .
6.4.7. Power failure ID: 14129
The settings and programme status are backed up against loss of power. After a power failure, op-
eration continues from where it left off before the interruption. If pressurisation of a line is interrupted,
it will begin again. Time elapsed in the cycle is not counted during a power failure.

ID: 321 0 en 2009-02-16
6.4.8. Alarms ID: 14130
The system is in alarm mode if the red indicator light for line 1, line 2, or pressurisation ( P) is flashing.
Low level alarm
The system triggers the low level alarm, stops the pressurisation, and switches to alarm mode if the
lubricant reservoir is empty - i.e., the reservoir’s low level switch is closed. At this point, code AGr
flashes on the display and red pressurisation indicator light P flashes. The pressurisation starts again
for the same line when the low limit switch has opened and the alarm has been reset using the
SET button.
Pressure alarm
The system triggers the pressure alarm and switches to alarm mode if the line pressure has not
decreased sufficiently by the time pressurising starts, or if the line pressure has not increased suffi-
ciently during the pressurisation.
High pressure alarm
If the line pressure has not decreased sufficiently when pressurising starts, the code AHP flashes on
the display and the red indicator light for the line 1 causing the alarm flashes.
In the pressure sensor operation, the alarm is triggered if the line pressure is over the selected low
limit when the pressurisation starts. The pressurisation starts again for the same line when the pres-
sure has decreased below the low limit and the alarm has been reset using the SET button.
Low pressure alarm
If the line pressure does not increase sufficiently during the pressurising, the code ALP flashes on
the display and the red indicator light for the line 1 causing the alarm flashes.
In pressure sensor operation, the alarm is triggered if the line pressure does not reach the set limit
value within the set maximum pressurisation time. The pressurisation starts again for the same line
when the alarm has been reset using the SET button.
6.5. Settings ID: 14131
The set values - for example, lubrication cycle and maximum pressurisation time - are setpoint values
for the lubrication system.
All settings are password-protected.
6.5.1. Entering the password ID: 14132
1.
Press the button to display the code for the setting to be changed.
2. Press the SET button.
The display shows the code PPP
After a while, the first character on the display starts flashing.
3.
Use the button to select the first digit of the password to be entered.
4. Press the button to move to the next digit.
NOTE! The password for the settings is 103
5. After entering all three digits of the password, press the SET button.
If the correct password is entered, the code ACC is displayed and the settings can be changed for
the next 10 minutes.
If the password is not entered correctly, the code Err is displayed and the display returns to normal
mode.

ID: 321 0 en 2009-02-16
6.5.2. Entering the settings ID: 14133
1.
Press the button to display the code for the setting to be changed.
2. Press the SET button.
3. The first digit of the value to be set is flashing.
4.
Use the button to select the desired digit.
5. Press the button to move to the next digit.
6. Press the SET button to save the new setting.
7. Exit setting mode by pressing the button. If no button is pressed within 1 minute, the display
returns automatically to normal mode.
Lubrication cycle counter

If necessary, the lubrication cycle counter can be reset.
1.
Press the button to display the lubrication cycle counter code Cou.
2. Reset the counter by pressing the SET button.
Lubrication cycle
The lubrication cycle setting is displayed in hours and minutes. Hours and minutes are separated by
a decimal point. The decimal point in the value set can be moved as described below.
1.
Press the and buttons to choose the desired value.
2. Press the button.
3. The decimal point starts flashing.
4.
Move the decimal point to the desired location by pressing the button.
5. Press the SET button to save the new setting.

