Hydraulics DD321
Original instructions 550 8 en 2012-12-20 THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting
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Original instructions 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting
Table of Contents 1. GENERAL ...................................................................................................................................... 7 2. SAFETY ......................................................................................................................................... 8 3. CONTROLS OF THC 561 DRILLING SYSTEM ............................................................................ 9 4. HYDRAULIC DIAGRAM ................................................................................................................ 14 4.1.
Components ....................................................................................................................................................... 15
5. HYDRAULIC COMPONENTS ........................................................................................................ 20 5.1.
General ................................................................................................................................................................ 20
5.2.
Lay-out of the valve blocks ............................................................................................................................ 21
5.3.
Percussion and feed control block .............................................................................................................. 22
5.4.
Anti-jamming and return automatics control block ................................................................................ 25
5.5.
Rotation control block ..................................................................................................................................... 26
5.6.
Feed pressure control block ......................................................................................................................... 27
5.7.
Feed deviation control block ......................................................................................................................... 27
5.8.
Rotation speed adjusting block .................................................................................................................... 28
5.9.
Impulse cylinders control block ................................................................................................................... 29
5.10. Stabilizer control block (option) ................................................................................................................... 30 5.11. Drilling module movement prevention valve block ................................................................................. 31
6. HYDRAULIC SYSTEM ................................................................................................................... 32 6.1.
Filtering of hydraulic fluid .............................................................................................................................. 32
6.2.
Air filtering of hydraulic oil tank ................................................................................................................... 32
6.3.
Cooling of hydraulic system ......................................................................................................................... 32
7. OPERATION OF THE SYSTEM .................................................................................................... 33 7.1.
Oil temperature of drilling .............................................................................................................................. 33
7.2.
Reading diagrams ............................................................................................................................................ 33
7.2.1. 7.3.
Valves .............................................................................................................................................................. 33 Free circulation ................................................................................................................................................. 34
7.3.1.
Operation of the free circulation .................................................................................................................. 35
7.3.2.
Rotation circuit ................................................................................................................................................ 35
7.3.3.
Percussion and feed circuits ........................................................................................................................ 35
7.3.4.
Pilot circuit ....................................................................................................................................................... 35
7.4. 7.4.1. 7.5. 7.5.1. 7.6. 7.6.1. 7.7. 7.7.1. 7.8. 7.8.1.
Rotation ............................................................................................................................................................... 36 Operation of the rotation ............................................................................................................................... 37 Feed ...................................................................................................................................................................... 38 Operation of the feed .................................................................................................................................... 39 Percussion ......................................................................................................................................................... 40 Operation of the percussion ......................................................................................................................... 41 Collaring .............................................................................................................................................................. 42 Operation of the collaring ............................................................................................................................. 43 Drilling ................................................................................................................................................................. 44 Operation of the drilling ................................................................................................................................. 45 Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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7.8.2. 7.9.
Feed-percussion monitoring ........................................................................................................................ 45 Stabilizer (option) ............................................................................................................................................. 48
7.9.1.
Operation of the stabilizer ............................................................................................................................ 49
7.9.2.
Stabilizer adjustment curve .......................................................................................................................... 50
7.10. Power extractor (option) ................................................................................................................................. 52 7.10.1.
Operation of the power extractor ................................................................................................................. 53
7.11. Drilling module movement prevention ....................................................................................................... 54 7.11.1.
Operation of the drilling module movement prevention ........................................................................... 55
7.12. Anti-jamming automatics ............................................................................................................................... 56 7.12.1.
Operation of the anti-jamming automatics ................................................................................................. 57
7.13. Flushing flow control (option) ....................................................................................................................... 58 7.13.1.
Operation of the flushing flow control ......................................................................................................... 59
7.14. Air-mist flushing (option) ............................................................................................................................... 60 7.14.1.
Operation of the air-mist flushing ................................................................................................................ 61
7.15. Impulse cylinder controlled return automatics ........................................................................................ 62 7.15.1.
Operation of the impulse cylinder controlled return automatics ............................................................. 63
7.16. Proximity switch controlled return automatics (alternative) ................................................................ 64 7.16.1.
General ............................................................................................................................................................ 64
7.16.2.
Function ........................................................................................................................................................... 65
7.17. Return automatics with air blowing automatics ...................................................................................... 66 7.17.1.
Operation of the return automatics with air blowing automatics ............................................................ 67
7.18. Manual control of fast feed ............................................................................................................................ 68 7.18.1.
Operation of the manual control of fast feed ............................................................................................. 69
8. SPECIAL FUNCTIONS .................................................................................................................. 70 8.1. 8.1.1. 8.2. 8.2.1. 8.3. 8.3.1. 8.4. 8.4.1.
Threading ............................................................................................................................................................ 70 Operation of the threading ........................................................................................................................... 71 Rattling ................................................................................................................................................................ 72 Operation of the rattling ................................................................................................................................ 73 Separate flushing ............................................................................................................................................. 74 Operation of the separate flushing .............................................................................................................. 75 Using the diesel engine for running rock drill .......................................................................................... 76 Operation when using the diesel engine for running rock drill ............................................................... 77
9. ADJUSTMENTS OF HYDRAULIC COMPONENTS ...................................................................... 78 9.1. 9.1.1.
Adjustments of variable displacement pump (1) ..................................................................................... 78 Adjusting variable displacement pump (1) ................................................................................................. 79
9.2.
Adjusting system main pressure ................................................................................................................. 80
9.3.
Adjusting pilot control pressure .................................................................................................................. 82
9.4.
Adjusting the max. pressure of rotation circuit ....................................................................................... 83
9.5.
Adjusting of the spool stroke of the rotation directional valve ........................................................... 84
9.6.
Adjusting anti-jamming pressure ................................................................................................................. 86
9.7.
Adjusting anti-jamming pressure (alternative method) ......................................................................... 88
9.8.
Adjusting min. percussion pressure ........................................................................................................... 89
9.9.
Adjusting percussion half-power ................................................................................................................. 90
9.10. Adjusting percussion full-power .................................................................................................................. 91
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
9.11. Adjusting feed pressure ................................................................................................................................. 92 9.11.1.
Adjusting nominal level of feed pressure ................................................................................................... 93
9.12. Adjusting fast feed max. pressure ............................................................................................................... 94 9.13. Adjusting fast feed max. speed .................................................................................................................... 95 9.14. Adjusting rotation speed ................................................................................................................................ 96 9.15. Adjusting boom circuit max. pressure ....................................................................................................... 97 9.16. Adjusting one-way restrictor valve .............................................................................................................. 98 9.17. Bleeding of the impulse cylinder block ...................................................................................................... 98 9.17.1.
Adjusting the pressure switches (123, 125) .............................................................................................. 98
9.17.2.
Bleeding of the impulse cylinders (129, 130) ............................................................................................ 99
9.18. Bleeding of the pressure switches (12), (137), (138), (205) and (217) ................................................. 99 9.19. Adjusting percussion hour meter / SLU on/off pressure switch (12), rotation pressure switch (205) and pressure switch of air-mist flushing selecting (217) ............................................................ 99 9.20. Adjusting stabilizer max. pressure switch (137) ...................................................................................... 100 9.21. Adjusting stabilizer min. pressure switch (138) ....................................................................................... 100 9.22. Adjusting stabilizer max. pressure .............................................................................................................. 101 9.23. Adjusting stabilizer min. pressure ............................................................................................................... 102 9.24. Adjusting stabilizer reference pressure ..................................................................................................... 103 9.25. Adjusting power extractor pressure ........................................................................................................... 104
10. TROUBLESHOOTING ................................................................................................................... 105 10.1. General ................................................................................................................................................................ 105 10.2. Pumps (1) and (50) do not rotate at all, or their speed is not normal ................................................. 105 10.3. Variable displacement pump (1) rotates normally, but the regulator settings are not normal .................................................................................................................................................................. 106 10.3.1.
Flow regulator (A) value deviates from the set value 22-30 bar ............................................................ 107
10.3.2.
Pressure regulator (B) value deviates from the set value 230 bar ........................................................ 108
10.4. Percussion not working at all ....................................................................................................................... 109 10.5. Percussion is on always when the powerpack or the diesel engine is running ............................. 109 10.6. Percussion full-power max. pressure too high ........................................................................................ 110 10.7. Percussion full-power max. pressure too low .......................................................................................... 111 10.8. Percussion half-power pressure too high ................................................................................................. 112 10.9. Percussion half-power pressure too low ................................................................................................... 112 10.10. Feed not working at all (drilling) ................................................................................................................... 113 10.11. Drilling feed pressure too low ....................................................................................................................... 114 10.12. Drilling feed pressure too high ..................................................................................................................... 115 10.13. Manually controlled fast feed not working ................................................................................................ 116 10.14. Manually controlled fast feed too slow ....................................................................................................... 117 10.15. Manually controlled fast feed too fast ........................................................................................................ 117 10.16. Rotation pressure too low .............................................................................................................................. 118 10.17. Rotation pressure too high during drilling ................................................................................................ 118 10.18. Rotation speed regulation not working ...................................................................................................... 119 10.19. Return automatics fast feed not working ................................................................................................... 119 10.20. Drilling functions, fast feed and separate flushing do not start .......................................................... 120
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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10.21. Disturbance in shank lubrication ................................................................................................................. 120 10.21.1. Pinpointing the fault in the pneumatic circuit ............................................................................................. 120 10.22. Too low or high stabilizer pressure ............................................................................................................. 120 10.23. Electric system troubleshooting .................................................................................................................. 121 10.24. Main reference values (factory settings) for troubleshooting of hydraulics .................................... 122
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 1.
GENERAL
These instructions describe the testing and adjusting procedures, and the operating principle of the THC 561 drilling hydraulic system. To clarify the operating principle in different situations, flowcharts with colour codes accompany the explanations. Sandvik Service is always willing to give advice and help in any service problems.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 2.
SAFETY
WARNING SKIN INJECTION HAZARD! High-pressure hydraulic fluid can penetrate the skin, causing serious injury. Never 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!
BURN HAZARD! The oil circulating in the hydraulic systems is hot. It can cause severe burns to the skin. Let the oil cool down before starting any maintenance work. ENVIRONMENT POLLUTION HAZARD! Improperly disposing of waste can threaten the environment and ecology. Dispose of waste oil properly in accordance with local environmental regulations. Do not pour waste onto the ground, down a drain, or into any water source. Use leakproof containers when draining fluids. GENERAL WARNING! This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Carefully read all safety messages in this manual and on your machine safety signs. Follow recommended precautions and safe operating practices. Service and adjustment procedures must be carried out only by personnel with specialized operation and service training. Read and ensure that you understand the control panel adjusting instructions before making any adjustments on it.
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 3.
CONTROLS OF THC 561 DRILLING SYSTEM
2
1
3
B
B
D C
7
C A
A B
A B
B
10
11
12
A
17
A B
D
B
D
M
A
C
9
A A D
M
B B
8
6
A
A
A
5
4
B
B
D C
C
C
C
14 13
25
22
A
A
B
B
23
15
16
24 18
A
A
A
B
B
B
19
21
20
Figure: Cabin model
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting
30
30 4
28
1
A
A
B
B
D C
7
C A
A
A B
B
8 A
A B
D
C C
C
13
12
B
D C
14
11
B
D
B
D
B
B
17
A
A
10
A
A
C
9
M
M
B
29
27
6
3
2 26
5
A
A
B
B
15
16
A
A
A
21
25
22
23
B
24 18
B
19
B
20
Figure: Canopy model 1
Telescopic feed control switch (S80) (optional)
0) Locked to desired length 1) Length setting 2) Drilling end position setting 3) Locked to minimum length
2
Air-mist flushing potentiometer (R76) (optional)
Water flow adjustment in air-mist drilling
3
Joystick of Two Rod System (S702)
A) Push lever forwards to close clamping device. B) Push lever right to withdraw rod handler. C) Pull lever backwards to open clamping device. D) Push lever left to extend rod handler.
4
Flushing flow control selector switch (S79) (optional feature)
A) Water flushing flow control ON B) Flushing flow control OFF C) Air-mist flushing flow control ON
5
SLU oil flow / air pressure error / stabilizer pressure indicator light (H72)
Indicator light is on (continuous) if SLU oil flow / air pressure error occurs. Indicator light is on (flashing) if stabilizer pressure is too low or too high.
6
Emergency stop button (S77)
Stops all electric motors and the diesel engine.
7
Power extractor push button (S90) (optional)
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 8
Air-mist flushing selector switch (S75) (optional)
A) Air-mist flushing OFF B) Air-mist flushing ON
9
Rod retainer -control switch (S700)
A) Rod retainer close B) Rod retainer open
10
Power pack start/stop switch (S78)
A) Turn the switch into the START-position and release to start the power pack. B) Powerpack running C) Turn the switch into the 0-position to stop the power pack.
11
Return automatics switch with air M) Manual blowing (S74) * A) Automatic B) Forced return
12
Return automatics switch (S73) * M) Manual A) Automatic B) Forced return
13
Boom lift and swing lever
A) Boom lowering B) Boom swing right C) Boom lifting D) Boom swing left
14
Boom zoom and boom head rotation lever
A) Boom zoom out B) Boom head rotation clockwise C) Boom zoom in D) Boom head rotation counterclockwise
15
Feed tilt and swing lever
A) Feed tilt down B) Feed swing right C) Feed tilt up D) Feed swing left
16
Feed transfer and extra tilt lever
A) Feed transfer forwards B) Bolting cylinder in / actuator right C) Feed transfer backwards D) Bolting cylinder out / actuator left
17
Bolting percussion control lever (optional)
Pull lever backwards to control bolting percussion on.
18
Rotation control lever (S72)
A) Push lever forwards to rotating clockwise (thread opening). B) Pull lever backwards to rotating counterclockwise (drilling).
19
Percussion control lever (S70)
A) Push lever forwards for full percussion (used to rattling). B) Pull lever backwards to activate percussion in drilling.
20
Feed control lever (S71)
A) Push lever forwards to activate feed backwards. B) Pull lever backwards to activate feed forwards.
21
Rotation speed control knob
Turn clockwise to increase rotation speed. Turn counterclockwise to decrease rotation speed.
22
Flushing control lever
A) Push lever forwards to activate air flushing. B) Pull lever backwards to activate water flushing.
23
Fast feed control lever
A) Push lever forward to activate fast feed backwards. B) Pull lever backwards to activate fast feed forwards.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 24
Feed force regulating knob
A) Turn clockwise to increase feed and percussion pressure. B) Turn counterclockwise to decrease feed and percussion pressure.
25
Feed deviation knob
Restricted from nominal level ±20 bar. A) Turn clockwise to increase feed force, i.e. to decrease the pressure difference between percussion and feed. B) Turn counterclockwise to decrease feed force, i.e. to increase the pressure difference between percussion and feed.
26
Water pressure gauge
1-25 bar
27
Rotation pressure gauge
1-250 bar
28
Percussion pressure gauge
1-250 bar
29
Feed pressure gauge
1-250 bar
30
Stabilizer pressure gauge (for boom 1 and 2) (optional)
1-250 bar
* Function of the switches 11 (S74) and 12 (S73) • Basic situation when S73 is in use and S74 is off - S73 (position M) and S74 (position M) = Automatic return is not in use - S73 (position A) and S74 (position M) = Automatic return from the front limit and without returning delay - S73 (position B) and S74 (position M) = Forced return without air blowing and without retrurning delay • Basic situation in air blowing when S74 is in use and S73 is off - S74 (position A) and S73 (position M) = Automatic return from the front limit after the air blowing - S74 (position B) and S73 (position M) = Forced return after the air blowing • Situation when both of the switches S73 and S74 are in use - S73 (position A) and S74 (position A) = Automatic return from the front limit with the air blowing and without returning delay - S73 (position B) and S74 (position A) = Forced return with the air blowing and without returning delay - S73 (position A) and S74 (position B) = Forced return with the air blowing and without returning delay
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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125
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Copyright © Sandvik Mining and Construction
ID: 550 8 en 2012-12-20
202
120
118
130
126
119
127
124
129
200
135
121
110
122
123
139
113
S85 10 bar
131
315
204
205
56
115
55
65 53
57
61
58
52
54
62
111
14
206
207
208
31
224
34
225 35
36
100
223 37
38
39
209
138
137
103
102
140
220
218
33
24
145
141
25
144
142
143
101
217
23
28
22
26
44
216
32
29
30
211
13
20
117
2
3
112
9
116
1
212
213
214
16
5
7
221
11
8
215
15
4
222
18
50
21
12
6
43
10
42
146
210
4.
60
59
51
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting HYDRAULIC DIAGRAM
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 4.1.
Components
1
Variable displacement pump
Output for percussion, feed, boom hydraulics, and pilot control + stabilizer (optional)
2
Percussion line pressure compensator
Keeps percussion pressure constant, irrespective of variations in input pressure
3
Percussion main valve
Controls oil flow to rock drill, controlled by percussion selector valve (4)
4
Percussion selector valve
Opens and closes percussion main valve (3) according to pilot control valve (14)
5
Percussion pressure selector valve
Selects half or full power percussion
6
Percussion half-power pressure relief valve
Determines pressure level for percussion half power
7
Percussion max. pressure relief valve
Determines percussion max. pressure
8
Rattling on/off valve
Switches off feed-percussion monitoring
9
Orifice
Restricts oil flow in percussion LS line
10
Shuttle valve
Directs percussion, feed, or boom LS signal to variable displ. pump
11
Percussion pressure gauge
Indicates percussion line pressure
12
Pressure switch
Switches on percussion hour meter and controls SLU air line on/off valve
13
Percussion mechanism
14
Percussion pilot control valve
Turns percussion on for drilling and thread-loosening
15
Shuttle valve
Directs pressure from percussion pilot valve (14) to percussion selector valve (4)
16
Shuttle valve
Directs pressure from percussion pilot valve (14) or feed pilot valve (31) to percussion pressure selector valve (5)
18
Monitoring valve
Determines min. percussion pressure when drilling at full power and generates feed/percussion monitoring
20
Feed pressure regulating valve
Determines feed pressure for collaring and in full power drilling, affects not only feed pressure but also percussion pressure (feed/percussion monitoring)
21
Feed pressure gauge
Indicates feed pressure
22
Feed line pressure compensator
Keeps feed pressure constant, irrespective of input pressure variations
23
Feed directional valve
Directs oil flow to feed according to pilot valves (31) and (33)
24
Feed line B max. pressure relief valve
25
Feed line A max. pressure relief valve
26
Shuttle valve
28
Feed cylinder
Directs oil flow in LS line of feed directional valve
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 29
Feed LS line selector valve
Selects normal feed pressure or fast feed pressure according to pilot valves (31) and (33)
30
Fast feed max. pressure relief valve
Determines max. pressure for fast feed movement
31
Feed pilot control valve
Determines feed speed and direction, and sets percussion to full power for drilling
32
Selector valve for feed LS line return circuit
Selects correct return line automatically for forward/ reverse feed
33
Fast feed pilot control valve
Determines fast feed speed and direction
34
Anti-jamming valve
Controls feed direction in an anti-jamming situation
35
Shuttle valve
Directs pressure information of feed pilot valve (31) to percussion pressure selector valve (5) and to feed LS line selector valve (29)
36
Shuttle valve
Directs pressure information of feed pilot valve (31) or fast feed control valve (33) to feed directional valve (23) (forward feed)
37
Shuttle valve
Directs pressure information of feed pilot valve (31) or fast feed control valve (33) to feed directional valve (23) (reverse feed)
38
Shuttle valve
Directs pressure information of feed pilot valve (31), fast feed pilot valve (33), or return automatics selector valve (39) to feed directional valve (23)
39
Return automatics selector valve Controls feed directional valve (23) according to the value set by pilot pressure regulating valve (43)
42
Shuttle valve
Directs LS signal of feed or boom circuit to variable displ. pump
43
Pilot pressure regulating valve
Sets pilot circuit pressure
44
Directional valve
Directs oil flow into the tank or into the feed circuit
50
Gear pump
Output of oil flow to rotation circuit
51
Rotation pressure gauge
Indicates rotation pressure
52
Pressure compensator
53
Rotation directional valve
54
Rotation mechanism
55
Regulating valve
Controls oil flow of rotation valve into tank during stand-by situation and during rotation control. Determines max. main pressure relief value of rotation circuit according to rotation LS-pressure relief valve (65).