ID: 321 0 en 2009-02-16
7. RECOMMENDED LUBRICANTS ID: 14134
A lubricant is composed of basic oil, thickening agent and additives. The basic oil, forming the majority
of the composition of a lubricant, determines the properties of the lubricant. The basic oil together
with the thickening agent determines the rheological properties of the lubricant. (Rheology = a science
dealing with the deformation and flow of matter.) The viscosity of the basic oil is a temperature--
dependent magnitude that indicates the fluidness of liquid: the smaller the viscosity value, the more
fluid the basic oil is.
By choosing the correct lubricant and lubrication system settings, you can also prevent semi--fluid
lubricant from running out from the lubrication point. For Safematic HEAVY lubrication systems, we
recommend grade NLGI 0 - 2 lubricants in summer and grade NLGI 00 - 0 lubricants in winter.
When choosing a lubricant, you should pay attention to the viscosity of the basic oil and the high
quality of the lubricant in addition to the NLGI classification.
Operation temperature NLGI grade Example

Below 0 °C 00 Shell Grease Centra W
Mobil Chassis LBZ
Esso Fliessfett S 420 (EGL 3818)
Above 0 °C 0-2 Teboil Solid 0 (NLGI 0)
Shell Grease Central W1 (NLGI 1)
Esso Beacon EP 1 (NLGI 1)
Shell Retinax EP 2 (NLGI 2)
Shell Alvania EP 2 (NLGI 2)
As a general rule in temperatures below 0_CNLGI --grade 00 greases are recommended. In tem-
peratures above 0_C NLGI --grades up to 2 can be used.
Note that other properties of the grease can affect pumpability and system performance.
The following table gives some examples of recommended greases.
PUMPABILITY OF GREASES IN SAFEMATIC MULTILUBE SYSTEM
GREASE NLGI Basic oil *) Viscocisity Thickener **) Safemobe Max

of basic oil temperature operating
cSt/40ºC recommend temperature
ed range ***)
All Temp 0 M 270 Polyurea -20ºC - + 285°C
Grease +30ºC
X--1R
Amsoil GLC 2 S 130 Li--komp +5ºC - +70ºC + 180°C
Yleisrasva
Gargo 8000 00 M 100 Li--komp -20ºC - + 110°C
+30ºC
Esso 00 S 185 Li -25ºC - + 140°C
Fliessfett S +30ºC
420 (EGL
3818)
Esso Unirez 0 M 68 Li--komp -25ºC - + 110°C
EP 0 +30ºC
Esso Beacon 1 M 160 Li -15ºC - + 125°C
EP 1 +30ºC
Mobil HP 222 2 M 220 Li--komp 0ºC - +70ºC + 150°C

ID: 321 0 en 2009-02-16

ed range ***)
Mobilith SHC 00 S 460 Li--komp -15ºC - + 120°C
007 +30ºC
Mobilith 00 M 46 Li -30ºC -
Chassic LBZ +10ºC
Tribol 00 M 1000 Li -15ºC -
3020--1000-- +30ºC
00
Molyb--Alloy 1 M 68 Ka -20ºC -
6780 +30ºC
Molyb--Alloy 000 M 29 Li -25ºC -
MPG 000 +20ºC
Pro Long 0 M 180 Li -20ºC -
Marine+ +30ºC
Shell Alvania 00 M 180 Li -20ºC - + 100°C
Grease EO +30ºC
(LF)0
Shell Grease 00 M 115 Li--komp -20ºC - + 100°C
Centra W +30ºC
Shell Grease 1 M 115 Li--komp -10ºC -
Centra W1 +30ºC
Shell Retinex 00 M 187 Li--komp -25ºC -
Grease CS +30ºC
00
Shell Retinax 2 M 190 Li 0ºC - +70ºC + 120°C
EP2
Shell SRS 2 M 1150 Ka -5ºC - +70ºC + 110°C
4000
SKF LGG B2 2 S 110 Li--ka -10ºC - + 90°C
+70ºC
Sogelub MD 00 S 40 Li--Ka -30ºC - + 100°C
15 EP 00 +10ºC
TB Universal 00 M 115 Li--komp -20ºC - + 100°C
CLS +30ºC
TB Universal 0.5 M 135 Li--komp -10ºC - + 120°C
CLS 1 +30ºC
Teboil Solid 0 0 M 1140 Ka -20ºC - + 90°C
+30ºC
Teboil Solid 2 2 M 1140 Ka -10ºC-- + 120°C
+70ºC
Texaco 00 S 40 Ka--Li -30ºC- +10ºC + 130°C
Multifak 6833
EP 00

ID: 321 0 en 2009-02-16

ed range ***)
Neste Center 00 M 105 Li--komp -20ºC-- + 100°C
Grease 00 +30ºC
EP
Neste Mult-- 1 M 200 Li -15ºC--
purpose EP1 +70ºC
Neste Center 00 S 110 Li -30ºC--
Grease BIO +30ºC
00 EP
Kendall 00 M 45 Li -30ºC -20ºC
L--9999
*) basic oil M = mineral oil, S = synthetic oil

**) thickener Li = lithium, Li--komp = lithium--complexi, Ka = kalcium, Ka--Li = kalcium--lithium
***) Manufacturers’ figure

ID: 321 0 en 2009-02-16
8. PERIODIC CHECKS ID: 14135
Periodic monitoring of the system is required to ensure trouble-free operation.

Daily checks
• check the control unit for faultless operation
Monthly checks
• check the piping in locations where it is vulnerable to external damage
Yearly checks (more often if necessary)

• clean the filter of the filling connector
8.1. Checking the operation of dosers ID: 14136
Check the operation of the dosers approximately one month after system start-up and then at intervals
determined by the operating conditions, but not less often than every 6 months. Check for potential
excessive or insufficient lubrication and adjust the dosers when necessary.
8.1.1. Check procedures ID: 14137
1. Disconnect the lubrication pipes and hoses from the lubrication points.
2. Pressurise the line.
3. Check that the lubricant flows from the lubricant pipes and hoses.
4. Reconnect the lubrication pipes and hoses to the lubrication points.
If no lubricant flows from the lubrication pipes or hoses, see the section Troubleshooting.

ID: 321 0 en 2009-02-16
9. TROUBLESHOOTING ID: 14138
Description of the Cause of the malfunction Corrective measure

malfunction
Control unit is not working.

Button panel indicator lights are No voltage supply to the Check voltage supply.
not lit. pumping unit.
Control unit alarms.
The P indicator light on the Lubricant reservoir is empty. Fill the lubricant reservoir. Reset
button panel is flashing. the alarm.
The indicator light for line 1 or 2 Header piping is leaking. Locate and repair the leak.
on the button panel is flashing. Air trapped in the pumping unit Bleed the pumping unit or head-
or header piping. er piping. Reset the alarm.
Incorrect lubricant. See ’Recommended lubricants’.
Malfunction in the MultiLube
pumping unit.
A lubrication point is
receiving an insufficient
amount of lubricant or no
lubricant at all.
Doser is not working. The lubrication point is clogged. Clean the lubrication point.
Lubrication pipe or hose is clog- Clean or replace the lubrication
ged. pipe or hose.
The doser is damaged. Replace the doser.
Grease leakage in the area of Lubrication piping between the Check and repair the damaged
lubrication piping. doser and lubrication point is lubrication piping.
damaged.
A lubrication point is
receiving an excessive
amount of lubricant
Considerable grease leakage at The doser is damag ed. Replace the doser.
the lubrication point. The
temperature of the bearing
increases.

ID: 321 0 en 2009-02-16
10. BRAIDED HOSE SOCKETS - INSTALLATION ID: 14139
10.1. 8/4 screw-type socket for braided hose - installation ID: 14140
Installation tools (see the spare parts manual):

• Hose pliers 8/4
• Nylon pipe cutter
1. Cut the 8/4 braided hose with the cutter. Clamp the braided hose between the jaws of the hose
pliers, leaving about 16 mm of the hose visible.
ID: 19806
2. Screw on the sleeve anti-clockwise until it is at the level of the jaws. The hose end should be 1–
2 mm from the bottom of the sleeve.
ID: 19807

ID: 321 0 en 2009-02-16
3. Grip the sleeve with the pliers. Lubricate the cone and thread of the nipple with oil.
ID: 19808
4. Screw the nipple to the sleeve clockwise.
ID: 19809
5. Assembly completed.
ID: 19810