56
Flow regulator
LS-pressure relieving valve
57
Non-return valve
Prevents oil flow back to pump (50)
58
Rotation pilot control valve
Determines direction of rotation
59
Rotation speed regulating valve
Sets rotation speed to desired value
60
Shuttle valve
Directs pilot control pressure info to rot. speed regul. valve (59)
61
Orifice
Restricts oil flow to directional valve of rotation (53) and to rotation speed regulating valve (59)
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Controls oil flow to rotation motor (54)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 62
Orifice
Restricts oil flow to directional valve of rotation (53) and to rotation speed regulating valve (59)
65
Rotation LS-pressure relief valve Determines max. LS-line pressure of rotation circuit
100 Water control valve
Controls water flow to rock drill
101 Air control valve
Controls air flow to rock drill
102 Selector valve for separate flushing
Opens/closes water or air control valve
103 Shuttle valve
Activates either automatic or separate water flushing
110 Hydraulic oil tank 111 Hydraulic oil temperature gauge 112 Pressure filter
Filters oil coming from variable displacement pump (1)
113 Return oil filter
Filters return oil coming from drilling and carrier hydraulics
115 Collecting piece
For drilling and carrier hydraulics return flows
116 Non-return valve
Prevents oil flow back to variable displacement pump
117 Non-return valve
Prevents oil flow from drilling control circuit to carrier circuit
118 Pressure relief valve
Determines pressure level for rear limit impulse cylinder
119 Pressure relief valve
Determines pressure level for front limit impulse cylinder
120 Orifice
Stabilizes rear limit impulse cylinder pressure
121 Orifice
Stabilizes front limit impulse cylinder pressure
122 Air filter / hydraulic tank 123 Pressure switch
Monitors pressure of the front limit impulse cylinder
124 Non-return valve
Prevents return flow from front limit impulse cylinder
125 Pressure switch
Monitors pressure of the rear limit impulse cylinder
126 Non-return valve
Prevents return flow from rear limit impulse cylinder
127 Pressure regulator / relief valve
Limits supply pressure for front and rear limit impulse circuit
129 Front impulse cylinder 130 Rear impulse cylinder 131 Pressure switch
Monitors pressure difference over the return oil filter (113)
135 Collecting piece
For non-pressure circuit hydraulic return flows
137 Pressure switch (optional)
Monitors stabilizer maximum pressure (130 bar)
138 Pressure switch (optional)
Monitors stabilizer minimum pressure (15 bar)
139 Shuttle valve
Directs rotation pressure to control block of return automatics
140 Directional control valve (optional) Closes the stabilizer pressure line and releases stabilizer pressure to tank when rattling is on 141 Pressure reducing / relieving valve (optional)
Controls stabilizer pressure and determines maximum pressure level for stabilizer
142 Monitoring valve (optional)
Monitors feed pressure and controls the valve (141)
143 Orifice (optional)
Supplies oil flow to the pilot control circuit of valves (141) and (142)
144 Directional control valve (optional) Sets feed pressure monitoring for stabilizer off and sets minimum pressure to stabilizer in collaring Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 145 Pressure reducing valve (optional)
Sets fixed reference pressure to the monitoring valve (142)
146 Stabilizer pressure gauge (optional)
Indicates stabilizer pressure
200 Oil level indicator 202 Drain cock
Drain water content of oil
204 One-way restrictor
Stabilizes rotation pressure switch line
205 Pressure switch
Monitors rotation pressure and controls SLU air line on/off valve
206 Anti-jamming valve of flushing control (optional feature)
Controls anti-jamming valve (34) and directs LS signal to variable displ. pump (1)
207 Shuttle valve
Directs anti-jamming pressure information from rotation circuit or anti-jamming valve of flushing control (206) to anti-jamming valve (34)
208 Shuttle valve
Directs LS signal of anti-jamming valve of flushing control (206) or drilling/boom circuit to variable displacement pump (1)
209 Air blowing automatics on/off valve
Directs pilot pressure to air control valve (101) when using return automatics with air blowing automatics
210 Pressure reducing/reliefing valve Reduces maximum pressure for boom circuit of the boom circuit 211 Main pressure relief valve
Limits drilling and boom circuit maximum pressure
212 Power extractor pressure selecting valve (optional)
Selects power extractor pressure adjusting line
213 Power extractor pressure relief valve (optional)
Determines power extractor pressure level
214 Power extractor mechanism (optional) 215 Power extractor on/off valve (optional)
Controls the oil flow to power extractor
216 Feed deviation valve
Reduces or increases feed force regardless of percussion pressure
217 Pressure switch (optional)
Recognizes when flushing is switched on (when air-mist flushing is on)
218 Air-mist flushing selector valve
Prevents pilot pressure to open water control valve (100) when air-mist flushing is selected
220 Shuttle valve
Directs pressure information of selector valve of separate flushing (102) or air blowing automatics on/off valve (209) to air control valve (101)
221 Drilling module movement prevention valve (pilot-control valve line)
Cuts off the feed pressure from the pilot-control valves
222 Drilling module movement prevention valve (boom line)
Cuts off the boom pressure line
223 Fast feed forwards selector valve Enables feed/percussion monitoring with fast feed forwards when percussion is on
18 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 224 Shuttle valve
Directs pressure information of feed pilot valve (31) or fast feed forwards pilot valve (33) when percussion is on to percussion pressure selector valve (5), to feed LS line selector valve (29) and to directional valve (44)
225 Orifice
Restricts oil flow in LS line
315 Cooler
Oil cooler for drilling and carrier hydraulics return flows
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
19 (122)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.
HYDRAULIC COMPONENTS
5.1.
General
The return automatics system has been controlled by impulse cylinders. Before any maintenance or adjusting operations, identify the construction of the return automatics (see the picture).
20 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.2.
Lay-out of the valve blocks 1
3
7
6
5
3
2
8
9
4
7
6
4
10
10
1
Pressure switches (percussion, rotation, stabilizer [option])
2
Impulse cylinders control block
3
Rotation control block
4
Percussion and feed control block
5
Anti-jamming and return automatics control block
6
Stabilizer control block (option)
7
Double-flushing valves
8
Pressure-controlled non-return valve
9
Shuttle valve
10
Drilling module movement prevention valve block
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
21 (122)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.3.
Percussion and feed control block
213 25
6
7 23
16 43
10
9
15
210
2
No
Component
Tightening torque [Nm] (for the cap)
2
Percussion line pressure compensator
40
6
Percussion half-power pressure relief valve
33,9
7
Percussion max. pressure relief valve
33,9
9
Orifice
10
Shuttle valve
33,9
15
Shuttle valve
33,9
16
Shuttle valve
33,9
23
Feed directional valve
22
25
Max. pressure relief valve for feed line A
40
43
Pilot pressure regulating valve
33,9
210 Pressure reducing/reliefing valve of the boom 60 circuit 213 Power extractor pressure relief valve (option- 33,9 al)
22 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
Tightening torque [Nm] (for the coil)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting
5
18
3
29
215
212
24
42
4
8
30
211
No
Component
Tightening torque [Nm] (for the cap)
3
Percussion main valve
240
4
Percussion selector valve
33,9
5
Percussion pressure selector valve
33,9
8
Rattling on/off valve
33,9
18
Monitoring valve
33,9
24
Max. pressure relief valve for feed line B
40
29
Feed LS line selector valve
33,9
30
Fast feed max. pressure relief valve
33,9
42
Shuttle valve
33,9
211 Main pressure relief valve
Tightening torque [Nm] (for the coil)
33,9
212 Power extractor pressure selecting valve (op- 33,9 tional)
6,8
215 Power extractor on/off valve (optional)
8
56
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
23 (122)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting M6
P2 X7 M5 A1 M3
T4 X8
M4
PE 2 3
LS2
215 1
T3 M2 M2
X5 1
X4
213
2
2
1
1
2
30
211
2
2 3
1
2
8
LS1
10
M7
18
4
1
212
42 1
7 3
2
3
2
2 3 4
X9
1
54
1
1
6 1
A
2
1 4
2
3
1 3
29
2
24
43
4
LS
23
22
1
1
2
T
25
3
1
2
2
16 3
3
210
2 1
2
1
15
P
24 (122)
d
3
2
T
c
43
2
1
3
26
M1
X1
P1
9
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
X3
X2 M9 X6 M8
1
B
3
2
9
M10 P5
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.4.
Anti-jamming and return automatics control block
223
36
225
37
39
209
208 207
206
224 38 225 35
206
36
209
39
34
208 37
223
38
35
224
207
34
No
Component
Tightening torque [Nm] (for the cap)
Tightening torque [Nm] (for the coil)
34
Anti-jamming valve
8.9
35
Shuttle valve
33.9
36
Shuttle valve
33.9
37
Shuttle valve
33.9
38
Shuttle valve
33.9
39
Return automatics selector valve
33.9
6.8
206 Anti-jamming valve of flushing control
33.9
6.8
207 Shuttle valve
33.9
208 Shuttle valve
33.9
209 Hole blowing automatics on/off valve
33.9
223 Fast feed forwards selector valve
33.9
224 Shuttle valve
33.9
6.8
225 Orifice
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
25 (122)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.5.
Rotation control block
204 65
56
P
T
LS
52
M
55 LS2
53 57
A
57
204
B
65 55
15 bar
56
53
52
No
Component
Tightening torque [Nm] (for the cap)
52
Pressure compensator
70
53
Rotation directional valve
55
Regulating valve
100
56
Flow regulator
20
57
Non-return valve
15
65
LS-pressure relief valve
20
204 One-way restrictor
26 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.6.
Feed pressure control block
20
20
No
Component
Tightening torque [Nm] (for the cap)
20
Feed pressure regulating valve
33.9
5.7.
Feed deviation control block 216 44 216
32 44 32
No
Component
Tightening torque [Nm] (for the cap)
32
Return circuit selector valve for feed LS line
33.9
44
Directional valve
33.9
216 Feed deviation valve
33.9
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
27 (122)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.8.
Rotation speed adjusting block
59
59
60
60
No
Component
Tightening torque [Nm] (for the cap)
59
Rotation speed regulating valve
33.9
60
Shuttle valve
33.9
28 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.9.
Impulse cylinders control block
123
125 139
126
121
124 127 118 119
120 124
118 125
119 123
126 121
120
127
139
No
Component
Tightening torque [Nm] (for the cap)
118 Pressure relief valve (rear)
22
119 Pressure relief valve (front)
22
120 Orifice / impulse circuit (rear)
10
121 Orifice / impulse circuit (front)
10
123 Pressure switch (front) 124 Non-return valve (front)
20
125 Pressure switch (rear) 126 Non-return valve (rear)
20
127 Pressure regulator / relief valve
65
139 Shuttle valve
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
29 (122)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.10.
Stabilizer control block (option)
141 145
140 143 50 bar
141 142
140
142 143
No
145 144
30 bar
144
Component
Tightening torque [Nm] (for the cap)
140 Directional control valve
33,9
141 Pressure reducing / relieving valve
60
142 Monitoring valve
33,9
143 Orifice 144 Directional control valve
33,9
145 Pressure reducing valve
33,9
30 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5.11.
Drilling module movement prevention valve block
221
222
221
No
Component
222
Tightening torque [Nm] (for the cap)
Tightening torque [Nm] (for the coil)
221 Drilling module movement prevention valve (pilot-control valve line)
33.9
6.8
222 Drilling module movement prevention valve (boom line)
40.7
13.5
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
31 (122)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 6.
HYDRAULIC SYSTEM
6.1.
Filtering of hydraulic fluid
The system uses pressure and return filtering. Pressure filtering is used in the pump (1) circuit only, but return flow filtering is common to both pumps (1 and 50). Hose-mounted filter (112) with filtering capacity of 20 µm abs. is used for pressure filtering. If the pressure difference over the filter rises over 2.5 bar, the indicator light H611 on the indicator light panel goes on, indicating that the filter element should be replaced. The filtering unit body is also equipped with by-pass valve that opens if the pressure difference exceeds 3.5 bar. The return flow of both pumps passes through the return filter (113). The return filter is mounted on the tank. The filtering capacity of the return filter element is 10 µm abs. If the pressure difference over the filter rises higher than 2 bar, the indicator light H607 on the indicator light panel goes on, indicating that the filtering element should be replaced. The filtering unit body is also equipped with by-pass valve that opens if the pressure difference exceeds 2.4 bar. The manufacturer’s recommendation for the purity class of the system is 20/15/12 according to the ISO 4406 (c) -standard.
If the oil is cold (below +30 °C), both pressure and return oil filter monitoring are bypassed to avoid unnecessary alarms caused by the high viscosity of cold oil.
6.2.
Air filtering of hydraulic oil tank
The hydraulic oil tank is also equipped with an air filter. Its filtering capacity is 5 µm. This filter has no monitoring indicators but, to ensure the cleanness of hydraulic oil, it should be replaced according to the service instructions.
6.3.
Cooling of hydraulic system
The oil returning from the various actuators (except leakage oil) is gathered together in common return line using a collector tube (115). From the collector tube (115) the return oil is led through the cooler (315) and the return oil filter (113) into the hydraulic oil tank (110). The oil cooler (315) is always in operation when water flushing is on. The cooling capacity of the cooler can be increased by opening the ball valve (315.01) at the cooler. The hydraulic system is also equipped with monitoring system for the hydraulic oil temperature. The oil temperature in the tank is measured by sensor (111). This temperature sensor stops the powerpack if the temperature rises higher than +75 °C. At the same time, the signal light H610 in the warning light panel goes on.
32 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.
OPERATION OF THE SYSTEM
7.1.
Oil temperature of drilling
After cold start, hydraulic oil should be warmed up to drilling temperature before drilling is started. This can be accomplished, for instance, by using an electric oil heater in the tank. The recommended oil temperature of the drilling is between 40-60 °C (depending on the type of the oil).
7.2.
Reading diagrams
The following colors has been used in hydraulic diagrams for explaining different drilling operations. Blue
Red
percussion
Dash blue Short dash blue
percussion LSline
Dash red
feed return line
feed
Short dash red
Green
Yellow
Brown 7.2.1.
feed LS-line
Short dash pink
feed deviation LS-line
Dash green
rotation return line
rotation
Short dash green
rotation LS-line
Dash yellow
pilot return line
pilot control
Short dash yellow Violet
percussion return line
stabilizer return automatics
pilot line
Dash violet
stabilizer return line
Dash brown
return automatics return line
Valves
The number of the coil is colored red when the coil is activated.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
33 (122)
125
Figure: Free circulation
34 (122)
Copyright © Sandvik Mining and Construction
ID: 550 8 en 2012-12-20
202
120
118
130
126
119
127
124
129
200
135
121
110
122
123
139
113
S85 10 bar
131
315
204
205
56
115
55
65 53
57
61
58
52
54
62
111
14
206
207
208
31
224
34
225 35
36
100
223 37
38
39
209
138
137
103
102
140
220
33
24
145
141
25
144
142
143
101
23
28
22
26
44
216
32
29
30
211
13
20
117
2
3
1
116
112
9
16
5
7
221
11
8
15
4
222
18
50
21
12
6
43
10
42
146
210
7.3.
60
59
51
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Free circulation
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.3.1.
Operation of the free circulation
Free circulation means a situation where the powerpack is running, but no hydraulic actuators are used. 7.3.2.
Rotation circuit
The rotation pump (50) sucks the oil from the tank (110) and pumps it into the rotation circuit. The oil flow produced by the rotation pump (50) flows through the regulating valve (55) of the rotation control block, the oil collector (115), the cooler (315) and the return oil filter (113) into the tank (110). 7.3.3.
Percussion and feed circuits
The variable displacement pump (1) takes oil in from the tank (110), through the intake connection (S), and pumps it into the percussion and feed circuits. As there is no consumption of oil in these circuits during free circulation, it means that there is no pressure in the load sensing line, either. The swash plate of the pump (1) is at 0 angle and the pump (1) is merely maintaining a certain pressure (stand-by pressure) in the pressure line. The stand-by pressure is regulated by the flow controller of the pump (1). The pressure regulator / relief valve (43) regulates the pilot line pressure. 7.3.4.
Pilot circuit
The variable displacement pump (1) takes oil in through the intake connection of the tank (110) and pumps it into the pilot circuit via the pilot pressure regulating valve (43) which regulates the pilot line pressure. After the pilot pressure regulating valve (43) oil flows to the pilot control valves (14, 31, 33, 58 and 102) via the drilling module movement prevention valve (221). Oil flows also to the return automatics selector valve (39) and the air blowing on/off valve (209).
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
35 (122)
125
Figure: Rotation
36 (122)
Copyright © Sandvik Mining and Construction
ID: 550 8 en 2012-12-20
202
120
118
130
126
119
127
124
129
200
135
121
110
122
123
139
204
131
315
113
S85 10 bar
205
56
115
55
65 57
53
61
58
52
54
62
111
14
206
207
208
31
225
36
100
34
35
224
223 37
38
39
209
138
137
103
102
140
220
33
24
145
141
25
144
142
143
101
23
28
22
26
44
216
32
29
30
211
13
20
117
2
3
1
11
112
9
16
5
7
221
11
8
15
4
222
18
50
21
12
6
43
10
42
146
210
7.4.
60
59
51
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Rotation
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.4.1.
Operation of the rotation
When the control lever of the rotation pilot control valve (58) is locked into a back position (rotation to counterclockwise), pilot pressure will be able to affect the port a of the rotation directional valve (53) and to the port P1 of the rotation speed regulating valve (59). The oil produced by the rotation pump (50) flows now to the port P of the rotation control block. From there the oil flows through the rotation directional valve (53), pressure compensator (52), non-return valve (57), again through the rotation directional valve (53) to the rock drill rotation motor (54). The oil flows also from the port P to the regulating valve (55) and the rotation pressure gauge (51). Through the pressure compensator (52) the oil flows into the LS-line of the rotation directional valve (53). The oil flows also to the LS-pressure relief valve (65), to the flow regulator (56) and to the regulating valve (55). In this situation the regulating valve (55) is activated and it tries to keep the pressure in the main pressure line P always 15 bar higher than LS-line pressure (= load pressure) resulting a constant pressure difference over the rotation directional valve (53). This means also constant rotation oil flow to the rotation motor set by the regulating valve (59). LS-pressure also reaches the SLU on/off pressure switch (205) through one-way restriction valve (204) and rock drill's shank lubrication starts. The pressure difference between P-line and LS-line is made by the spring of the regulating valve (55). The function of the flow regulator (56) is to unload the LS-line after stopping the movement and centering the main spool. The flow regulator (56) is a small pressure compensated flow control valve with a flow approximately 1 l/min. The extra oil flow which is not needed in the rotation circuit is taken into the tank through the regulating valve (55). The return flow from the rotation motor (54) passes through the rotation directional valve (53), the collecting piece (115), the cooler (315), and the return oil filter (113) and ends up into the pressurized chamber of oil tank (110). The leak oil from the rotation pilot control valve (58) and rotation speed regulating valve (59) will be first directed to the collecting piece (135) and from there into unpressurized chamber of oil tank (110) Oil flows also from the connection M of the rotation control block through the shuttle valve (139) to the connection P of the control block of return automatics. From there oil flows through the pressure reducing and reliefing valve (127) and the check valve (124) to the pressure switch (123), to the pressure relief valve (119) and to the front impulse cylinder (129), through the check valve (126) to the pressure switch (125), to the pressure relief valve (118) and to the rear impulse cylinder (130). Oil flows also through the orifices (121) and (120) to the oil collector (135). From there oil flows into unpressurized chamber of oil tank (110). When using rock drill with stabilizer oil flows also from the connection (P2) of the drilling control block to the connection (P) of the stabilizer control block. From there oil flows to the pressure reducing valve (145) and the pressure reducing/reliefing valve (141). From here the oil continues to flow to the directional control valve (140) and the stabilizer of the rock drill. Oil also affects to the monitoring valve (142), the directional control valve (144), the pressure switches (137) and (138) and the pressure gauge (146).
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
37 (122)
125
Figure: Feed
38 (122)
Copyright © Sandvik Mining and Construction
ID: 550 8 en 2012-12-20
202
120
118
130
126
119
127
124
129
200
135
121
110
122
123
139
113
S85 10 bar
131
315
204
205
56
115
55
65 53
57
61
58
52
54
62
111
14
206
207
208
31
224
34
225 35
36
100
223 37
38
39
209
138
S126.2
137
103
102
140
220
33
24
145
141
25
144
142
143
101
23
28
22
26
44
216
32
29
30
211
13
20
117
2
3
1
116
112
9
16
5
7
221
11
8
15
4
222
18
50
21
12
6
43
10
42
146
210
7.5.
60
59
51
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Feed
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.5.1.
Operation of the feed
Feed pressure is determined by the valves (20 + 216) or the valve (25) depending on which one has a lower set value. The valve (216) can be adjusted from the THC-panel (approx. ±20 bar). Adjusting affects only to feed pressure regardless of percussion pressure. The valve (20) can also be adjusted from the THC-panel and it affects also to feed pressure but at the same time also to percussion pressure. When the control lever of the feed pilot control valve (31) is locked into a back position (feed forward), pilot control pressure will be able to affect to control line c of the feed directional valve (23) through the anti-jamming valve (34) and the shuttle valve (36). In addition, the pilot pressure affects to the feed LS line selector valve (29) through the shuttle valves (35) and (224), and to the percussion pressure selector valve (5) through the shuttle valve (16). The pilot pressure affects also to the directional valve (44) via shuttle valves (35) and (224). The oil produced by the variable displacement pump (1) flows through the non-return valve (116), the pressure filter (112) and the orifice (225) to the anti-jamming valve of flushing control (206) and the port P1 of control block of drilling . From here the oil continues to flow through the feed line pressure compensator (22) to the control spool of feed directional valve (23) and from there to the feed line A max. pressure relief valve (25) and through the connector A to the feed cylinder (28). From feed directional valve (23) oil flows also to the spring housing of the feed line pressure compensator (22) and through the shuttle valve (26) and the feed LS line selector valve (29) to the feed pressure regulating valve (20) and feed deviation valve (216). After the shuttle valve (26) the oil is able also to flow to the feed pressure gauge (21), the monitoring valve (18) and through the shuttle valves (42), (10) and (208) to the flow control valve of variable displacement pump (1). From connector P1 of control block of drilling the oil is able to flow to the pilot pressure regulating valve (43), the drilling module movement prevention valve (221) and from there to the rotation pilot control valve (58), the percussion pilot control valve (14), the feed pilot control valve (31), the selector valve for separate flushing (102), the fast feed pilot control valve (33) the return automatics selector valve (39) and the hole blowing automatics on/off valve (209). Oil from the feed cylinder (28) flows to the connection B of feed directional valve (23) and from there to feed line B max. pressure relief valve (24). From here oil flows through the tank connector T3 of control block of drilling to the collecting piece (115), via the oil cooler (315) to the return oil filter (113) and the oil tank (110). The leak oil from the feed pilot control valve (31) is first directed to the collecting piece (135) and from there to the hydraulic oil tank (110). When using rock drill with stabilizer oil flows also from the connection (P2) of the drilling control block to the connection (P) of the stabilizer control block. From there oil flows to the pressure reducing valve (145) and the pressure reducing/reliefing valve (141). From here the oil continues to flow to the directional control valve (140) and the stabilizer of the rock drill. Oil also affects to the monitoring valve (142), the directional control valve (144), the pressure switches (137) and (138) and the pressure gauge (146).
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
39 (122)
125
Figure: Percussion half-power
40 (122)
Copyright © Sandvik Mining and Construction
ID: 550 8 en 2012-12-20
202
120
118
130
126
119
127
124
129
200
135
121
110
122
123
139
113
S85 10 bar
131
315
204
205
56
115
55
65 53
57
61
58
52
54
62
111
14
206
207
208
31
224
34
225 35
36
100
223 37
38
39
209
138
137
103
102
140
220
33
24
145
141
25
144
142
143
101
23
28
22
26
44
216
32
29
30
211
13
20
117
2
3
1
116
112
9
16
5
7
221
11
8
15
4
222
18
50
21
12
6
43
10
42
146
210
7.6.
60
59
51
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Percussion
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.6.1.
Operation of the percussion
When the percussion pilot control valve (14) is locked into the back position, pilot control pressure affects the fast feed forwards selector valve (223) and also the water control valve (100) through the shuttle valve (103), and turns water flushing on. Pilot control pressure also activates the pressure switch (12) of the operating hour meter and SLU on/off (rock drill's shank lubrication starts), and affects the percussion selector valve (4) through the shuttle valve (15). The percussion selector valve (4) opens the percussion main valve (3), and the output of the variable displacement pump flows through the non-return valve (116), the pressure filter (112), the compensator (2), and the percussion main valve (3) to the percussion mechanism (13). In addition, the percussion circuit pressure reaches the pressure relief valve (6) for half-power percussion, passing through the orifice (9) and the percussion pressure selector valve (5). After the orifice (9), the pressure also affects the pressure compensator (2), the percussion max. pressure relief valve (7), the rattling on/off valve (8), the monitoring valve (18), and reaches the load-sensing line of the variable displacement pump (1) through the the shuttle valves (10) and (208). The pressure also affects to the main pressure relief valve (211) and the pressure reducing/reliefing valve of the boom circuit (210). The pressure after the percussion main valve (3) also affects the percussion pressure gauge (11). The pressure after the pressure filter (12) also affects the anti-jamming valve of flushing (206) via the orifice (225). The return flow from the rock drill (13) passes via the collecting piece (115), the cooler (315), and the return oil filter (113) to the hydraulic oil tank (110). Leak oil from the percussion pilot control valve (14) is directed first to the collecting piece (135) and from there to the hydraulic oil tank (110). When using rock drill with stabilizer oil flows also from the connection (P2) of the drilling control block to the connection (P) of the stabilizer control block. From there oil flows to the pressure reducing valve (145) and the pressure reducing/reliefing valve (141). From here the oil continues to flow to the directional control valve (140) and the stabilizer of the rock drill. Oil also affects to the monitoring valve (142), the directional control valve (144), the pressure switches (137) and (138) and the pressure gauge (146).
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
41 (122)
125
Figure: Collaring
42 (122)
Copyright © Sandvik Mining and Construction
ID: 550 8 en 2012-12-20
202
120
118
130
126
119
127
124
129
200
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Collaring
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.7.1.
Operation of the collaring
Collaring is composition of rotation, feed and percussion. With the THC 561 system, collaring can be done accurately and smoothly by using the stepless feed and rotation speed, and feed pressure adjustments. In collaring, feed and percussion are connected in parallel. The control lever of feed pilot control valve (31) is used for selecting collaring and full-power drilling. The lever offers two operating ranges: half-power and full-power drilling. On the lever movement, these two ranges are separated from one another by a noticeable step. Full-power drilling starts when this step is passed. Drilling is started by locking the levers of the pilot control valves for rotation (58) and percussion (14) into the back position.When the lever for the feed pilot control valve (31) is pulled backwards, the rock drill moves at the desired speed until the drill bit has sufficiently penetrated the rock. Full-power drilling is started by locking the control lever of the feed pilot control valve (31) into the back position. Another method for collaring is to turn the feed pressure regulating valve (20) fully open (counterclockwise) and then lock all three control levers (rotation, percussion and feed) into the back position. Drilling starts now with half power, and continues so until the drilling values are returned to correspond to full-power drilling by turning the feed pressure regulating valve (20). When using rock drill with stabilizer oil flows also from the connection (P2) of the drilling control block to the connection (P) of the stabilizer control block. From there oil flows to the pressure reducing valve (145) and the pressure reducing/reliefing valve (141). From here the oil continues to flow to the directional control valve (140) and the stabilizer of the rock drill. Oil also affects to the monitoring valve (142), the directional control valve (144), the pressure switches (137) and (138) and the pressure gauge (146). The directional control valve (144) is active during collaring, so the stabilizer pressure does not follow the feed pressure (stabilizer pressure is minimum).
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Figure: Drilling
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Drilling
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.8.1.
Operation of the drilling
After successful collaring, full-power drilling is started by locking the control lever of the feed pilot control valve (31) into the back position. The percussion pressure selector valve (5) changes its position and closes a connection through the percussion half-power pressure relief valve (6). In percussion LS-circuit oil flows furthermore through the rattling on/off valve (8) and the monitoring valve (18). Feed pressure and feed deviation pressure are directed to monitoring valve (18), which then controls percussion pressure as a function of these pressures. The pressure difference between feed and percussion is determined by feed deviation valve (216) and the monitoring valve (18). The min. pressure of percussion is determined by spring force of the monitoring valve (18). The max. pressure of percussion is determined by the percussion max. pressure relief valve (7). When using rock drill with stabilizer oil flows also from the connection (P2) of the drilling control block to the connection (P) of the stabilizer control block. From there oil flows to the pressure reducing valve (145) and the pressure reducing/reliefing valve (141). From here the oil continues to flow to the directional control valve (140) and the stabilizer of the rock drill. Oil also affects to the monitoring valve (142), the directional control valve (144), the pressure switches (137) and (138) and the pressure gauge (146). 7.8.2.
Feed-percussion monitoring
Basic principle of feed-percussion monitoring is that the percussion pressure is adjusted as a function of feed pressure. With the help of the feed deviation it is also possible to: • • • • •
compensate frictions of the feed beam compensate the mass of the drilling equipment in uphole and downhole drilling compensate the feed force suitable for different feed models change the feed force suitable for different rock drill models react to feed-percussion monitoring ratio in different rock conditions
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting
PERCUSSION PRESSURE
Function of feed-percussion monitoring
Max. percussion pressure Adjustment of feed deviation knob (216)
Adj. percussion pressure
Feed force adjusting • feed pressure changes • percussion pressure changes
Adjustment of feed force regulating knob (20)
Min. percussion pressure
Feed pressure value in which feed-percussion monitoring starts
Dynamic region
Static region
Adj. feed pressure
Feed deviation
Max. feed pressure
FEED PRESSURE
Figure: Percussion pressure behaviour as a function of feed pressure Feed pressure varies during drilling depending on the rock conditions (soft/hard rock, fragmented rock, cavity). During drilling feed max. pressure is restricted with the feed force regulating knob (20). Feed pressure rises for that value at the maximum. Percussion pressure follows actual feed pressure with a certain ratio (determined by the monitoring valve). Operator determines the starting moment of the feed-percussion monitoring with the feed deviation knob (216). By increasing the feed deviation i.e. turning the knob clockwise feed force increases without changes in percussion pressure. By decreasing the feed deviation i.e. turning the knob counterclockwise feed force decreases without changes in percussion pressure. With the feed deviation knob (216) it is possible to adjust app. ±20 bar of feed pressure from the nominal level.
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting
P max.
percussion Adjusting feed deviation pressure, percussion pressure constant
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Adjusting range of feed-percussion monitoring
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Full-power drilling
Figure: Drilling behaviour Factory settings of feed and percussion pressures Factory settings for percussion and feed pressure relation is following (max. percussion pressure may vary): RD525 rock drill • Percussion 210 bar • Feed - TF500 125 bar - TFX500 140 bar • TFX500 upper cylinder back pressure approx. 30 bar RD520/HLX5 rock drill • Percussion 210 bar • Feed - TF500 115 bar - TFX500 130 bar • TFX500 upper cylinder back pressure approx. 30 bar To the required feed force affect: • rock drill model • rock conditions To the required feed pressure affect: • feed model (TF/TFX) • frictions of feed beam • mass of the drilling equipment, uphole/downhole
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Figure: Stabilizer
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Stabilizer (option)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.9.1.
Operation of the stabilizer
Stabilizer control block function is to adjust the stabilizer pressure as a function of feed pressure to the specific max. limit during drilling. During half-power drilling and collaring stabilizer pressure remains in the minimum. During rattling there is no pressure in the stabilizer and stabilizer line has been connected to the tank. During drilling percussion pressure must be at least 20 bar higher than stabilizer pressure. Operation during full-power drilling When drilling is started oil flows from the variable displacement pump (1) through the non-return valve (116) and the pressure filter (112) to the port P1 of the percussion and feed control block. From here the oil continues to flow to the connection P of the stabilizer control block via the port P2 of the percussion and feed control block. From there oil flows to the pressure reducing valve (145) and the pressure reducing/reliefing valve (141). Pressure reducing/reliefing valve (141) adjusts the stabilizer pressure and also limits maximum stabilizer pressure. From here the oil continues to flow to the directional control valve (140), to the pressure switches (137) and (138), to the stabilizer pressure gauge (146)and the stabilizer of the rock drill. Oil flows also to orifice (143) which supplies oil to pilot circuit. Depending on relation between stabilizer and percussion pressure, oil flow direction can also be reverse. Oil then flows from the stabilizer of the rock drill to the directional control valve (140) to the pressure reducing/relieving valve (141) and continues to the oil collector (115), the oil cooler (315) and the return oil filter (113) into the hydraulic tank (110). Feed pressure affects to the monitoring valve (142) via the directional control valve (144). The monitoring valve (142) adjusts pilot pressure and according to that pressure reducing/reliefing valve (141) adjusts stabilizer pressure. Pressure reducing valve (145) sets a constant pressure, so called reference pressure, to the monitoring valve (142). When the feed pressure is lower than adjustment of pressure reducing valve (145) (e.g. 50 bar), monitoring valve (142) does not control the pressure reducing/reliefing valve (141) and stabilizer pressure stays at minimum level. This feature can be used for example to compensate the mass of the drilling equipment and the frictions of the feed beam. Operation during half-power drilling and collaring During half-power drilling and collaring the directional control valve (144) is activated via port X8. Feed pressure is not affecting to the monitoring valve (142) and stabilizer pressure stays at minimum level. Minimum stabilizer pressure is set with spring force of monitoring valve (142). Operation during rattling During rattling the directional control valve (140) is activated via port X7. There is no pressure in the stabilizer and the oil flows from the stabilizer via the oil collector (115), the oil cooler (315) and the return oil filter (113) into the hydraulic oil tank (110).
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150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0
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Stabilizer adjustment curve
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting
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Figure: Power extractor
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Power extractor (option)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.10.1. Operation of the power extractor When using the power extractor, rattling must be switched on by pushing the percussion pilot control valve (14) in the front position. When the power extractor is switched on by pushing the button (S90) on the control panel, power extractor pressure selecting valve (212) and power extractor on/off valve (215) are activated. Oil flows to the power extractor mechanism (214) through the percussion line pressure comepensator (2), percussion main valve (3) and power extractor on/off valve (215). Oil flows also through the orifice (9) and power extractor pressure selecting valve (212) to the power extractor pressure relief valve (213). This valve (213) determines the power extractor pressure level. Oil flows also to percussion mechanism (13). When using the power extractor, pressure level for the percussion and the power extractor is the same. The return oil from the power extractor mechanism flows through the collecting piece (115) and cooler (315) to the tank (110).
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Figure: Drilling module movement prevention
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Drilling module movement prevention
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.11.1. Operation of the drilling module movement prevention The drilling module movement prevention valves (221) and (222) are activated always when the diesel engine or powerpack is on. At this situation oil flows through these valves (221) and (222) to the pilot control valves and the boom valves. When the drilling module movement is prevented, valves (221) and (222) change position preventing the oil flow to the pilot control and boom valves. Oil from the pilot control and boom valves then flows to the tank (110) through the drilling module movement prevention valves (221) and (222), and the collecting piece (135).
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Figure: Anti-jamming automatics
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Anti-jamming automatics
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.12.1. Operation of the anti-jamming automatics The anti-jamming system operates in a situation where the rotation pressure of the drill rod rises above a set value due to, for instance, a fissure in the rock. In this situation, the operation of the hydraulic system differs from normal as follows: When rotation pressure rises above the value set with the anti-jamming valve (34), the valve (34) changes its position. The pilot control pressure now reaches the port d of the feed directional valve (23) through the shuttle valves (37) and (38). This means that the feed directional valve (23) also changes its position, and feed pressure enters the feed line B, and feed starts pulling backwards. Feed pressure also reaches the load-sensing line of the variable displacement pump (1) through the LS channel of the feed directional valve (23) and the shuttle valves (26), (42), and (10). After the shuttle valve (26), the pressure in the feed LS line also reaches the pressure gauge (21). As feed backwards is on, the reversing pressure affects the tank line T1 of the feed deviation control block. In this situation, the feed pressure regulating valve (20) does not determine the max. reversing pressure but it is determined by the max. pressure regulating valve (24) of the feed line B of the feed directional valve (23). During the reversing phase, the rock drill (13) operates with full-power percussion. The percussion pressure is restricted by the percussion max. pressure relief valve (7). Feed reversing stays on until rotation pressure drops below the value set with the anti-jamming valve (34). After this, the anti-jamming valve (34) changes its position and the control pressure from the pilot control valve (31) reaches the control line c of the feed directional valve (23) through the shuttle valve (36). The feed directional valve (23) changes its position and feed pressure reaches the feed line A, whereby feed starts forwards. Feed and percussion pressures are lower than normal, which is caused by the lower feed resistance and the feed/percussion monitoring. Monitoring valve (18) doesn’t allow the percussion pressure go under the setting value. The feed and percussion pressures return to their normal set values as the feed resistance rises normal. The return flow from the rock drill rotation motor (54) passes through the rotation directional valve (53), the collecting piece (115), the cooler (315), and the return oil filter (113), and ends up into the hydraulic oil tank (110). The return flow from the percussion mechanism (13) passes through the collecting piece (115), the cooler (315), and the return oil filter (113), ending up into the hydraulic oil tank (110). The return flow from the feed cylinder (28) passes through the feed directional valve (23), the collecting piece (115), the cooler (315), and the return oil filter (113), and ends up into the hydraulic oil tank (110). The return flow from the control block of return automatics passes through the collecting piece (135) and ends up into the hydraulic oil tank (110). The leak oil of the pilot control valves (14), (31) and (58) is directed first to the collecting piece (135) and from there to the hydraulic oil tank (110). When using rock drill with stabilizer oil flows also from the connection (P2) of the drilling control block to the connection (P) of the stabilizer control block. From there oil flows to the pressure reducing valve (145) and the pressure reducing/reliefing valve (141). From here the oil continues to flow to the directional control valve (140) and the stabilizer of the rock drill. Oil also affects to the monitoring valve (142), the directional control valve (144), the pressure switches (137) and (138) and the pressure gauge (146).
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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Figure: Flushing flow control
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Flushing flow control (option)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.13.1. Operation of the flushing flow control Flushing flow control is an optional function. When this function is required, the rig will be supplied with a water or air flow switch in the flushing circuit. Each boom has its own separate water or air flow switch. When the water or air flow in the flushing circuit drops below the set value of the flow switch (for example, due to lack of water or blocked drill bit), the anti-jamming valve of flushing control (206) is activated. Now oil flows through the anti-jamming valve of flushing control (206) and shuttle valve (207) and gives a pilot control pressure to an anti-jamming valve (34) which changes its position. The feed pilot control pressure now reaches the port d of the feed directional valve (23) through the shuttle valves (37) and (38). This means that the feed directional valve (23) also changes its position, and feed pressure enters the feed line B, and feed starts pulling backwards until the water or air flow is normal. Oil flows also to the LS-line of the variable displacement pump (1).
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Figure: Air-mist flushing
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Air-mist flushing (option)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.14.1. Operation of the air-mist flushing When drilling with water flushing, pilot pressure reaches the water control valve (100) via the air-mist flushing selector valve (218) when percussion or separate flushing is switched on. When drilling with air-mist flushing, air-mist flushing must be switched on with the switch (S75) on the THC-panel. When air-mist flushing is activated, the air-mist flushing selector valve (218) is activated, whereby the pilot pressure can't reach the water control valve (100). In this situation the pressure switch (217) reacts and recognizes that air-mist flushing has to be started. The pressure switch (217) controls (via the relays) the electrically controlled air-mist valve which lets the small amount of water to mix into air. At the same time the pressure switch (217) also activates the coil Y454 of the air blowing automatics on/off valve (209), whereby the control pressure flows to the air control valve (101) and air line opens. When the percussion is on, the percussion selector valve (4) also opens the percussion main valve (3), and the output of the variable displacement pump flows through the non-return valve (116), the pressure filter (112), the compensator (2), and the percussion main valve (3) to the percussion mechanism (13).
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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Figure: Return automatics
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Impulse cylinder controlled return automatics
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.15.1. Operation of the impulse cylinder controlled return automatics When return automatics is on and the rock drill reaches the front limit, starts the return moveK70 ment, with rotation turned on. As the rock drill reaches the rear limit, fast feed is switched off and relay K70 is delaying by 0.2 sec and during this time the rotation of drill rod stops. If the return automatics is desired to use without rotation, the control diode V19 in the JB 102 -box must be reV19 moved.
Return automatics can also be used as an auxiliary function. In this case, the selector switch S73 for return automatics must be turned to the right and then back, whereby the rock drill starts return movement with rotation. When the rock drill reaches the front impulse cylinder (129), the pressure switch (123/S80) is activated, whereby percussion and feed control valves (14) and (31) are centralized (the rotation pilot control valve (58) remains on). After that the control pressure in the said control lines disappears, and the percussion selector valve (4) changes its position and closes the percussion main valve (3). Control pressure is also removed from the water control valve (100), and water flushing is shuts off. The pressure switch (123/S80) activates the coil Y47 of the return automatics selector valve (39), whereby the pilot control pressure is able to reach the control line d of the feed directional valve (23) through the return automatics selector valve (39) and the shuttle valve (38). In this situation, the feed directional valve (23) immediately changes its position, and fast feed is switched on. Feed pressure also reaches the load sensing line of the variable displacement pump (1) through the shuttle valve (26), (42), and (10), and after the shuttle valve (26), also the feed pressure gauge (21). Fast feed backwards is on until the rear impulse cylinder (130) is activated the limit switch (125/S81) . At the same time, the rotation pilot control valve (58) is centralized, and rotation is turned off, also fast feed to backwards stops. The return flow from the rock drill rotation motor (54) passes through the rotation directional valve (53), the collecting piece (115), the cooler (315), and the return oil filter (113), into the hydraulic oil tank (110). The return flow from the feed cylinder (28) passes through the feed directional valve (23), the collecting piece (115), the cooler (315), and the return oil filter (113), into the hydraulic oil tank (110). The return flow from the control block of return automatics passes through the collecting piece (135) and ends up into hydraulic oil tank (110). The leak oil of the pilot control valves (14), (31) and (58) is directed first to the collecting piece (135) and from there to the hydraulic oil tank (110).
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting The function of the return automatics
7.16.