ID: 321 0 en 2009-02-16
10.2. 8/4 press-type socket for braided hose - installation ID: 14141
1. Push the pipe end inside the canvas hose.
ID: 19811
2. Push the sleeve through the pipe end on the canvas hose.
ID: 19812
3. Push the body of the press tool (part 1) on the hose against the sleeve (the outlet screw (part 2)
has to be loosened).
2 1
ID: 19813

ID: 321 0 en 2009-02-16
4. Tighten the nut (part 3). Ensure that the hose and the spindle remain against the sleeve end.
ID: 19814
The cone jaws have to be placed in a way the cone broadens

NOTE!
towards the sleeve.
5. Loosen the nut and remove it. Detach the body of the press tool from the cone jaws with the help
of the outlet screw; pull the jaws (part 4) and the body over the hose end. Before pressing you
may lubricate the cone jaws with oil. This makes the detaching easier.
ID: 19815

ID: 321 0 en 2009-02-16
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410 0 en 2009-05-13

1. COMPONENTS OF AIR CONDITIONING ............................................................................. 3

2. OPERATION OF AIR CONDITIONER ................................................................................... 6

3. COMPONENT FUNCTIONS .................................................................................................. 7

4. INSTRUCTIONS FOR USE ................................................................................................... 8

5. HOW TO MAKE THE MOST OF THE AIR CONDITIONER .................................................. 9

6. PERIODIC MAINTENANCE .................................................................................................. 10

7. ELECTRIC SYSTEM .............................................................................................................. 13

8. AIR CONDITIONER TROUBLESHOOTING ......................................................................... 14

Copyright © Sandvik Mining and Construction 1 (18)

1. COMPONENTS OF AIR CONDITIONING ID: 34032

Copyright © Sandvik Mining and Construction 3 (18)

1 Compressor • Pressurizes refrigerant and makes it circulate.

4 (18) Copyright © Sandvik Mining and Construction

9 Thermostat • Controls cabin temperature when air conditioning is on.

Copyright © Sandvik Mining and Construction 5 (18)

2. OPERATION OF AIR CONDITIONER ID: 34047

The compressor circulates refrigerant R134a in a closed circuit system.

6 (18) Copyright © Sandvik Mining and Construction

3. COMPONENT FUNCTIONS ID: 34035

1 Air conditioner control switch • locates on the main switch panel

Copyright © Sandvik Mining and Construction 7 (18)

4. INSTRUCTIONS FOR USE ID: 34036

Warm weather, normal humidity

Very warm weather, high humidity

Fall or early winter, high humidity, windows tend to get foggy

Cold winter weather

Very cold weather, low humidity

Open the air recirculation valve. Adjust cabin temperature as required.

8 (18) Copyright © Sandvik Mining and Construction

5. HOW TO MAKE THE MOST OF THE AIR CONDITIONER ID: 3224

Copyright © Sandvik Mining and Construction 9 (18)

6. PERIODIC MAINTENANCE ID: 34037

The system should be checked once a week.

1. Set the engine speed to 1500 rpm.

10 (18) Copyright © Sandvik Mining and Construction

6.1. Interpreting the Sight Glass ID: 34062

Sight Description Explanations and notes

6.2. Checks During Periodic Maintenance ID: 34042

Check the following points during periodic maintenance:

Copyright © Sandvik Mining and Construction 11 (18)

12 (18) Copyright © Sandvik Mining and Construction

7. ELECTRIC SYSTEM ID: 34045

Copyright © Sandvik Mining and Construction 13 (18)

8. AIR CONDITIONER TROUBLESHOOTING ID: 34046

Trouble Probable cause Procedure

Trouble Probable cause Procedure

Trouble Probable cause Procedure

14 (18) Copyright © Sandvik Mining and Construction

Trouble Probable cause Procedure

Trouble Probable cause Procedure

Abnormal pressure gauge readings

Trouble Probable cause

Copyright © Sandvik Mining and Construction 15 (18)

Trouble Probable cause

Suction pressure: 0,1 - 2,0 bar

16 (18) Copyright © Sandvik Mining and Construction

Copyright © Sandvik Mining and Construction 17 (18)

ROD GREASING DEVICE

2. FILLING OF PUMP UNIT CONTAINER ................................................................................ 5