Proximity switch controlled return automatics (alternative)
7.16.1. General The function principle of the proximity switch controlled return automatics is the same as in the impulse cylinder controlled return automatics. The main differences are as follows: • Impulse cylinders are replaced with proximity switches • Return automatics control block is removed from the control system • Main functions (percussion, feed, rotation) are controlled directly via proximity switches
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.16.2. Function When the rock drill reaches the front limit proximity switch (S80), the percussion and feed control valves (14) and (31) are centralized (the rotation pilot control valve (58) remains on). After that the control pressure in the aforementioned control lines disappears and the percussion selector valve (4) changes its position and closes the percussion main valve (3). Control pressure is also removed from the water control valve (100) and air control valve (101), and air mist flushing is shutting off. The front limit proximity switch (S80) activates the coil Y47 of the return automatics selector valve (39) whereby the pilot control pressure regulated by the pilot control pressure regulating valve (43) is able to reach the control line d of the feed directional valve (23) through the return automatics selector valve (39) and the shuttle valve (38). In the same time the control pressure after the valve (39) is able to reach the shuttle valve (134) and the air valve (101). In this situation the feed directional valve (23) immediately changes its position and fast feed is switched on and air flushing is turned on. Feed pressure also reaches the load sensing line of the variable displacement pump (1) through the shuttle valves (26), (42) and (10), and after the shuttle valve (26) also the feed pressure gauge (21). Fast feed backwards is on until the rear limit proximity switch (S81) is activated.At the same time the rotation pilot control valve (58) is centralized and rotation is turned off. Also fast feed backwards stops. The return flow from the rock drill rotation motor (54) passes through rotation directional valve (53), the collecting piece (115), the cooler (114) and the return oil filter (113) into the hydraulic oil tank (110). The return flow from the feed cylinder (28) passes through the feed directional valve (23), the collecting piece (115), the cooler (114) and the return oil filter (113) into the hydraulic oil tank (110). The leak oil of the pilot control valves (14), (31) and (58) is directed into the hydraulic oil tank (110).
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Figure: Return automatics with air blowing automatics
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Return automatics with air blowing automatics
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.17.1. Operation of the return automatics with air blowing automatics Return automatics can also be used with an air blowing. In this case return automatics with air blowing must be selected with the swich S74 on the THC-panel, whereby air is blowed to the hole for 6 seconds before the rock drill starts return movement with rotation. When the rock drill reaches the front impulse cylinder (129), the pressure switch (123/S80) is activated,whereby percussion and feed control valves (14) and (31) are centralized (the rotation pilot control valve (58) remains on). After that the control pressure in the said control lines disappears, and the percussion selector valve (4) changes its position and closes the percussion main valve (3). Control pressure is also removed from the water control valve (100), and water flushing is shuts off. The pressure switch (123/S80) activates the coil Y454 of the air blowing automatics on/off valve (209), whereby the control pressure flows to the air control valve (101). After the air blowing the coil Y454 deactivates and the coil Y47 of the return automatics selector valve (39) activates, whereby the pilot control pressure is able to reach the control line d of the feed directional valve (23) through the return automatics selector valve (39) and the shuttle valve (38). In this situation, the feed directional valve (23) immediately changes its position, and fast feed is switched on. Feed pressure also reaches the load sensing line of the variable displacement pump (1) through the shuttle valve (26), (42), and (10), and after the shuttle valve (26), also the feed pressure gauge (21). Fast feed backwards is on until the rear impulse cylinder (130) is activated the limit switch (125/S81) . At the same time, the rotation pilot control valve (58) is centralized, and rotation is turned off, also fast feed to backwards stops. The return flow from the rock drill rotation motor (54) passes through the rotation directional valve (53), the collecting piece (115), the cooler (315), and the return oil filter (113), into the hydraulic oil tank (110). The return flow from the feed cylinder (28) passes through the feed directional valve (23), the collecting piece (115), the cooler (315), and the return oil filter (113), into the hydraulic oil tank (110). The return flow from the control block of return automatics passes through the collecting piece (135) and ends up into hydraulic oil tank (110). The leak oil of the pilot control valves (14), (31) and (58) is directed first to the collecting piece (135) and from there to the hydraulic oil tank (110). Factory setting time for the front limit air blowing is 6 seconds. Time can be adjusted by turning the K78 blue adjusting screw of the relay K78 in the JB 102 -box. Adjusting range is 1 to 10 seconds.
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Figure: Manual control of fast feed
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Manual control of fast feed
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7.18.1. Operation of the manual control of fast feed The manual control of fast feed is a proportional function, i.e. the inclination angle of the control lever for the fast feed pilot control valve (33) determines the speed of fast feed (the bigger the angle the faster the speed). The control lever of the fast feed pilot control valve (33) is centralized by a spring. Manual control of fast feed can, for instance, be used for flushing drilled holes. During fast feed (forwards) the system operates as follows: Rotation and percussion are not on in this situation, as the rotation pilot control valve (58) and the percussion pilot control valve (14) are in the central position. When the control lever of the fast feed pilot control valve (33) is pulled to the back position, pilot control pressure passes through the shuttle valve (36) to the control line c of the feed directional valve (23). Now, the spool of the feed directional valve (23) changes its position, and the pressure from the percussion circuit passes through the compensator (22) and the feed directional valve (23) to the feed line A, and to the feed cylinder (28). Feed pressure also passes through the shuttle valves (26), (42), and (10) to the load sensing line of the variable displacement pump (1), and after the shuttle valve (26) to the feed pressure gauge (21). The max. feed pressure of fast feed forwards is restricted by the max. pressure relief valve (25) for the feed line A of the feed directional valve, and by the fast feed max. pressure relief valve (30) for fast feed backwards. The return flow from the feed cylinder (28) passes through the feed directional valve (23), the collecting piece (115), the cooler (315), and the return oil filter (113), and ends up into the hydraulic oil tank (110). The leak oil of the pilot control valve (33) is directed first to the collecting piece (135) and from there to the hydraulic oil tank (110). Fast feed forwards can be used with percussion on, in which case fast feed pressure is determined by the feed pressure regulating valve (20) and the feed deviation valve (216) and percussion pressure is adjusted according to feed/percussion monitoring.
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Figure: Threading
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SPECIAL FUNCTIONS
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 8.1.1.
Operation of the threading
Threading means a situation where the drill rod is threaded on or off with a rock drill shank. Threading is done with the control levers for the rotation pilot control valve (58) and the feed pilot control valve (31). In threading, the system operates as follows: Rotation is turned on by pulling back the control lever of the rotation pilot control valve (58) (if required, the speed of rotation can be adjusted with the regulating valve (59) for rotation speed). Pull the control lever of the feed pilot control valve (31) backwards to feed the rock drill forwards at a speed that corresponds to the thread pitch. Keep the feed speed constant throughout the threading operation. Feed pressure can be adjusted suitable with the feed deviation valve (216) (normal feed pressure for drilling can be used as the basic setting). Feed speed can be adjusted suitable with the feed speed regulating valve (150).
During threading, rotation pressure must be kept below the antijamming activation pressure. If the pressure rises to this value, feed direction is reversed.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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Figure: Rattling
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Rattling
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 8.2.1.
Operation of the rattling
Rattling pressure is determined according to the adjustment of the percussion max. pressure relief valve (7). When the percussion pilot control valve (14) is pushed into the front position (Note! Pilot control valve (14) can't be locked into the front position), pilot control pressure affects into the rattling on/off valve (8), into the percussion selector valve (4) through the shuttle valve (15) and also into the percussion pressure selector valve (5) through the shuttle valve (16). The percussion pressure selector valve (5) changes position and closes the connection to the percussion half-power pressure relief valve (6). Also the rattling on/off valve (8) changes position and closes the connection to the monitoring valve (18). The percussion selector valve (4) opens the percussion main valve (3), and the output of the variable displacement pump (1) flows through the non-return valve (116), the pressure filter (112), the compensator (2), and the percussion main valve (3) into the percussion mechanism (13). After the orifice (9), the pressure affects into the pressure compensator (2), and reaches the load-sensing line of the variable displacement pump (1) through theshuttle valve (10). Oil flows also to the percussion pressure selector valve (5), the rattling on/off valve (8) and the percussion max. pressure relief valve (7) which determines the rattling pressure. The pressure after the percussion main valve also affects into the percussion pressure gauge (11). The return flow from the percussion mechanism (13) passes through the collecting piece (115), the cooler (315), and the return oil filter (113), ending up into the hydraulic oil tank (110). The leak oil of the pilot control valve (14) is directed first to the collecting piece (135) and from there to the hydraulic oil tank (110). When using rock drill with stabilizer oil flows also from the connection (P2) of the drilling control block to the connection (P) of the stabilizer control block. From there oil flows to the pressure reducing valve (145) and the pressure reducing/reliefing valve (141). From here the oil continues to flow to the directional control valve (140). Oil also affects to the monitoring valve (142), the directional control valve (144), the pressure switches (137) and (138) and the pressure gauge (146). The directional control valve (140) is activated when using loosening the thread function. In this situation the re is no pressure in the stabilizer and the oil flows from the stabilizer via the oil collector (115), the oil cooler (315) and the return oil filter (113) into the hydraulic oil tank (110).
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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Figure: Separate flushing
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Separate flushing
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 8.3.1.
Operation of the separate flushing
The THC 561 drilling system is equipped with a selector valve (102) for separate flushing. This makes it possible to flush the drilled hole with air or water as a separate function after the actual drilling. The selector valve (102) for separate flushing can be locked, so that flushing can be left on for longer periods. When the separate flushing selector valve is locked into the rear position, water flushing is turned on, while the front position is for air flushing. When water flushing (selector valve 102) is selected, the separate flushing function is as follows: When the selector valve is locked to the rear position, the pressure from the pilot control pressure regulating valve (43) passes through the separate flushing selector valve (102) and the shuttle valve (103) to the water control valve (100), and water flushing is turned on. The leak oil of the pilot control valve (102) is directed first to the collecting piece (135) and from there to the hydraulic oil tank (110).
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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Figure: Using the diesel engine for running rock drill
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting Using the diesel engine for running rock drill
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 8.4.1.
Operation when using the diesel engine for running rock drill
The THC 561 drilling system also allows the use the feed of rock drill with diesel. This function is convenient in maintenance work, when the powerpacks cannot be used.When the rock drill needs to be fed forwards or backwards with diesel power, the boom control operating valve for zoom or feed transfer must be used in addition to the feed pilot control valve (31) in order to close the free circulation valve at the boom control valve. The directions of these two movements must always be chosen so that no danger is caused to the operator, the third persons or the rig. When diesel power is used for running the rock drill forwards, the system operates as follows: When the feed pilot control valve (31) is pulled to the back position and, simultaneously, the boom zoom cylinder, for instance, is run inwards, the pressure that comes from the pilot control pressure regulating valve (43) reaches the feed control line c through the feed pilot control valve (31), the antijamming valve (34), and the shuttle valve (36). In addition, pilot control pressure passes through the shuttle valves (35) and (224) to the feed LS line selector valve (29). The pilot pressure affects also to the directional valve (44) via the shuttle valves (35) and (224). The oil produced by the carrier’s gear pump passes through the non-return valve (117), the pressure filter (112), the pressure compensator (22), and the feed directional valve (23) to the feed cylinder (28). Oil flows also through the port P1 of the percussion and feed control block, the pressure reducing/reliefing valve of the boom circuit (210), the port P5 of the percussion and feed control block and the drilling module movement prevention valve (222) to the boom control valve. The pressure in the LS line of the feed directional valve passes through the shuttle valve (26) and selector valve (29) of the feed LS line, to the feed pressure regulating valve (20), the feed deviation valve (216) and further through the selector valve (32) of the feed LS line return circuit to the return line of the feed cylinder (28). The pressure in the feed LS line also affects the feed pressure gauge (21). The pressure in the feed A line affects the pressure relief valve / intake valve (25), and the feed B line pressure affects the pressure relief valve / intake valve (24). Oil from the feed cylinder (28) flows to the connection B of feed directional valve (23) and from there to feed line B max. pressure relief valve (24). From here oil flows through the tank connector T3 of control block of drilling to the collecting piece (115), via the oil cooler (315) to the return oil filter (113) and the oil tank (110). The leak oil from the feed pilot control valve (31) is first directed to the collecting piece (135) and from there to the hydraulic oil tank (110).
Never use percussion mechanism with diesel. Low pressure of diesel controlled hydraulic system can damage components of the pressure accumulator.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.
ADJUSTMENTS OF HYDRAULIC COMPONENTS
9.1.
Adjustments of variable displacement pump (1) Before starting the powerpack, make sure that the adjusting screw of the flow controller (controller A) of variable displacement pump (1) is turned almost fully open (counterclockwise). Before starting any adjustments remember that the hydraulic oil temperature must be between 40-50 °C.
LS
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A
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B
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.1.1.
Adjusting variable displacement pump (1)
1. Remove the caps from the flow controller (A) and the pressure controller (B) and undo the locking nuts of their adjusting spindles. 2. Open the adjusting screws of the pressure controller (B) and the flow controller (A) almost fully open (counterclockwise). 3. Connect the pressure gauge to the pressure measuring point (M1) of the drilling control block. 4. Start the powerpack. 5. Turn the adjusting screw of the flow controller (A) fully closed (clockwise). Note! The pump is now operating at constant pressure. 6. Turn the adjusting screw of the pressure controller (B) clockwise until the pressure gauge shows 100 bar. Let the LS-line bleed into a separate container by loosening the hose connection of the flow controller (A). Let the connection stay loosened until all air has escaped. Then tighten the hose connection of the flow controller (A). 7. Turn the adjusting screw of the pressure controller (B) clockwise until the pressure gauge shows 230 bar. Read the pressure value from the pressure gauge connected to the measuring point M1. 8. Lock the adjustment of the pressure controller (B) with the locking nut. 9. Turn the adjusting screw of the flow controller (A) almost fully open (counterclockwise). 10. Allow the pressure stabilize in the pressure gauge connected to the measuring point M1. 11. Adjust the stand-by pressure to 30 bar from the flow controller (A) by turning the adjusting screw clockwise. NOTE! If there are oscillations in the hydraulic system, the adjustment value can be changed between 22-30 bar. 12. Lock the adjusting screw of the flow controller (A) with the locking nut. 13. Stop the powerpack. 14. Allow the pressure come down (to zero) in the pressure gauge connected to the measuring point M1. 15. Start the powerpack. 16. Allow the pressure stabilize in the pressure gauge connected to the measuring point M1. 17. If the stand-by pressure is in the recommended range in the pressure gauge connected to the measuring point M1, install the protective caps to the flow controller (A) and pressure controller (B). 18. If the stand-by pressure is not in the right range, readjust the flow controller (A) according to the steps 9-18. 19. Stop the powerpack. 20. Remove the pressure gauge from the measuring point M1.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.2.
Adjusting system main pressure
211
The system main pressure is adjusted with the main pressure relief valve (211). The adjusting procedure is as follows: 1. Loosen the locking nut of the adjusting screw of the main pressure relief valve (211). 2. Tighten the adjusting screw of the main pressure relief valve (211) almost to its end (over 270 bar). 3. Remove the caps from the flow controller (A) and the pressure controller (B) and undo the locking nuts of their adjusting spindles. 4. Open the adjusting screws of the pressure controller (B) and the flow controller (A) almost fully open (counterclockwise). 5. Connect the pressure gauge to the pressure measuring point (M1) of the drilling control block. 6. Start the powerpack. 7. Turn the adjusting screw of the flow controller (A) fully closed (clockwise). Note! The pump is now operating at constant pressure. 8. Turn the adjusting screw of the pressure controller (B) clockwise until the pressure gauge shows correct pressure (see table below). Rock drill
Pressure
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250 bar
9. Loosen the adjusting screw of the main pressure relief valve (211) until adjusting begins to effect. Valve begins to fizz when restricting pressure. Check the pressure value from the percussion pressure gauge (11).
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10. Adjust the variable displacement pump (1) back to its value (see table below), according to the chapter: Adjusting variable displacement pump (1). Rock drill
Pressure
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230 / 22-30 bar
11. Tighten the locking nut of the adjusting screw of the main pressure relief valve (211). 12. Stop the powerpack.
Hydraulic system is getting warmer while the main pressure relief valve restricts pressure. Take care that the main pressure relief valve does not penetrate a flow for a long time.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.3.
Adjusting pilot control pressure
M8
43
The pilot control pressure is adjusted with the pilot control pressure regulating valve (43). The adjusting procedure is as follows: 1. Loosen the locking nut of the adjusting screw of the pilot control pressure regulating valve (43). 2. Turn the adjusting screw of the valve (43) almost fully open (counterclockwise). 3. Connect a pressure gauge to the pressure measuring point M8 of the percussion and feed control block. 4. Start the powerpack. 5. Push the control lever of the feed pilot control valve (31) to the front position (feed backwards). 6. Adjust the pilot control pressure to 30 bar by turning the adjusting screw of the pilot control pressure regulating valve (43) clockwise. Read the pressure value in the gauge connected to the measuring point M8. 7. Release the control lever of the feed pilot control valve (31) to the middle position (feed backwards off). 8. Lock the adjusting screw of the pilot control pressure regulating valve (43). 9. By turning on feed backwards, check the adjusted pressure value in the pressure gauge connected to the measuring point M8. If the reading is not as recommended, readjust the pilot control pressure. 10. Stop the powerpack. 11. Remove the pressure gauge from the measuring point M8.
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.4.
Adjusting the max. pressure of rotation circuit
The maximum pressure for rotation is adjusted with the rotation LS- pressure relief valve (65) located in the rotation control valve.
65
The adjusting procedure is following: 1. 2. 3. 4.
Start the power pack. Run the rock drill against the rear stopper. Stop the power pack. Loosen the locking nut of the pressure relief valve (65) mounted to the rotation control valve. 5. Turn the pressure relief valve (65) adjusting screw almost fully open (counterclockwise). 6. Prevent the drill rod from rotating by disconnecting the rotation hose from the hose support and plug the hose ends.
7. Turn the rotation speed regulating valve (59) closed (clockwise). 8. Start the power pack. 9. Lock the control lever of the rotation pilot control valve (58) in the back position. 10. Adjust the rotation max. pressure to 180 bar with the pressure relief valve (65). Read the pressure in the rotation pressure gauge (51). 11. Lock the adjusting screw of the max. rotation pressure relief valve (65). 12. Release the control lever of the rotation pilot control valve (58) to the middle position. 13. Stop the power pack. 14. Reconnect the rotation hose to the hose support. 15. Start the power pack. 16. Turn drilling rotation on again by locking the control lever of the rotation pilot control valve (58) in the back position. 17. Adjust the drill steel rotation speed to the desired value by turning the rotation speed regulating valve (59) counterclockwise. 18. Release the control lever of the rotation pilot control valve (58) to the middle position. 19. Stop the power pack. NOTE! The regulating valve (55) adjusts the max system pressure of the rotation. This pressure is 25 bar over the value of the rotation LS-pressure.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.5.
Adjusting of the spool stroke of the rotation directional valve
A a
B
b
The rotation directional valve is supplied with the stroke limitation possibility. The stroke limit adapters with which limitation is done are located at the end of the hydraulic control covers. The adjustment of the stroke limitation is recommended to be done to prevent unnecessarily high rotation speed and to avoid the overload of the electric motor. The adjustment is done as follows: 1. Move the booms so that there is a possibility to measure safely the revolutions of the drilling rod or the shank of the rock drill. 2. Install a suitable oil container under the rotation directional valve. 3. Disconnect the hydraulic hose from the end of the hydraulic control cover b and plug the hose end. 4. Remove the adapter from the end of the hydraulic control cover b. 5. Turn the screw of the spool limiter counterclockwise until it reaches the face of the stroke limit adapter. 6. Start the power pack (if not running). 7. Activate the rotation counterclockwise on by locking the rotation control lever backwards (towards the operator). 8. Adjust the max revolutions of the drilling rod or the shank of the rock drill by the rotation speed regulating valve (59) according to the size of the rotation motor used in rock drill. Adjusting value is +10 % of the recommended rotation speed, according to the chapter "Adjusting rotation speed" (p. 96) . 9. Keep the rotation counterclockwise on and turn the adjusting screw of the spool limiter clockwise until it reaches the spool end. 10. Release the rotation control lever to the middle position. 11. Stop the power pack. 12. Install the adapter back to the end of the hydraulic control cover b. 84 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 13. Reconnect the hydraulic hose to the adapter at end of the hydraulic control cover b. 14. Disconnect the hydraulic hose from the end of the hydraulic control cover a and plug the hose end. 15. Remove the adapter from the end of the hydraulic control cover a. 16. Turn the screw of the spool limiter counterclockwise until it reaches the face of the stroke limit adapter. 17. Start the power pack. 18. Activate the rotation clockwise on by locking the rotation control lever forwards (away from the operator). 19. Adjust the max revolutions of the drilling rod or the shank of the rock drill according to the step 8. 20. Keep the rotation clockwise on and turn the adjusting screw of the spool limiter clockwise until it reaches the spool end. 21. Release the rotation control lever to the middle position. 22. Stop the power pack. 23. Install the adapter back to the end of the hydraulic control cover a. 24. Reconnect the hydraulic hose to the adapter at end of the hydraulic control cover a. 25. Remove the oil container under the rotation directional valve.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.6.
Adjusting anti-jamming pressure
The activation pressure of the anti-jamming automatics can be adjusted according to rock type. The range recommended by the manufacturer is 110 to 140 bar, and the factory setting is 120 bar. The activation pressure is adjusted with the antijamming valve (34), and it can be done during drilling. However, the adjustment is recommended to be done as follows:
M3
34
1. Loosen the locking nut of the anti-jamming valve (34) adjusting screw. 2. Turn the anti-jamming valve (34) adjusting screw first fully closed (clockwise), and open it then 2 turns (counterclockwise). 3. Start the powerpack. 4. Run the rock drill against the rear stopper. 5. Stop the powerpack. 6. Loosen the locking nut of rotation LS-pressure relief valve (65) of rotation control block adjusting screw. 7. Turn the LS-pressure relief valve (65) adjusting screw almost fully open (counterclockwise). 8. Turn the rotation speed regulating valve (59) closed (clockwise). 9. Plug the pressure side hose of the feed cylinder.
10. Prevent the drill rod from rotating by disconnecting the rotation hose from the hose support and plug the hose ends.
11. Install a pressure gauge to the measuring point M3 of the anti-jamming/return automatics block. 12. Start the powerpack. 13. Lock the control levers of rotation and feed pilot control valves (58) and (31) to the back position. 86 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 14. Adjust the desired anti-jamming activation pressure with the rotation LS-pressure relief valve (65) by turning the adjusting screw clockwise (factory setting 120 bar). Read the pressure value in the rotation pressure gauge (51). 15. Adjust the anti-jamming valve (34) so that it directs feed pilot control pressure at the set pressure to the measuring point M3 of the anti-jamming/return automatics block. Read the feed pilot control pressure (approx. 19-21 bar) in the pressure gauge installed in the measuring point M3. 16. When the anti-jamming valve (34) is correctly adjusted, lock the adjusting screw of the valve (34). 17. Adjust rotation pressure with the rotation LS-pressure relief valve (65) to 180 bar by turning the adjusting screw clockwise. Read the pressure in the rotation pressure gauge (51). 18. Lock the adjusting screw of the rotation LS-pressure relief valve (65). 19. Release the control levers of rotation and feed pilot control valves (58) and (31). 20. Stop the powerpack. 21. Remove the plugs from the disconnected rotation hoses (Cf. point 10) and reconnect the hoses together. 22. Remove the plugs from the feed cylinder pressure side feed line (Cf. point 9), and reconnect the hose to the feed cylinder. 23. Start the powerpack. 24. Turn drilling rotation on again by locking the control lever of rotation pilot control valve (58) in the back position. 25. Adjust the drill rod rotation speed to the desired value by turning the rotation speed regulating valve (59) counterclockwise. 26. Release the control lever of the rotation pilot control valve (58). 27. Stop the powerpack. 28. Remove the pressure gauge from the measuring point M3 for the anti-jamming/return automatics.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.7.
Adjusting anti-jamming pressure (alternative method)
1. Loosen the locking nut of the anti-jamming valve (34) adjusting screw.
34
2. Prevent the drill rod from rotating by disconnecting the rotation hoses from the hose support and plug the hose ends.
3. 4. 5. 6.
Start the power pack. Run the feed forwards slowly. Engage the rotation carefully with the rotation pilot control valve (58). Read from the feed and rotation pressure gauges (21 and 51) when the anti-jamming will be activated. Rotation pressure has to be in the desired anti-jamming value (for example 100 bar), when the feed moves backwards and the feed pressure falls. 7. Turn the anti-jamming valve (34) adjusting screw and repeat the previous steps until the antijamming pressure is required. 8. When the anti-jamming valve (34) is correctly adjusted, lock the adjusting screw of the valve (34). 9. Release the control levers of rotation and feed pilot control valves (58) and (31). 10. Stop the power pack. 11. Remove the plugs from the disconnected rotation hoses (Cf. point 2) and reconnect the hoses together.
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.8.
Adjusting min. percussion pressure
18
6
Monitoring valve (18) and percussion half-power pressure relief valve (6) locate in parallel in percussion LS-circuit. Lower adjusting value of these valves determines the percussion half-power pressure. Adjusting value of monitoring valve (18) always determines the minimum adjustable percussion pressure when drilling with full-power. See the adjusting of percussion half-power, according to the chapter "Adjusting percussion half-power" (p. 90) . Min. percussion pressure is adjusted with the monitoring valve (18) as follows: Loosen the locking nut of the half-power pressure relief valve (6). Turn the adjusting screw of the half-power pressure relief valve (6) almost fully closed (clockwise). Loosen the locking nuts of the monitoring valve (18). Turn the adjusting screw of the monitoring valve (18) fully open (counterclockwise) and then close it by 3½ turns. 5. Start the powerpack. 6. Turn percussion half-power on by locking the control lever of percussion pilot control valve (14) to the back position. 7. Adjust min. percussion pressure to 120 bar with the monitoring valve (18). Read the pressure value from the percussion pressure gauge (11). 8. Tighten the locking nut of the adjusting screw for the monitoring valve (18). 9. Adjust percussion half-power pressure relief valve (6) according to the chapter "Adjusting percussion half-power" (p. 90) . 10. Release the control lever of the percussion pilot control valve (14). 11. Stop the powerpack. 1. 2. 3. 4.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.9.
Adjusting percussion half-power
6
Monitoring valve (18) and percussion half-power pressure relief valve (6) locate in parallel in percussion LS-circuit. Lower adjusting value of these valves determines the percussion half-power pressure. See the adjusting of monitoring valve (18), according to the chapter "Adjusting min. percussion pressure" (p. 89) . Percussion half-power can vary between 80-100 bar. Factory setting is 100 bar. Percussion half-power is adjusted with the percussion half-power pressure relief valve (6) as follows: 1. Loosen the locking nut of the adjusting screw of percussion half-power pressure relief valve (6). 2. Turn the adjusting screw of the percussion half-power pressure relief valve (6) first fully closed (clockwise), and then open it by 7 1/4 turns (counterclockwise). 3. Start the powerpack. 4. Turn percussion half-power on by locking the control lever of percussion pilot control valve (14) to the back position. 5. Adjust percussion half-power pressure to 100 bar with the percussion half-power pressure relief valve (6). Read the pressure value from the percussion pressure gauge (11). 6. Tighten the locking nut of the adjusting screw for the percussion half-power pressure relief valve (6). 7. Release the control lever of the percussion pilot control valve (14). 8. Stop the powerpack.
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.10.
Adjusting percussion full-power
7
The pressure of percussion full-power is adjusted to the desired value with the percussion full-power pressure relief valve (7). Percussion full-power pressure should be adjusted according to the hardness of the rock and the drill steels used. The max. pressure of percussion may vary between 150-230 bar with respect to the above factors. The factory setting is 210 bar. Percussion full-power pressure is adjusted as follows: 1. Loosen the locking nut of the adjusting screw of the percussion full-power pressure relief valve (7). 2. Turn the adjusting screw of the percussion full-power pressure relief valve (7) first fully closed (clockwise) and then open the adjusting screw 5 turns (counterclockwise). 3. Start the powerpack. 4. Push the control lever of the percussion pilot control valve (14) to the front position. 5. Adjust the percussion full-power pressure to the desired level with the adjusting screw of the percussion full-power pressure relief valve (7). Turn clockwise to increase the pressure and counterclockwise to decrease it. Read the pressure value from the percussion pressure gauge (11). 6. Tighten the locking nut of the adjusting screw of the percussion full-power pressure relief valve (7). 7. Release the control lever of the percussion pilot control valve (14). 8. Stop the powerpack.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.11.
Adjusting feed pressure
Feed pressure is adjusted with the feed pressure regulating valve (20) and the feed deviation valve (216). These valves are used for adjusting the max. feed pressure in the system for the time the feed is run through the feed pilot control valve (31). In addition to this, the feed lines A (25) and B (24) are equipped with a fixed pressure relief/intake valve cartridges as follows: Feed
A line (25)
B line (24)
Cylinder feed TF 500
175 bar
210 bar
Cylinder feed TFX 500
175 bar
210 bar
24
25
The max. feed pressures for cylinder feed equipment are following: Feed
Max. feed pressure
Cylinder feed TF 500
140 bar
Cylinder feed TFX 500
160 bar
NOTE! The min. feed pressure for all feeds is about 20 bar. Factory settings for percussion and feed pressure relation is following (max. percussion pressure may vary): Rock drill
Feed
Percussion pressure
Feed pressure
RD525
TF 500
210 bar
125 bar
RD525
TFX 500
210 bar
140 bar
RD520/HLX5
TF 500
210 bar
115 bar
RD520/HLX5
TFX 500
210 bar
130 bar
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.11.1. Adjusting nominal level of feed pressure Percussion and feed pressures are adjusted to the values, which are mentioned in the chapter "Adjusting feed pressure". Remove the hand wheel of the feed deviation valve (216). Start the power pack. Turn the switches of the return automatics (S73 and S74) to the M-position. Run the rock drill to the rear position. Pull the control lever of the percussion pilot control valve (14) to the back position and push the feed pilot control valve (31) to the front position. 6. Adjust percussion pressure to the correct level with the feed pressure regulating valve (20). Refer to the chapter "Adjusting feed pressure". 7. Adjust feed pressure to the correct level with the feed deviation valve (216). Refer to the chapter "Adjusting feed pressure". 8. Release the control levers of the percussion pilot control valve (14) and the feed pilot control valve (31). 9. Stop the power pack. 10. Attach the hand wheel of the feed deviation valve (216) into the initial position (pointer pin straight ahead). Feed deviation can now be adjusted ±20 bar from the basic level. 1. 2. 3. 4. 5.
Basic adjustment for feed pressure can also be done with help of rotation pressure. In normal fullpower drilling rotation pressure has to be approx. 90-100 bar. Adjust feed pressure with the feed deviation so, that rotation pressure stays at the desired level.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.12.
Adjusting fast feed max. pressure
30
The max. pressure of fast feed is adjusted with the fast feed max. pressure relief valve (30). The adjustment is done as follows: 1. Loosen the locking nut of the fast feed max. pressure relief valve (30). 2. Start the powerpack. 3. Run the rock drill against the rear stopper by locking the control lever of fast feed pilot control valve (33) into the front position and adjust at the same time the fast feed max. pressure by the pressure relief valve (30). Read the pressure value from the pressure gauge (21). The value of fast feed pressure relief valve depends on the feed in use as follows: Feed
Value of the fast feed relief valve (30)
TF 500
210 bar
TFX 500
180 bar
4. Release the control lever of the fast feed pilot control valve (33). 5. Lock the adjusting screw of the fast feed max. pressure relief valve (30). 6. Stop the powerpack.
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.13.
Adjusting fast feed max. speed
23
B A
The max. fast feed speeds are adjusted with the adjusting screws at the feed directional valve (23). The lower screw (A) is for adjusting fast feed max. speed forwards and the upper (B) for max. speed backwards. Sandvik recommends the following fast feed speeds: Direction of fast feed
Sandvik recommendation
Forwards
TF 500 ≈ 0.3 m/s TFX 500 ≈ 0.3 m/s
Backwards
TF 500 ≈ 0.5 m/s TFX 500 ≈ 0.3 m/s
Fast feed speeds are adjusted as follows: 1. Remove the drill rod from the rock drill to enable free running of rock drill from end to end on the feed. 2. Start the powerpack. 3. Loosen the locking nuts of the adjusting screws for fast feed speeds at the feed directional valve (23). 4. Lock the control lever of the fast feed pilot control valve (33) to the back position to run fast feed forwards. Adjust the movement speed to approx. 0.3 m/s with the lower adjusting screw at the feed directional valve. 5. Release the control lever of the fast feed pilot control valve (33). 6. Lock the lower adjusting screw for fast feed speed at the feed directional valve (23). 7. Check the adjustment and readjust as necessary. 8. Lock the control lever of the fast feed pilot control valve (33) to the front position to run fast feed backwards. Adjust the movement speed to approx. 0.5 m/s (0,3 m/s with TFX500) with the upper adjusting screw at the feed directional valve. 9. Release the control lever of the fast feed pilot control valve (33). 10. Lock the upper adjusting screw for fast feed speed at the feed directional valve (23). 11. Check the adjustment and readjust as necessary. 12. Stop the powerpack.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.14.
Adjusting rotation speed
The drill rod rotation speed is adjusted with the rotation speed regulating valve (59). Turn the adjusting knob counterclockwise to decrease the speed and clockwise to increase the speed. The correct drill rod rotation speed depends on the hardness of the rock and on the hole diameter. Sandvik recommends the following rotation speeds for different hole diameters:
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Drill bit size
Rotation speed ± 10 % (HLX5/RD520)
Rotation speed ± 10 % (RD525[/HFX5T])
Ø32
250 rpm
300 rpm
Ø38
250 rpm
300 rpm
Ø45
200 rpm
240 rpm
Ø51
200 rpm
240 rpm
Ø64
150 rpm
180 rpm
Ø76
150 rpm
180 rpm
Ø89
110 rpm
130 rpm
Ø102
110 rpm
130 rpm
Ø115
80 rpm
95 rpm
Ø127
80 rpm
95 rpm
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.15.
Adjusting boom circuit max. pressure
210
M10
The boom circuit max. pressure is adjusted with the pressure reducing/reliefing valve (210). The adjusting procedure is as follows: 1. Loosen the locking nut of the adjusting screw of the pressure reducing/reliefing valve (210). 2. Connect a pressure gauge to the pressure measuring point M10 of the percussion and feed control block. 3. Start the powerpack. 4. Run the boom control operating valve for zoom or feed transfer.. The directions of these two movements must always be chosen so that no danger is caused to the operator or the rig. 5. Adjust the boom circuit max. pressure to 230 bar with the pressure reducing/reliefing valve (210). Read the pressure value in the gauge connected to the measuring point M10. 6. Tighten the locking nut of the adjusting screw of the pressure reducing/reliefing valve (210). 7. Stop the powerpack.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.16.
Adjusting one-way restrictor valve
One-way restrictor valve (204) cause a little delay when the rotation is switched off (refer to chapter: Rotation control block). 1. 2. 3. 4.
Loosen the locking nut of the adjusting screw. Rotate the adjusting screw fully closed. Open the adjusting screw then 1/4 turns. Tighten the locking nut of the adjusting screw.
204
9.17.
Bleeding of the impulse cylinder block
The pressure switches (S80 and S81) of the impulse cylinder block are bleeded as follows: 1. Start the powerpack. 2. Remove the cover from the measuring plugs (MF and MR) of the impulse cylinder block. 3. Install end of the overflow hoses to the measuring plugs (MF and MR) and the other ends to overflow receptacle. 4. Bleeding is done when outcoming oil is free of air bubbles. 5. Remove the overflow hoses from the measuring plugs (MF and MR). 6. Stop the powerpack.
MR MF
9.17.1. Adjusting the pressure switches (123, 125) Adjusting the pressure switches (S80 and S81) of the impulse cylinder block must be done in a special test bench. The activating pressure of the pressure switches is 18 bar.
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.17.2. Bleeding of the impulse cylinders (129, 130) The impulse cylinders are bleeded as follows: 1. Start the powerpack. 2. Place the overflow receptacle under the impulse cylinder. 3. Rotate the bleeding screw (A) of the impulse cylinder carefully open (counterclockwise). 4. When all of the air has came out, tighten the bleeder-screw (A) (clockwise). 5. Stop the powerpack.
9.18. 1. 2. 3. 4. 5.
A
Bleeding of the pressure switches (12), (137), (138), (205) and (217)
Locate the overflow receptacle under the pressure switch. Start the powerpack. Loosen a joint between pressure switch and hose joint. When all of the air has came out, tighten the joint. Stop the powerpack.
9.19.
Adjusting percussion hour meter / SLU on/off pressure switch (12), rotation pressure switch (205) and pressure switch of air-mist flushing selecting (217)
The adjusting value is 10 bar. Adjust the pressure switches as follows: 1. Turn the adjusting screw of the pressure switch closed (clockwise). 2. Turn the adjusting screw of the pressure switch 15,5 turns counterclockwise. 3. Check the adjusting value of the pressure switch: • Start the powerpack. • Move the control lever of specific function backwards. • Check that the function of the control lever starts: - Percussion control lever => Function: Shank lubrication has to be started. - Rotation control lever => Function: Shank lubrication has to be started. - Flushing control lever => Function: Air mist flushing has to be start. NOTE! Air mist flushing selector switch (S75) has to be activated first. • Move the control lever back to the middle position. - Function of the control lever has to be stopped. 4. Stop the powerpack.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.20.
Adjusting stabilizer max. pressure switch (137)
The adjusting value is 130 bar. Adjust the pressure switch as follows: 1. 2. 3. 4.
Turn the adjusting screw of the max. pressure switch (137) almost closed (clockwise). Start the power pack. Run the feed cylinder against the front limit. Adjust the stabilizer pressure to 130 bar with the pressure reducing/reliefing valve (141). Read the pressure value in the stabilizer pressure gauge (146). 5. Open the adjusting screw of the max. pressure switch (137) until it disconnects and the stabilizer indicator light (H72) starts to flash on the control panel. 6. Adjust the stabilizer max. pressure to the right value (110 bar), according to the chapter "Adjusting stabilizer max. pressure" (p. 101) . Note! The adjusting value of the stabilizer max. pressure switch (137) must be approx. 20 bar higher than the stabilizer max. pressure.
9.21.
Adjusting stabilizer min. pressure switch (138)
The adjusting value is 15 bar. Adjust the pressure switch as follows: 1. Turn the adjusting screw of the min. pressure switch (138) almost open (counterclockwise). 2. Start the power pack. 3. Adjust the stabilizer pressure to 15 bar with the pressure reducing/reliefing valve (141). Read the pressure value in the stabilizer pressure gauge (146). 4. Tighten the adjusting screw of the min. pressure switch (138) until it disconnects and the stabilizer indicator light (H72) starts to flash on the control panel. 5. Adjust the stabilizer max. pressure to the right value (110 bar), according to the chapter "Adjusting stabilizer max. pressure" (p. 101) .
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.22.
Adjusting stabilizer max. pressure
Refer to the chapter: Operation of the stabilizer.
141
Stabilizer max. pressure depends on the used feed pressure. The stabilizer max. pressure is adjusted with the pressure reducing/reliefing valve (141). Factory setting is 110 bar. The adjusting procedure is as follows: 1. 2. 3. 4.
Loosen the locking nut of the adjusting screw of the pressure reducing/reliefing valve (141). Start the powerpack. Run the feed cylinder against the front limit. Adjust the stabilizer max. pressure, for example 110 bar, with the pressure reducing/reliefing valve (141). Read the pressure value in the stabilizer pressure gauge (146). Note! During drilling percussion pressure must be all the time at least 20 bar higher than stabilizer pressure. 5. Tighten the locking nut of the adjusting screw of the pressure reducing/reliefing valve (141). 6. Stop the powerpack.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.23.
Adjusting stabilizer min. pressure
Refer to the chapter: Operation of the stabilizer.
142
The stabilizer min. pressure is adjusted with the monitoring valve (142). Factory setting is 50 bar. The adjusting procedure is as follows: 1. 2. 3. 4.
Loosen the locking nut of the adjusting screw of the monitoring valve (142). Start the powerpack. Run the feed cylinder against the rear limit. Adjust the stabilizer min. pressure, for example 50 bar, with the monitoring valve (142). Read the pressure value in the stabilizer pressure gauge (146). Note! Stabilizer min. pressure must be at least 15-20 bar higher than the pressure of the accumulators of the rock drill. 5. Tighten the locking nut of the adjusting screw of the monitoring valve (142). 6. Stop the powerpack.
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.24.
Adjusting stabilizer reference pressure
Refer to the chapter: Operation of the stabilizer.
R
145
In stabilizer pressure adjustment, the reference pressure is used to compensate the mass of the drilling equipment and the frictions of the feed beam. The stabilizer reference pressure is adjusted with the pressure reducing valve (145). Factory setting is 30 bar. The adjusting procedure is as follows: 1. 2. 3. 4. 5.
Loosen the locking nut of the adjusting screw of the pressure reducing valve (145). Connect a pressure gauge to the pressure measuring point R of the stabilizer control block. Start the powerpack. Run the rock drill against the rear limit. Adjust the stabilizer reference pressure, 30 bar, with the pressure reducing valve (145). Read the pressure value in the gauge connected to the measuring point R. 6. Tighten the locking nut of the adjusting screw of the pressure reducing valve (145). 7. Stop the powerpack.
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 9.25.
Adjusting power extractor pressure
213
Power extractor pressure is adjusted with the power extractor pressure relief valve (213). Factory setting is 150 bar. The adjusting procedure is as follows: 1. Loosen the locking nut of the adjusting screw of the power extractor pressure relief valve (213). 2. Start the power pack. 3. Engage rattling by pushing the control lever of the percussion pilot control valve (14) to the front position. 4. Switch on the power extractor by pushing the push button (S90) on the THC-panel. 5. Adjust the power extractor pressure to the 140-180 bar with the power extractor pressure relief valve (213). Read the pressure value from the percussion pressure gauge (11). 6. Tighten the locking nut of the adjusting screw of the power extractor pressure relief valve (213). 7. Switch off the power extractor. 8. Release the control lever of the percussion pilot control valve (14). 9. Stop the power pack.
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.
TROUBLESHOOTING
10.1.
General
If the drilling system is not working as it should, check the following points before making any further measurements: • Signal lights, e.g. - hydraulic oil level - hydraulic oil temperature - pressure differences over return and pressure filters - water and air pressure control - powerpacks’ direction of rotation - etc. • External leaks at hoses, connection, adapters, and other hydraulic components. • Mechanical functions (e.g. sliding pieces, rollers and return wheels) • Supply voltage to the drilling rig / the different devices. • External cable damage. • Mounting of electric plugs. • Pressure gauge readings.
10.2.
Pumps (1) and (50) do not rotate at all, or their speed is not normal
1. Measure the supply voltage to the powerpack. If the voltage is correct, it is likely that the fault is mechanical. If the electric motor does not receive sufficient control voltage, refer to electric system troubleshooting. 2. Check if a mechanical damage prevents the pumps from rotating. 3. Repair or replace the damaged component.
Noisy powerpack normally predicts a mechanical fault. It is best to immediately repair (or replace) the component that causes the noise in order to avoid any greater damage.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.3.
Variable displacement pump (1) rotates normally, but the regulator settings are not normal
The settings of the variable displacement pump (1) regulator are as follows: • Flow regulator (A) 22-30 bar • Pressure regulator (B) 230 bar These settings of the variable displacement pump (1) can be checked as follows: 1. Install a pressure gauge to the measuring point M1 for feed and percussion. 2. Start the powerpack. 3. Read the stand-by pressure value in the pressure gauge at the measuring point M1 (allow the pressure to stabilize). 4. Run, for instance, the zoom cylinder inwards and at the same time read the pressure in the pressure gauge at the measuring point M1. 5. Stop the powerpack. 6. Remove the pressure gauge from the measuring point M1.
LS
1
A
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B
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.3.1. Flow regulator (A) value deviates from the set value 22-30 bar 1. Install a pressure gauge to the measuring point M7 for feed and percussion. 2. Start the powerpack. 3. If the pressure at the measuring point M7 of the feed and percussion control block is normal tank pressure, it is likely that the regulator A of the pump (1) is incorrectly adjusted or sticking. Adjust the free circulation pressure of the pump (1) to the correct value with the regulator A (Cf. "Adjusting variable displacement pump (1)" (p. 79) ). 4. If the above measures did not help, stop the powerpack and repair or replace the whole regulator unit. Adjust the regulator A or the regulator unit according to chapter "Adjusting variable displacement pump (1)" (p. 79) ). 5. If the pressure at the pressure measuring point M7 of the feed and percussion control block is over the normal tank pressure, it may be that one of the valves (3), (4), (14), (23), (31), (33), (39), or of the boom valves, is sticking (i.e. one of the above valves is leaking, and giving a control signal to the pump (1)). 6. Start troubleshooting by checking the condition of the pilot control valves (14), (31), and (33), and the return automatics selector valve (39). They can be inspected as follows: a. Start the powerpack. b. Install a pressure gauge to the following measuring points alternately:
c. d.
e.
f.
g.
• measuring point M9 of the feed and percussion control block • measuring points M1, M2, and M3 of the anti-jamming and return automatics control block If the measuring point M9 receives pressure, it is likely that the spool of the percussion pilot control valve (14) is sticking. If the measuring point M2 or M3 of the anti-jamming and return automatics control block receives pressure, it is likely that the fast feed pilot control valve (33) or the return automatics selector valve (39) is sticking. If the measuring points M1 and M2 or M1 and M3 of the anti-jamming and return automatics control block receive pressure simultaneously, it is likely that the feed pilot control valve (31) is sticking. If the measuring points M1 and M2 of the anti-jamming and return automatics control block do not receive pressure, but port LS1 does, it is likely that the anti-jamming valve of flushing control (206) is sticking. Stop the powerpack and replace the faulty valves.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 7. If the above measures did not help, check the operation of the valves (3), (4), (23), and of the boom valve. They are inspected as follows: a. Install a pressure gauge to the measuring point M1 of the feed and percussion control block. b. Start the powerpack. c. If the readings of the percussion (11) and feed (21) pressure gauges is zero, but the pressure at the measuring point M1 is over stand by-pressure, it is likely that the boom valve is sticking. d. Stop the powerpack. e. Clean, repair, or replace the boom valve. f. Remove the pressure gauge from the measuring point M1. g. If pressure reaches the percussion pressure gauge (11) and percussion operates normally when the powerpack is running, it is likely that the percussion main valve (3) or the percussion selector valve (4) is faulty. In this case, do as follows: • Stop the powerpack. • Clean and repair, or replace the faulty valve. h. If pressure reaches the feed pressure gauge (21) when the powerpack is running, it is likely that the spool of the feed directional valve (23) is sticking. In this case, do as follows: • • • •
Stop the powerpack. Remove the spool of the feed directional valve (23). Clean the spool and the spool housing carefully. Reinstall the spool (do not use excessive force).
10.3.2. Pressure regulator (B) value deviates from the set value 230 bar 1. Install a pressure gauge to the measuring point M1 of the feed and percussion control block. 2. Start the powerpack. 3. Run, for instance, the zoom cylinder inwards and at the same time adjust the pressure regulator (B) of the pump (1) to the set value 230 bar. 4. If the pressure regulator does not react to adjustment, it is either sticking or faulty. 5. Stop the powerpack. 6. Clean and repair the regulator (B), or replace the whole regulator unit (adjust according to chapter "Adjusting variable displacement pump (1)" (p. 79) ). 7. If the pressure regulator (B) operates normally during drilling, but the max. pressure value of 230 bar is not reached when the boom is run, it is likely that the boom valve’s main pressure limit is faulty. In this case, look up into “Hydraulic TB boom” manual.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.4.
Percussion not working at all
1. If the percussion pressure gauge (11) shows a reading, but percussion does not work when the control lever of the percussion pilot control valve (14) is locked into the rear position, it is likely that the rock drill is faulty. In this case, do the following: a. Stop the powerpack. b. Repair or replace the rock drill (refer to rock drill manuals). 2. If the percussion pressure gauge (11) does not show any reading when the percussion control lever (14) is locked into the rear position, it is likely that either the percussion main valve (3) or the percussion selector valve (4) is sticking. Check the operation of the valves as follows: a. Stop the powerpack. b. Clean and repair, or replace the faulty valve(s). 3. If the percussion pressure gauge (11) shows a reading, but percussion starts only partially (or not at all) when the control lever of the percussion pilot control valve (14) is locked into the rear position, and while boom functions are normal, it is likely that the orifice (9) in the load-sensing line is blocked. Check the orifice as follows: a. Stop the powerpack. b. Remove the adapter from the port 9 of the feed and percussion control block. c. Remove the orifice (9) and check if it is blocked (clear the hole as necessary). d. Mount the orifice (9) carefully back on the port 9 of the feed and percussion control block.
10.5.
Percussion is on always when the powerpack or the diesel engine is running
1. First, check tank line pressure of the drilling pilot control valves (58), (14), and (31). This pressure should be less than 1 bar. The tank pressure is checked as follows: a. Stop the powerpack. b. Install a pressure gauge to the tank line of the drilling pilot control valves (58), (14), and (31). c. Start the powerpack. d. If the pressure in the tank line is over 1 bar, check if the tank line is correctly installed or is there something blocking the line. 2. If the tank line pressure of the pilot control valves (58), (14), and (31) is below 1 bar, it is likely that either the valves (3) and (4) or the valve (14) is sticking. The operation of the valves can be checked as follows: a. Install a pressure gauge to the measuring point M9 of the feed and percussion control block. b. Start the powerpack. c. If the measuring point M9 shows no pressure, it is likely that the valve (3) or (4) is sticking. Check the valves as follows: • Stop the powerpack. • Clean and repair, or replace the faulty valve(s). d. If the measuring point M9 shows a pressure reading, it is likely that the valve (14) is sticking (leaking). Check the operation of the valve as follows: • Stop the powerpack. • Replace the percussion pilot control valve (14).
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.6.
Percussion full-power max. pressure too high
1. If the rattling on/off valve (8) is faulty or sticking, clean and repair, or replace the valve. 2. If the percussion pressure is too high, start troubleshooting by checking the adjustment of the percussion max. pressure relief valve (7) according to chapter "Adjusting percussion full-power" (p. 91) . If the percussion pressure relief valve (7) is not working properly, clean and repair, or replace the valve. 3. If the above measures do not make the pressure level correct, the fault may be that the loadsensing line orifice (9) has loosened. The mounting of the orifice (9) is checked from the port 9 of the feed and percussion control block as follows: a. Stop the powerpack. b. Remove the adapter from the port 9 of the feed and percussion control block. c. Check if the orifice (9) is properly seated at the bottom of the drilling port 9. d. If the orifice has loosened, retighten it carefully. e. Mount the adapter back on the port 9 of the feed and percussion control block.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.7.
Percussion full-power max. pressure too low
1. If the percussion pressure is too low, start out by checking the operation of the percussion max. pressure relief valve (7) according to chapter "Adjusting percussion full-power" (p. 91) . If the percussion pressure relief valve (7) does not adjust as described in the chapter "Adjusting percussion full-power" (p. 91) , clean and repair, or replace the valve. 2. Next, check the feed pilot control pressure value: a. Remove the drill rod. b. Install a pressure gauge to the measuring point M1 for the anti-jamming and return automatics. c. Start the powerpack. d. Run the rock drill against the front stopper by locking the control lever of the feed pilot control valve into the rear position. e. If the pressure at the measuring point M1 is not 19-21 bar, it is likely that the feed pilot control valve (31) is faulty. f. Stop the powerpack. g. Replace the feed pilot control valve (31). h. If the pressure at the measuring point M1 is approx. 19-21 bar, it is likely that the percussion pressure selector valve (5) and/or the monitoring valve (18) is faulty or sticking. Check the operation of the monitoring valve (18) as follows: • Start the powerpack. • Engage rattling. - If rattling pressure is same as the max. percussion pressure, the monitoring valve (18) is faulty or sticking. • Stop the powerpack. • Clean and repair, or replace the faulty valve (5) and/or (18). 3. Percussion pressure may also drop if the load-sensing line orifice (9) becomes blocked. Check the orifice (9) as follows: a. Start the powerpack. b. Turn percussion on by locking the control lever of the percussion pilot control valve (14) into the rear position, and move the boom at the same time. c. If the boom functions are normal, but the percussion pressure remains low, it is likely that the orifice (9) in the load-sensing line is at least partly blocked. Check the orifice (9) hole as follows: • Stop the powerpack. • Remove the adapter from the port 9 of the feed and percussion control block. • Remove the orifice (9) to check it (clear the hole as necessary). • Mount the orifice (9) back carefully. 4. If the output of the pump (1) is insufficient, the percussion pressure will drop. The output of the pump (1) can be checked by installing flow meters to the percussion and feed lines. The flow rates for percussion (HLX5/RD) and feed (TF500/TFX500) are following: Percussion
Feed
100-115 l/min
4-8 l/min
If the flow rates are higher than those given above, you should immediately check the condition of the rock drill or the feed cylinder.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 5. A drop in percussion pressure may also be caused by a leaking shuttle valve (10) and/or (208) or directional valve (223). Check the shuttle valves as follows: a. Stop the powerpack. b. Clean or replace the valve (10) and/or (208). 6. Check the condition of the pressure gauge (11) with a calibrated reference gauge.
10.8.
Percussion half-power pressure too high
1. If the percussion half-power pressure is too high, check the adjustment of the percussion halfpower pressure relief valve (6) and the monitoring valve (18) according to chapters "Adjusting percussion half-power" (p. 90) and "Adjusting min. percussion pressure" (p. 89) . If the pressure relief valve (6) or the monitoring valve (18) does not work as it should, clean and repair, or replace the faulty valve. 2. If the pressure level is not correct after the above repair, the reason may also be that the orifice (9) of the load-sensing line has loosened. The mounting of the orifice (9) is checked from the port 9 of the feed and percussion control block as follows: a. Stop the powerpack. b. Remove the adapter from the port 9 of feed and percussion control block. c. Check if the orifice (9) is properly seated at the bottom of the drilling port 9. d. If the orifice has loosened, retighten it carefully. e. Mount the adapter back on the port 9 of the feed and percussion control block. 3. High pressure level of percussion half-power may also result if the percussion pressure selector valve (5) is sticking. Check the operation of the valve as follows: a. Stop the powerpack. b. Clean and repair, or replace the valve (5).
10.9.
Percussion half-power pressure too low
1. If the percussion half-power pressure is too low, check the adjustment of the percussion halfpower pressure relief valve (6) according to chapter "Adjusting percussion half-power" (p. 90) and/or the monitoring valve (18) according to chapter "Adjusting min. percussion pressure" (p. 89) . If the pressure relief valve (6) and/or the monitoring valve (18) do not work as they should, clean and repair, or replace the valves. 2. If the pressure level is not correct after the above repair, the reason may also be that the orifice (9) of the load-sensing line has become blocked. Check the orifice (9) from the port 9 of the feed and percussion control block as follows: a. Stop the powerpack. b. Remove the adapter from the port 9 of feed and percussion control block. c. Remove the orifice (9) at the bottom of the drilling. d. Clear the orifice hole as necessary. e. Mount the orifice (9) back to the bottom of the hole carefully. f. Mount the adapter back on port 9 of the feed and percussion control block.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.10. Feed not working at all (drilling) If drilling feed is not working at all, check the adjustment of feed pilot control pressure. Feed pilot control pressure is checked as follows: 1. Install a pressure gauge to the measuring point M1 of the anti-jamming and return automatics block. 2. Start the powerpack. 3. Lock the control lever of the feed pilot control valve (31) into the rear position. 4. If the pressure at the measuring point M1 is approx. 19-21 bar, and the feed pressure gauge (21) also shows a pressure reading, it is likely that the feed cylinder is faulty, or a mechanical fault prevents feed. Repair or replace the faulty component(s). 5. If the pressure at the measuring point M1 is approx. 19-21 bar, but the feed pressure gauge (21) does not show any reading, it is likely that the spool of the feed directional valve (23) is sticking. Check the operation of the spool as follows: a. Stop the powerpack. b. Remove the front cover of the feed directional valve (23). The spool comes out with the cover. c. Clean the spool and the valve housing carefully. d. Mount the spool back with care. 6. If there is no pressure at the measuring point M1, it is likely that the feed pilot control valve (31) is faulty. Repair as follows: a. Stop the powerpack. b. Replace the valve (31).
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.11. Drilling feed pressure too low Troubleshooting should be started by checking the operation of the feed regulating valve (20) and/or feed deviation valve (216). This is done as follows: 1. Start the powerpack. 2. Lock the control lever of the feed pilot control valve (31) into the front position. 3. Check if the feed pressure regulating valve (20) and/or feed deviation valve (216) adjusts the feed pressure according to the chapter "Adjusting feed pressure" (p. 92) . Read the pressure value in the pressure gauge (21). 4. Release the control lever of the feed pilot control valve (31) into the middle position. 5. Stop the powerpack. 6. If the feed pressure regulating valve (20) and/or feed deviation valve (216) does not adjust according to the chapter "Adjusting feed pressure" (p. 92) , it is likely that either the valve (20) and/or valve (216) or the feed cylinder is faulty. Check the condition of the components as follows: a. Stop the powerpack. b. Plug the feed pressure line. c. Start the powerpack and check if the feed pressure regulating valve (20) and/or feed deviation valve (216) adjusts according to the chapter "Adjusting feed pressure" (p. 92) . d. If the valve (20) and/or valve (216)adjusts according to the chapter "Adjusting feed pressure" (p. 92) , it is likely that the feed cylinder is faulty. Repair or replace the faulty component. e. If the feed pressure regulating valve (20) and/or feed deviation valve (216) is still not adjusting, it is likely that the valve (20) and/or valve (216) is faulty. Clean and repair or replace the valve. 7. If the above repairs did not remedy the feed pressure adjustment, check the feed pilot control pressure value. It should be approx. 19-21 bar. Check the pressure as follows: a. Install a pressure gauge to themeasuring point M1 of the anti-jamming and return automatics block. b. Remove the drill rod. c. Lock the control lever of the feed pilot control valve (31) into the rear position. d. If the pressure at the measuring point M1 is not approx. 19-21 bar, it is likely that the feed pilot control valve (31) is faulty. Repair as follows: • Stop the powerpack. • Replace the faulty pilot control valve (31).
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.12. Drilling feed pressure too high 1. First, check the operation of the feed pressure regulating valve (20) and/or feed deviation valve (216) as instructed in chapter "Drilling feed pressure too low" (p. 114) , steps 1-5. If the pressure regulating valve (20) and/or feed deviation valve (216) does not adjust according to the chapter "Adjusting feed pressure" (p. 92) , it is likely that either the valve (20) and/or valve (216) is faulty. Repair as follows: a. Stop the powerpack. b. Clean and repair, or replace the valve (20) and/or valve (216). 2. If the fault was not removed, follow the instructions in the chapter "Drilling feed pressure too low" (p. 114) , step 5. If the pressure at the measuring point of the anti-jamming and return automatics block is well over 21 bar, it is likely that the feed pilot control valve (31) or the fast feed pilot control valve (33) is faulty. Check the operation of the valves as follows: a. Install pressure gauges to the measuring points M1 and M2 of the anti-jamming and return automatics block. b. Start the powerpack. c. If pressure reaches the measuring point M2 only, it is likely that the fast feed pilot control valve (33) is faulty, but if both measuring points receive pressure simultaneously, it is likely that the feed pilot control valve (31) is faulty. d. Stop the powerpack. e. Replace the faulty valve. 3. If the fault still was not removed, it is likely that the compensator (22) of the feed directional valve (23) is faulty. In this case, the feed directional valve (23) must be replaced as a complete unit.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.13. Manually controlled fast feed not working 1. If manually controlled fast feed is not working at all, troubleshooting should be started by checking whether other movements function according to the chapter "Drilling functions, fast feed and separate flushing do not start" (p. 120) . 2. If the other movements (mentioned above) are working, then check the pilot control pressure of fast feed. The pressure is checked as follows: a. Install pressure gauges to the measuring points M2 and M3 of the anti-jamming and return automatics block. b. Remove the drill rod. c. Start the powerpack. d. Run fast feed back and forth by turning the control lever of the fast feed pilot control valve (33) forwards and backwards. 3. If the measuring points M2 and M3 receive an approx. 30 bar pressure, and the feed pressure gauge (21) also shows a pressure reading, it is likely that the feed cylinder is faulty, or a mechanical fault prevents the movement. a. Repair or replace the faulty component(s). 4. If the measuring points M2 and M3 receive an approx. 30 bar pressure, but the feed pressure gauge (21) shows no reading, it is likely that the spool of the feed directional valve (23) is sticking. Check the operation of the spool as follows: a. Stop the powerpack. b. Remove the front cover of the feed directional valve (23). The spool comes out with the cover. c. Clean the spool and the valve housing carefully. d. Insert the spool back with care, and mount the front cover. 5. If the measuring points M2 and M3 receive no pressure, it is likely that the fast feed pilot control valve (33) is faulty. Repair as follows: a. Stop the powerpack. b. Replace the faulty valve (33).
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Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.14. Manually controlled fast feed too slow 1. Start troubleshooting by checking the pilot control pressures of fast feed in both directions. The pressures are checked as follows: a. Install pressure gauges to the measuring points M2 and M3 of the anti-jamming and return automatics block. b. Remove the drill rod. c. Start the powerpack. d. Run fast feed back and forth by turning the control lever of the fast feed pilot control valve (33) forwards and backwards. 2. If both measuring points show an approx. 30 bar pilot control pressure, it is likely that the fault is caused by either the adjustments of fast feed max. speeds or the adjustment of fast feed max. pressure. Check the adjustments as follows: a. Run the rock drill against the rear stopper by locking the control lever of the fast feed pilot control valve (33) into the front position. b. If the feed pressure gauge (21) shows the set 210 bar pressure, it is likely that the fast feed max. speeds are incorrectly adjusted. Adjust the fast feed max. speeds according to instructions in chapter "Adjusting fast feed max. speed" (p. 95) . c. If the fast feed max. pressure is not at the set value, adjust the pressure according to chapter "Adjusting fast feed max. pressure" (p. 94) . If the adjustment does not correct the situation, the fault is caused by either the fast feed max. pressure relief valve (30) or the feed cylinder. • • • •
Stop the powerpack. Plug the feed cylinder. Start the powerpack. Run fast feed forwards by pulling the control lever of the fast feed pilot control valve (33) backwards. • If the fast feed pressure now adjusts to the set value, it is likely that the feed cylinder is leaking or the feed has mechanical fault. Repair or replace the faulty component(s). • If the pressure does not adjust with the fast feed max. pressure relief valve (30), it is likely that the valve is faulty. Clean and repair, or replace the valve (30), and adjust as instructed in chapter "Adjusting fast feed max. pressure" (p. 94) .
10.15. Manually controlled fast feed too fast If manually controlled fast feed is too fast in either direction, the fast fed max. speeds are incorrectly adjusted. Refer to chapter "Adjusting fast feed max. speed" (p. 95) .
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.16. Rotation pressure too low 1. If rotation pressure is insufficient during drilling, you should immediately check the setting of LSpressure relief valve (65) of the rotation control block. Refer to chapter "Adjusting the max. pressure of rotation circuit" (p. 83) . If the LS-pressure relief valve (65) does not adjust to the recommended value (180 bar), it is likely that the valve (65) is faulty. In this case, clean and repair or replace the valve and adjust it according to the instructions in chapter "Adjusting the max. pressure of rotation circuit" (p. 83) . 2. If the rotation pressure is lower than normal during drilling, the reasonmay be that the feed pressure is too low or the oil flow to feed is too small. In this situation, there is a risk of underfeed, and the following points should be checked: a. Adjust feed pressure with the feed deviation valve (216) so that rotation pressure sets between 80 and 100 bar. If this won't help follow the steps 2b to 2g. b. Install a pressure gauge to the measuring point M1 of the anti-jamming and return automatics block. c. Remove the drill rod. d. Start the powerpack. e. Lock the control lever of the feed pilot control valve (31) to the rear position. f. If the pressure at the measuring point M1 is approx. 19-21 bar, it is likely that the feed pressure is insufficient. g. If the pressure is well below 19 bar, it is likely that the feed pilot control valve (31) is faulty. Replace the faulty valve (31). 3. If the rotation pressure persistently remains low, it is likely that the rock drill rotation motor is leaking. a. Replace the rock drill rotation motor.
10.17. Rotation pressure too high during drilling 1. Too high rotation pressure during drilling may be caused by too high feed pressure or incorrect drill rod rotation speed. a. Refer to chapter "Adjusting rotation speed" (p. 96) for rotation speed adjustment. b. Adjust feed pressure with the feed deviation valve (216) so that rotation pressure sets between 80 and 100 bar. Refer to chapter "Adjusting feed pressure" (p. 92) . 2. If the above adjustments did not bring down the rotation pressure, it is likely that the rock drill rotation motor or the rotation mechanism is faulty. a. Refer to the rock drill maintenance manuals.
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.18. Rotation speed regulation not working 1. If the regulation of rotation speed is not working, start troubleshooting by checking the rotation speed pilot control pressure. The pressure is checked as follows: a. Install measuring adapters and pressure gauges to the pilot control lines a and b of the rotation control block. b. Turn the rotation speed regulating valve (59) fully closed (clockwise). c. Start the powerpack. d. Lock the control lever of the rotation pilot control valve (58) into the rear position. e. Lock the control lever of the rotation pilot control valve (58) into the front position. f. Release the control lever of the rotation pilot control valve (58) to the middle position. g. Stop the powerpack. h. If the pilot control lines of the rotation directional valve (53) received an stand by-pressure, it is likely that the rotation regulating valve (59) is faulty or the rotation directional valve (53) is sticking. Check the operation of the valves as follows:
i.
• Clean and repair, or replace the rotation speed regulating valve (59). • Start the powerpack. • Lock the control lever of the rotation pilot control valve (58) into the rear position. • Turn the rotation speed regulating knob between extreme positions. • Release the control lever of the rotation pilot control valve (58) to the middle position. • Stop the powerpack. If the rotation speed regulation still did not work, it is likely that the rotation directional valve (53) is sticking. Check the operation of the valve (53) as follows:
• Stop the powerpack. • Remove the the rotation directional valve (53). • Clean the spool and the valve housing carefully. • Mount the valve back in place. 2. If the above repairs did not help to remedy the rotation speed regulation, it is likely that the rock drill rotation motor or the rotation mechanism is faulty. a. Refer to the rock drill maintenance manuals.
10.19. Return automatics fast feed not working If the rock drill does not start return movement automatically from the front limit, check if the return automatics selector switch is in the correct position (middle). If it is, check if the coil Y47 of the return automatics selector valve (39) at the anti-jamming and return automatics block is receiving control voltage. • If the coil of the valve (39) receives control voltage, it is likely that the valve (39) is sticking. - Clean and repair, or replace the valve. • If the coil of the valve (39) is not receiving control voltage, refer to instructions in chapter "Electric system troubleshooting" (p. 121) .
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THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.20. Drilling functions, fast feed and separate flushing do not start If the powerpack is on and drilling module movement prevention is off (switch SH292/SH293) and drilling functions, fast feed and separate flushing do not start (at the same time), it is likely that the drilling module movement prevention valve Y455 (221) is sticking or does not receive a control signal. 1. Check whether the valve (221) receives contol (is the LED on the valve socket on?). 2. If the valve receives a control signal, check the operation as follows: a. Stop the powerpack. b. Clean and repair, or replace the faulty valve. 3. If the valve does not receive control (the LED is not lit), check the electric connections. Refer to the separate electic system instruction.
10.21. Disturbance in shank lubrication The SLU unit monitors the oil flow. If no flow is detected, the indicator light (H72) on the drilling panel comes on and automatic drilling is stopped. This is reset by restarting the percussion or rotation and testing whether lubrication starts. In the shank lubrication system, the air pressure for shank lubrication is also monitored, separately for each rock drill. If the air pressure falls below 2.8 bar, the indicator light (H72) on the drilling panel comes on and automatic drilling is stopped. The oil level in the SLU oil tank is monitored as well. If the oil level in the SLU oil tank drops below the preset minimum level, all power packs are stopped and the low shank lubrication oil level indicator light (H608) on the QN panel comes on. 10.21.1. Pinpointing the fault in the pneumatic circuit If the drilling is stopped repeatedly and the indicator light (H72) indicates that the fault is in shank lubrication, the fault can be pinpointed in the pneumatic circuit as follows: 1. Turn rotation on. Shank lubrication starts. 2. Check whether the rock-drill-specific SLU air valve on the carrier receives control (is the LED on the valve cover lit?). 3. If the valve receives a control signal, measure the air pressure going to the pressure switch that monitors the shank lubrication. The pressure switch should be triggered at 2.8 bar and inform the monitoring system that the air pressure is sufficient. 4. If the air valve is working properly and the air pressure at the switch is sufficient, the fault is either in the air pressure switch or in the SLU pump unit – i.e., in the oil flow.
10.22. Too low or high stabilizer pressure The stabilizer pressure control system monitors for insufficient or excessive pressure. The control has a two-second delay. The stabilizer pressure control is activated when the power pack of the boom in question is started. If a stabilizer pressure fault occurs, the stabilizer indicator light (H72) on the drilling panel starts to flash and automatic drilling is stopped. The stabilizer pressure control has no separate reset procedure; drilling can be continued as soon as the stabilizer pressure is within the permissible range. 120 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.23. Electric system troubleshooting Trouble
Reason
Operation
Pilot control valves for drilling do S70, S71, and S72 do not stay not stay on on
• Check power supply fuse • Check power supply feed cable • Check if front limit pressure switch S80 is activated • Check operation of relays K77, K74, K129, K70
Pilot control valves for drilling do S72 does not stay on although not stay on S70 and S71 do
Check that V18 is fitted
Drilling does not stop
No automatic return of rock drill • Check position of switch S73 from front end and S74 (return does not work in manual position) • Check operation of front limit pressure switch S80 • Check relays (does relays K70, K71pull at front limit) • Check relay (does relay K78 pull at front limit with 6 sec delay) • Check Y47 operation at front limit (LED indicator). If LED illuminates, check operation of hydraulic system
Drilling stops and rock drill tries If forced return works with switch • Check operation of rear limit to return, but stops S73, rear limit S81 is maybe pressure switch S81 damaged • Check relay (does relay K72 pull at rear limit) Forced return not working with switch S73
Switch maybe damaged
Check operation of switch S73
Rock drill rotation stays on after Time relay K70 maybe damaged Check operation of time relay rear end K70 Forced return not working with switch S74
Switch maybe damaged
Rear limit S81 is maybe damDrilling stops but air blowing does not start (switch S74 in po- aged sition "automatic")
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
Check operation of switch S74 • Check operation of rear limit pressure switch S81 • Check relay (does relay K72 pull at rear limit)
121 (122)
THC 561 DRILLING HYDRAULICS Rotation with gear pump; Testing and adjusting 10.24. Main reference values (factory settings) for troubleshooting of hydraulics Object
Value
Variable displacement pump (1) • pressure controller • flow controller
230 bar 22-30 bar
Pilot control pressure for rotation, percussion, flushing and fast feed
30 bar
Pilot control pressure for feed
19-21 bar
Half-power percussion pressure
100 bar
Min. percussion pressure
120 bar
Full-power percussion pressure • for TF 500 or TFX 500
210 bar
Max. pressure of rotation circuit (relief valve (65))
180 bar
Max. fast feed pressure • for TF 500 • for TFX 500
210 bar 180 bar
Anti-jamming sensitivity pressure
120 bar
Max. speed forwards (fast feed) • for TF 500 • for TFX 500
≈ 0.3 m/s ≈ 0.3 m/s
Max. speed backwards (fast feed) • for TF 500 • for TFX 500
≈ 0.5 m/s ≈ 0.3 m/s
Return automatics (hydraulic control) • pressure reducing • max. pressure (impulse circuits)
10 bar 30 bar
Main pressure relief valve (211)
250 bar
Boom max. operating pressure
230 bar
Control pressures of stabilizer (optional)
min. 50 bar max. 110 bar ref. 30 bar
Power extractor pressure (optional)
150 bar
122 (122)
Copyright © Sandvik Mining and Construction ID: 550 8 en 2012-12-20
www.sandvik.com
Instrucciones originales 341 0 es 2009-01-27
BOMBA DE CAUDAL VARIABLE
Índice de contenidos 1. ESTRUCTURA DE LA BOMBA .................................................................................................... 3 2. FUNCIONAMIENTO DE LA BOMBA ............................................................................................ 6 3. UNIDAD DE REGULACIÓN .......................................................................................................... 7 3.1.
Controlador de presión ................................................................................................................................... 9
3.2.
Controlador de caudal ..................................................................................................................................... 9
3.2.1.
Conductos de detección de carga .............................................................................................................. 9
3.2.2.
Presión de reserva ........................................................................................................................................ 9
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BOMBA DE CAUDAL VARIABLE ESTRUCTURA DE LA BOMBA ID: 28577
1.
Los movimientos de pistón de la bomba llevan el aceite desde el lado de aspiración al lado de presión. Se trata de una bomba de pistón axial en la que los pistones se mueven en la dirección del eje motriz. La bomba de caudal variable usada por Sandvik es una bomba de tipo placa oscilante. Los extremos del pistón se deslizan contra la placa oscilante, cuyo ángulo depende de la señal LS (presión). Los orificios de la bomba están marcados como se indica a continuación: S = orificio de aspiración B = orificio de presión L = orificio de drenaje X = orificio piloto
1
2
B
L
S
ID: 28578
1
Controlador de presión
2
Controlador de caudal
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BOMBA DE CAUDAL VARIABLE
2
1
3
2
X 5
4
6
ID: 28579
Figura: Vista transversal de una bomba de la serie 31 5 3
6
4
2
ID: 28580
Figura: Vista transversal de una bomba de la serie 52
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Copyright © Sandvik Mining and Construction ID: 341 0 es 2009-01-27
BOMBA DE CAUDAL VARIABLE 1
Contrapistón
2
Pistones
3
El muelle de la placa de ángulo sujeta la placa en ángulo máximo (salida máxima) si la unidad de regulación no reduce el ángulo (salida).
4
Placa de oscilación
5
Pistón de control
6
Unidad de control
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BOMBA DE CAUDAL VARIABLE 2.
FUNCIONAMIENTO DE LA BOMBA ID: 28581
El caudal el proporcional a la velocidad de accionamiento y al desplazamiento. Ajustando la posición de la placa oscilante, se puede variar el caudal de forma continua. Carrera
Ángulo máximo = caudal máximo
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Carrera
Ángulo reducido = caudal reducido
Carrera = 0
Ángulo cero = caudal cero
Copyright © Sandvik Mining and Construction ID: 341 0 es 2009-01-27
BOMBA DE CAUDAL VARIABLE UNIDAD DE REGULACIÓN ID: 28585
3.
F
X
D 1
2
P
B1
A
C
T
ID: 28591
Figura: Unidad de regulación DRS 1
Controlador de caudal
2
Controlador de presión
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BOMBA DE CAUDAL VARIABLE 1 2 X1
X2
V 3
4 X 5 F
6 8
P
B1
7 T
A
10
B 11
9
S
13
L
35° _ 12
14
15
ID: 28592
Figura: Diagrama de flujo del sistema hidráulico Conducto de presión Conducto de retorno Conducto de presión de control
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1
Presión máx. del dispositivo
2
Válvula de doble efecto
3
Válvula con control eléctrico
4
Conducto de detección de carga
5
Controlador de caudal
6
Controlador de presión
7
Unidad controladora
8
Manómetro
9
Cilindro o motor conducido
10
Bomba
11
Válvula principal de alivio de presión
12
Termostato
13
Refrigerador
14
Filtro
15
Depósito de aceite
Copyright © Sandvik Mining and Construction ID: 341 0 es 2009-01-27
BOMBA DE CAUDAL VARIABLE La unidad de control montada en la bomba controla el ángulo de la placa oscilante. La bomba cuenta con controladores independientes para la presión y el caudal. El conducto B1 de la unidad de control recibe la presión del sistema. A través de los orificios de los husos de la unidad de control, la presión pasa al extremo izquierdo de los husos de control. El conducto A va hasta el pistón de control, que controla el ángulo de la placa oscilante. El conducto T va hasta la carcasa de la bomba, y se conecta al depósito a través de la línea de drenaje.
3.1.
Controlador de presión ID: 28596
Cuando se incrementa la presión en la línea B1, el huso de la unidad de control P se desplaza a la derecha, contra el resorte. Cuando se alcanza la máxima presión establecida, la conexión de B1 a A se abre, y el aceite fluye al pistón de control que reduce el ángulo de la placa oscilante. El tornillo de ajuste C se usa para ajustar la presión máxima del sistema. La presión debe ser aprox. 20 bares inferior a la presión de apertura de la válvula principal de alivio de presión (=válvula de seguridad).
3.2.
Controlador de caudal ID: 28597
El caudal varía dependiendo de la demanda del sistema. La presión del sistema a través de B1 afecta al extremo izquierdo del husillo F. La presión procedente del conducto de detección de carga X afecta al extremo derecho, donde está situado el muelle. La diferencia de presión en la válvula direccional del sistema V fuerza al huso del regulador F contra el muelle. Si se incrementa la diferencia de presión, la conexión entre las líneas B1 y A se abre, y la bomba se ajusta a un caudal más bajo. Si se redcue la diferencia de presión, la conexión entre las líneas A y T se abre, incrementándose también el caudal de la bomba. 3.2.1.
Conductos de detección de carga ID: 28598
Es posible ajustar varios sistemas (X1, X2, etc.) al mismo tiempo controlando las presiones LS de cada sistema. 3.2.2.
Presión de reserva ID: 28599
Si no hay ningún dispositivo en funcionamiento, el conducto de detección de carga X no tiene presión, porque está conectado a la línea del depósito a través de la válvula direccional. La presión del sistema procedente de B1 fuerza al huso regulador de caudal F hacia la derecha, contra el muelle. La conexión de B1 a A se abre, y la bomba se ajusta a caudal cero y presión baja. La presión de reserva del sistema se ajusta con el tornillo D. Cada valor deberá ajustarse siguiendo las instrucciones de ajuste de la bomba (depende del sistema).
Copyright © Sandvik Mining and Construction ID: 341 0 es 2009-01-27
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BOMBA DE CAUDAL VARIABLE
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Instrucciones originales 342 0 es 2009-01-26
SIMBOLOS USADOS EN LOS DIAGRAMAS PARA EL SISTEMA HIDRAULICO Y NEUMATICO
Índice de contenidos 1. SÍMBOLOS PARA EL SISTEMA HIDRÁULICO Y NEUMÁTICO ................................................. 3
Copyright © Sandvik Mining and Construction ID: 342 0 es 2009-01-26
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Copyright © Sandvik Mining and Construction ID: 342 0 es 2009-01-26
SIMBOLOS USADOS EN LOS DIAGRAMAS PARA EL SISTEMA HIDRAULICO Y NEUMATICO 1.
SÍMBOLOS PARA EL SISTEMA HIDRÁULICO Y NEUMÁTICO ID: 28424 Conducto de funcionamiento (conducto de alimentación, de retorno, de aspiración y de presión). Conducto de control piloto Conducto de drenaje o purga Conducto flexible Línea eléctrica
La línea punteada rodea los componentes que están ensamblados en una unidad
Eje, palanca, varilla, vástago del pistón Empalme de la canalización Canalizaciones cruzadas Dirección del caudal en el sistema hidráulico (por ejemplo, caudal de aceite en bombas y motores) Dirección del caudal en el sistema neumático (por ejemplo, caudal de aire en compresores y motores de aire) Dirección Dirección de rotación Recorrido y dirección de las válvulas de caudal transversal. La línea pequeña perpendicular describe el movimiento de la flecha. Indicación de la posibilidad de regulación Muelle Muelle ajustable BOMBAS Y COMPRESORES Bomba hidráulica de capacidad fija con una dirección de flujo Bomba hidráulica de capacidad fija con dos direcciones de flujo Compresor
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SIMBOLOS USADOS EN LOS DIAGRAMAS PARA EL SISTEMA HIDRAULICO Y NEUMATICO MOTORES Motor eléctrico (Sandvik usa la misma marca para motores de radiador) Motor hidráulico de capacidad fija con una dirección de flujo Motor hidráulico de capacidad fija con dos direcciones de flujo Motor neumático de capacidad fija con una dirección de flujo (motor de aire) Motor oscilante (hidráulico) CILINDROS Cilindro de accionamiento simple
Cilindro de accionamiento simple con retorno por muelle
Cilindro de accionamiento doble
Cilindro con émbolo MÉTODOS DE CONTROL Muscular control Símbolo general Por palanca Por pedal Mechanical control Por muelle (por ejemplo, movimientos de retorno) Retén (por ejemplo, para mantener el carrete de la válvula de control en una posición determinada) Electrical control Por solenoide (un bobinado) Por solenoide (dos bobinados funcionando en direcciones opuestas) Control by pressure
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Copyright © Sandvik Mining and Construction ID: 342 0 es 2009-01-26
SIMBOLOS USADOS EN LOS DIAGRAMAS PARA EL SISTEMA HIDRAULICO Y NEUMATICO Control indirecto Control directo (recorrido interno)
VÁLVULAS Se trata de un cuadrado en una fila de cuadrados, cada uno de los cuales muestra una posición de funcionamiento de la válvula. VÁLVULAS DE CONTROL DIRECCIONAL Válvulas que abren o cierran uno o más recorridos de soplado (por ejemplo, controles del brazo). La válvula de control direccional es una fila de cuadrados en los que las líneas están conectadas al cuadrado que representa la posición básica.
A
B Marcas de orificios en las válvulas de control direccional:
P
T P = presión desde la bomba T = depósito A, B, C... = conductos de funcionamiento X, Y, Z... = conductos de presión piloto a, b, c... = conexiones para el control eléctrico Un recorrido de caudal Dos recorridos de caudal Un recorrido de caudal (dos puertos cerrados) Dos recorridos de caudal (un puerto cerrado) En los sgiguientes ejemplos, el primer número indica la cantidad de conexiones (aberturas), y el segundo número indcia la cantidad de posiciones de funcionamiento. Las conexiones de presión de control no aparecen representadas. 3/2 válvula de control, control piloto en ambas direcciones 4/3 válvula de control, controlada por palanca, centrado mediante muelle 6/3 válvula de control (válvula de control móvil) Válvula de cierre (por ejemplo, válvula esférica)
VÁLVULAS DE CONTROL DE PRESIÓN Válvulas que controlan la presión Pressure relief valve (safety valve)
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SIMBOLOS USADOS EN LOS DIAGRAMAS PARA EL SISTEMA HIDRAULICO Y NEUMATICO La presión de entrada se controla abriendo la abertura de escape al depósito de reserva, o a la atmósfera contra la fuerza opuesta. (Válvula hidráulica a la izquierda y neumática a la derecha) Pressure reducing valve (pressure regulator) La unidad con presión de entrada variable proporciona una considerable presión de salida constante, teniendo en cuenta que la presión de entrada permanece por encima de la presión de salida requerida. Sin orificio de salida
Con orificio de salida Overcenter valve La válvula permite un caudal libre en una dirección. También es posible el caudal en la dirección opuesta, teniendo en cuenta que una presión piloto externa abre la válvula, o la fuerza generada por la presión de entrada excede la fuerza del resorte. VÁLVULAS SIN RETORNO Válvulas que sólo permiten el caudal en una dirección Non-return valve Se abre con una pequeña diferencia de presión entre la entrada y la salida. Se abre debido a una diferencia significativa contra el muelle (por ejemplo, filtros de aceite). Pilot-controlled non-return valve La presión piloro abre la válvula. One-way restrictor La unidad permite el flujo libre en una dirección, pero en la otra dirección el flujo estará limitado. El caudal limitado es ajustable (por ejemplo, para controlar la velocidad del movimiento del cilindro). Shuttle valve El orificio de entrada conectado a la presión más alta se conecta automáticamente al orificio de salida, mientras que el otro orificio de entrada está cerrado. VÁLVULAS DE CONTROL DE CAUDAL Las válvulas que controlan el caudal Válvula de estrangulación Flow control valve Las variaciones en la presión de entrada no afectan al caudal volumétrico. 6 (10)
Copyright © Sandvik Mining and Construction ID: 342 0 es 2009-01-26
SIMBOLOS USADOS EN LOS DIAGRAMAS PARA EL SISTEMA HIDRAULICO Y NEUMATICO
Salida variable
Símbolo simplificado para el anterior
Salida variable con orificio de alivio
Símbolo simplificado para el anterior Flow dividing valve La válvula divide el caudal en dos caudales en una proporción fija, significativamente independiente de las variaciones de presión.
TOMA DE POTENCIA Enchufado (para la conexión de un manómetro o toma de potencia) Conectado. Con válvulas sin retorno de apertura mecánica DEPÓSITOS DE RESERVA Depósito de reserva, generalmente Depósito de reserva con conducto de entrada por encima del nivel del fluido Depósito de reserva con conducto de entrada por debajo del nivel del fluido Depósito de reserva (aire comprimido) Acumulador de presión FILTRO Filtro o colador LLAVE DEL AGUA Drenaje manual LUBRICADOR La unidad añade pequeñas cantidades de aceite al aire que pasa a través de la unidad
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SIMBOLOS USADOS EN LOS DIAGRAMAS PARA EL SISTEMA HIDRAULICO Y NEUMATICO REFRIGERADORES Refrigerador de aire
Refrigerador de agua
INSTRUMENTOS DE MEDICIÓN Manómetro Termómetro OTROS EQUIPAMIENTOS Presostato eléctrico Silenciador (suele usarse en aberturas de escape de aparatos neumáticos)
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Copyright © Sandvik Mining and Construction ID: 342 0 es 2009-01-26
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V 57215-1 en 1004 KTR Kupplungstechnik GmbH D-48407 Rheine
KTR-N sheet: edition:
ROTEX® GS mounting instructions
45510 E 1 5
The ROTEX® GS is a plug-in shaft coupling for measuring technique and automatic control engineering. It is able to compensate shaft displacement caused by an inaccurate manufacture, thermal expansion etc.
General Hints Please read through these mounting instructions carefully before you set the coupling into operation. Please pay special attention to the safety instructions! The mounting instructions are part of your product. Please keep them carefully and close to the coupling. The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.
Safety and Advice Hints STOP
DANGER !
Danger of injury to persons.
!
CAUTION !
Damages on the machine possible.
ATTENTION !
Pointing to important items.
F
General Hints to Danger
STOP
DANGER ! With assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is protected against unintentional engagement. You can be seriously hurt by rotating parts. Please make absolutely sure to read through and observe the following safety instructions.
• All operations on and with the coupling have to be performed taking into account "safety first". • Please make sure to disengage the power pack before you perform your work. • Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement or removing the fuse for current supply. • Do not touch the operation area of the coupling as long as it is in operation. • Please protect the coupling against unintentional touch. Please provide for the necessary protection devices and caps.
Proper Use You may only assemble, operate and maintain the coupling if you • have carefully read through the mounting instructions and understood them • and if you are authorized and have proper skills The coupling may only be used in accordance with the technical data (see ROTEX® GS catalogue). Unauthorized modifications on the coupling design are not admissible. We do not take any warranty for resulting damages. To further develop the product we reserve the right for technical modifications. The ROTEX® GS described in here corresponds to the technical status at the time of printing of these mounting instructions.
Urheberschutz Gezeichnet: 09.11.01 Sha/De gemäß DIN 34 Geprüft: 23.01.02 Sha
Ersatz für: KTR-N v. 15.06.93 Ersetzt durch:
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K
V
Verteiler VA
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KC
KTR Kupplungstechnik GmbH D-48407 Rheine
KTR-N sheet: edition:
ROTEX® GS mounting instructions
45510 E 2 5
The coupling is generally delivered in parts. Before the assembly, the coupling has to be controlled regarding its completeness.
Components of ROTEX® GS shaft coupling
Component
Quantity
1 2 3
2 1 2
Designation hub spider set screw
hardness of spider (shore) 80 Sh A-GS 92 Sh A-GS 95/98 Sh A-GS
picture 1: ROTEX® GS, size 5 - 38
standard - spiders marking marking hardness of (colour) (colour) spider (shore) blue green size 7 - 38 64 Sh D-GS yellow pale green size 42 - 75 red
picture 2: ROTEX® GS, size 42 - 75
Components of ROTEX® GS clamping hubs Component 1 2 3
Quantity Designation 2 clamping hub 1 spider 2 cap screw DIN 912
hub designs: size 5 - size 19 design 2.0 - clamping hub with 1 slot without feather key design 2.1 - clamping hub with 1 slot with feather key size 24 - size 75 design 2.5 - clamping hub with 2 slot without feather key design 2.6 - clamping hub with 2 slot with feather key picture 3: ROTEX® GS, clamping hub
Components of ROTEX® GS clamping ring hub Component 1 2 3 4
Quantity Designation 2 clamping ring 2 clamping ring hub 1 spider cap screw s. table 2 DIN 912
picture 4: ROTEX® GS, clamping ring hub
Urheberschutz Gezeichnet: 09.11.01 Sha/De gemäß DIN 34 Geprüft: 23.01.02 Sha
Ersatz für: KTR-N v. 15.06.93 Ersetzt durch:
W
K
V
Verteiler VA
M
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KTR Kupplungstechnik GmbH D-48407 Rheine
KTR-N sheet: edition:
ROTEX® GS mounting instructions
45510 E 3 5
Mounting Hint The design of the ROTEX® GS simplifies assembly axially with the plug feature after the assembly of the hubs on the shafts. The plug in design eliminates the need for the assembly openings in the housing that are necessary to tighten screws for many other types of couplings. The teeth of the elastomer spider includes small buttons which are used to establish the correct hub spacing which makes assembly easier and prevents positioning the hubs too tight together. All teeth are beveled on the face to assist blind assembly. When pushing the coupling hubs together with the ROTEX® GS spider there is an axial assembly force required as a result of the elastic pre-stress of the star-shaped elastomer spider. This assembly force varies depending on the coupling size, the spider hardness and the manufacture tolerances. This axial coupling force is balanced after pushing the hubs together and does not increase the axial load on the adjacent bearings. The assembly force can be reduced by a slight spraying of the elastomer with oil (e. g. Castrol 4 in 1).
Assembly Suggestion for the Bore
STOP
DANGER ! The max. permitted bore diameters d1max. and d2max. (see ROTEX® GS catalogue) must not be exceeded. In case of non-observance of these values, the coupling can crack. Danger to life due to broken pieces flying around. • In case of manufacture of the hub bore by the customer, the true running and run-out (see picture 5) must be observed. • Please absolutely observe the values for d1max. and d2max. • Align the hubs carefully when assembling the finish bore. • Plan a set screw or an end disk for the axial safety of the hubs. picture 5: truth of running and run-out
Axial alignment
!
CAUTION ! Please observe the dimension E (table 3) during the assembly, so that the spider is axially movable in the insert. In case of non-observance, the coupling can be damaged.
Displacements The values of displacement indicated in table 3 offer safety in order to compensate external influences like e. g. thermal expansions or foundation sinkings.
!
CAUTION ! In order to ensure a long life of the coupling, the shaft ends have to be exactly aligned. Please absolutely observe the indicated values of displacement (see table 3). If you exceed the values, the coupling will be damaged.
Please note: • The values of displacement indicated in table 3 are max. values which must not occur simultaneously. If the radial and the angular displacement occur simultaneously, the permitted values of displacement must only be used proportionally. • Please control with a metering clockwork, a ruler or a feeler gauge it the permitted values of displacement indicated in table 3 are observed.
Urheberschutz Gezeichnet: 09.11.01 Sha/De gemäß DIN 34 Geprüft: 23.01.02 Sha
Ersatz für: KTR-N v. 15.06.93 Ersetzt durch:
W
K
V
Verteiler VA
M
KC
KTR Kupplungstechnik GmbH D-48407 Rheine
KTR-N sheet: edition:
ROTEX® GS mounting instructions
45510 E 4 5
Displacements
angular displacements
radial displacements
axial displacements
∆KW [mm] = L1max - L1min
Lmax = L + ∆KA picture 6: displacements
Assembly of the coupling parts (shaft-hub connection with feather key)
F
ATTENTION ! We recommend you to check the bores, shaft, keyway and feather key regarding their dimensional accuracy before the assembly.
Before starting the assembly, the set bores must be delivered from means of preservation. The shaft ends have to be cleaned, too.
!
CAUTION ! Please observe the manufacturer´s instructions concerning the use of cleaning materials.
The axial safety must be effected by a set screw DIN 916 with cup point or end plate. Please see table 3 concerning tightening torques for set screws. By a slight warming-up of the hubs (approx. 80 °C), an easier push onto the shaft is possible.
STOP
DANGER ! If you touch the warmed-up hub, you will get burns. Please wear protective gaunts.
Assembly of clamping hubs (design 2.0, 2.1, 2.5 and 2.6) The power transmission of the ROTEX® GS clamping hubs is effected frictionally engaged (design 2.0 and 2.5). In design 2.1 and 2.6 there is additionally a positive transmission by a feather key. Please observe the following procedure the assembly: • Clean and degrease the hub bore and the shaft. • Release the clamping screw slightly. • Push the hub onto the shaft. • Tighten the clamping screws with the tightening torques indicated in table 1.
!
CAUTION ! The frictionally engaged and transmittable torques of the clamping hubs are dependent on the bore diameter.
Urheberschutz Gezeichnet: 09.11.01 Sha/De gemäß DIN 34 Geprüft: 23.01.02 Sha
Ersatz für: KTR-N v. 15.06.93 Ersetzt durch:
picture 7: assembly of the clamping hub
W
K
V
Verteiler VA
M
KC
KTR Kupplungstechnik GmbH D-48407 Rheine
KTR-N sheet: edition:
ROTEX® GS mounting instructions
45510 E 5 5
Assembly of clamping hubs (design 2.0, 2.1, 2.5 and 2.6) Table 1: ROTEX® GS size clamping screw M1 tightening torque TA [Nm]
5
7
9
12
14
19
24
28
38
42
48
55
65
75
M1,2
M2
M2,5
M3
M3
M6
M6
M8
M8
M10
M12
M12
M12
M16
-
0,37
0,76
1,34
1,34
10,5
10,5
25
25
69
120
120
120
295
352 225 356 200 369 149 373 134 389 97 393 90 405 74 413 66 421 59 433 51 446 44 454 41 462 38 474 34
425 128 441 92 446 86 458 70 466 62 474 56 486 48 498 42 506 38 514 35 527 31
462 80 466 75 478 61 486 54 494 48 506 41 518 36 527 33 535 30 547 27
964 150 972 140 995 114 1010 101 1025 90 1048 77 1071 67 1086 61 1102 56 1125 50
torque capacity of the clamping hub [Nm] bore-Ø Ø2 Ø3 Ø4 Ø5 Ø6 Ø7 Ø8 Ø9 Ø10 Ø11 Ø12
surface pressure [N/mm2] * * * *
0,84 71,02 0,91 43,02 0,97 29,50 1,04 21,85 1,10 17,06 1,17 13,83
2,07 68,51 2,18 46,15 2,28 33,65 2,39 25,90 2,50 20,73 2,61 17,09 2,72 14,42 2,83 12,40
3,65 109,9 3,81 73,5 3,98 53,3 4,14 40,8 4,31 32,5 4,48 26,6 4,64 22,4 4,81 19,2 4,97 16,7
Ø14 Ø15 Ø16 Ø19 Ø20 Ø24 Ø25 Ø28 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45
Urheberschutz Gezeichnet: 09.11.01 Sha/De gemäß DIN 34 Geprüft: 23.01.02 Sha
4,48 134,9 4,64 89,5 4,81 64,4 4,97 48,9 5,14 38,7 5,30 31,6 5,47 26,4 5,64 22,5 5,80 19,4 6,13 15,1 6,30 13,5 6,46 12,2
23,6 139,3 24,3 105,2 25,0 82,8 25,7 67,2 26,3 55,9 27,0 47,4 27,7 40,8 29,0 31,4 29,7 28,0 30,4 25,2 32,4 19,0 33,1 17,5
32,4 131,0 33,1 105,7 33,8 87,3 34,4 73,6 35,1 63,1 36,5 48,1 37,1 42,7 37,8 38,2 39,8 28,5 40,5 26,2 43,2 19,4 43,9 18,2 45,9 15,2
74,3 171,3 75,5 143,9 76,7 122,9 79,2 93,2 80,4 82,5 81,7 73,6 85,4 54,6 86,6 50,0 91,6 36,7 92,8 34,3 96,5 28,4 99,0 25,4 101,5 22,9 105,2 19,8 108,9 17,4
89,1 105,9 91,6 80,0 92,8 70,6 94,1 62,9 97,8 46,3 99,0 42,4 104,0 30,9 105,2 28,8 108,9 23,8 111,4 21,2 113,9 19,0 117,6 16,4 121,3 14,4 123,8 13,2 126,2 12,2 129,9 11,0
Ersatz für: KTR-N v. 15.06.93 Ersetzt durch:
216 172 219 152 221 135 230 99 232 91 244 66 246 61 255 51 260 45 266 40 274 35 282 31 288 28 293 26 302 23
W
K
V
Verteiler VA
M
KC
KTR Kupplungstechnik GmbH D-48407 Rheine
45510 E 6 5
KTR-N sheet: edition:
ROTEX® GS mounting instructions
Assembly of clamping hubs (design 2.0, 2.1, 2.5 and 2.6) Continuation Table 1: ROTEX® GS size clamping screw M1 tightening torque TA [Nm]
5
7
9
12
14
19
24
28
38
42
48
55
65
75
M1,2
M2
M2,5
M3
M3
M6
M6
M8
M8
M10
M12
M12
M12
M16
-
0,37
0,76
1,34
1,34
10,5
10,5
25
25
69
120
120
120
295
486 30 494 28 514 24
539 28 547 26 567 23 587 20 608 17
559 24 567 23 587 19 608 17 626 15 648 13
1148 45 1163 42 1201 36 1239 31 1278 27 1316 24 1354 22 1392 20
torque capacity of the clamping hub [Nm] bore-Ø
surface pressure [N/mm2] 310 21 315 20
Ø48 Ø50 Ø55 Ø60 Ø65 Ø70 Ø75 Ø80
Assembly of clamping ring hubs design 6.0 The friction of the hub-shaft affects the torque transmission capacity of the ROTEX® GS clamping ring hub. The clamping ring’s internal taper and the taper of the hub that shrinks the hub onto the shaft creates the surface pressure necessary to carry the load. The torques indicated in table 2 assumes that the hub tolerance is DIN H7/k6 and the shaft fit of Ø55 G7/m6. In case of looser tolerances the torques in table 2 are reduced. The shafts (especially hollow shafts) must be selected for strength and size with sufficient safety to prevent plastic deformation. This can be roughly checked with the following criterion.
Rp0,2 − 2 ⋅ pW
If hollow shafts are used with clamping hubs, the necessary inside diameter of the hollow shaft diw is calculated with the following formula:
diW ≤ d ⋅
Tangential tension at the shaft inside diameter for hollow shaft:
σ tiW ≈ −
Tangential tension for full shaft:
σ tW = − p W N / mm2
Rp0,2 pW
= =
[N / mm ]
2 ⋅ pW 1 − CW 2
2
[
yield point of shaft material [Nmm2] surface pressure hub / shaft [N/mm2]
diW d CW
= = =
[mm]
Rp0,2
]
inside diameter of the hollow shaft [mm] shaft diameter [mm] diW / d
The necessary strength is not assured if the bore of the hollow shaft is larger than the calculated max. inside bore or if the tangential tension / clamping exceeds the yield point of the material. For detailed calculation please contact the KTR Engineering Department.
Urheberschutz Gezeichnet: 09.11.01 Sha/De gemäß DIN 34 Geprüft: 23.01.02 Sha
Ersatz für: KTR-N v. 15.06.93 Ersetzt durch:
W
K
V
Verteiler VA
M
KC
KTR Kupplungstechnik GmbH D-48407 Rheine
KTR-N sheet: edition:
ROTEX® GS mounting instructions
45510 E 7 5
Assembly of clamping ring hubs design 6.0 Please observe the following procedure during the assembly: • Clean the hub bore and the shaft and oil them afterwards with liquid oil (e. g. with Castrol 4 in 1 or Klüber Quitsch EX). CAUTION ! Do not use oil and grease with molybdenum disulphide or other high pressure additions as well as sliding grease pastes.
!
• Release the clamping screw slightly and pull off the clamping ring slightly from the hub, so that the clamping ring is released. • Push the clamping ring hub onto the shaft. • Tighten the clamping screws evenly and crosswise step by step until reaching the final tightening torque indicated in table 2. You have to repeat this until all clamping screws show this tightening torque. Also in the intermediate steps you have to repeat this process until reaching the tightening torque with all clamping screws.
picture 8: assembly clamping ring hub with clamping ring
Disassembly: Release the clamping screws evenly one after the other. Every screw must be released only a half rotation each revolution. Unscrew all clamping screws 3 4 threads. Elimiate the screw next to the threads for pull-off screws and screw them into the planned threads for pull-off screws. You can release the clamping ring by an even and crosswise tightening of the screws in the threads for pull-off screws. Tighten the screws step by step.
!
CAUTION ! In case of non-observance of these advices, the function of the coupling can be influenced.
Urheberschutz Gezeichnet: 09.11.01 Sha/De gemäß DIN 34 Geprüft: 23.01.02 Sha
Ersatz für: KTR-N v. 15.06.93 Ersetzt durch:
picture 9: disassembly clamping ring hub with clamping ring
W
K
V
Verteiler VA
M
KC
KTR Kupplungstechnik GmbH D-48407 Rheine
KTR-N sheet: edition:
ROTEX® GS mounting instructions
45510 E 8 5
Assembly of clamping ring hubs design 6.0 Table 2: ROTEX® GS size clamping screw M number z (each clamping ring hub) tightening torque TA [Nm]
14
19
24
28
38
42
48
55
65
75
M3
M4
M5
M5
M6
M8
M10
M10
M12
M12
4
6
4
8
8
4
4
4
4
4
1,34
2,9
6
6
10
35
60
69
120
120
918 170 954 151 1052 148 1040 134 1185 131 1220 119 1318 118 1359 102 1646 102 1662 88 1960 88
1568 174 1569 160 1768 155 1833 141 1968 139 2049 122 2438 119 2495 105 2898 103
torque capacity of the clamping ring hub [Nm] bore-Ø d1 Ø6 Ø10 Ø11 Ø14 Ø15 Ø16 Ø19 Ø20 Ø24 Ø25 Ø28
surface pressure [N/mm2] 8,6 225 13,8 130 14,7 118 22,7 108
41 272 45 248 62 211 68 203 67 171 83 153 90 149
48 214 67 182 74 175 72 148 90 132 97 129 112 102 120 100 143 96
Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 Ø48 Ø50
142 243 154 231 189 203 188 178 237 157 250 153 280 136 307 131 310 115 353 110 389 103
269 196 337 172 356 167 398 148 436 142 442 126 501 120 533 107 572 104 615 102 644 92
399 198 445 176 506 172 470 145 566 143 581 125 647 124 630 111 728 110 836 109 858 103
Ø55
533 229 639 216 650 192 685 180 809 175 841 155 926 152 916 137 1042 135 1181 133 1125 118 1311 113
Ø60 Ø65 Ø70 Ø80
Urheberschutz Gezeichnet: 09.11.01 Sha/De gemäß DIN 34 Geprüft: 23.01.02 Sha
Ersatz für: KTR-N v. 15.06.93 Ersetzt durch:
W
K
V
Verteiler VA
2246 175 2338 161 2500 158 2620 138 3082 134 3179 119 3657 116 4235 103
M
KC
KTR Kupplungstechnik GmbH D-48407 Rheine
KTR-N sheet: edition:
ROTEX® GS mounting instructions
45510 E 9 5
Technical Data alignment of the coupling
shaft distance „E“
picture 10: assembly of the coupling Table 3: coupling type (for all materials)
5
7
9
distance dimension E dimension s dimension b dimension dH
5 0,5 4 -
8 1 6 -
10 1 8 7,2
12 1 10 8,5
dimension G dimension t tightening torque TA [Nm]
M2 2,5 -
M3 3,5 -
M4 5 1,5
M4 5 1,5
12
14
19
24
28
38
42
48
55
65
75
20 2,5 15 30
24 3 18 38
26 3 20 46
28 3,5 21 51
30 4 22 60
35 4,5 26 68
40 5 30 80
M5 10 2
M6 15 4,8
M8 15 10
M8 20 10
M8 20 10
M10 20 17
M10 20 17
M10 25 17
dimensions of assembly 13 1,5 10 10,5
16 2 12 18
18 2 14 27
threads for setscrews M4 5 1,5
M5 10 2
displacements max. axial displacement ∆Ka [mm] max. radial displacement with 80 Sh A-GS ∆Kr [mm] max. radial displacement with 92 Sh A-GS ∆Kr [mm] max. radial displacement with 95/98 Sh A-GS ∆Kr [mm] max. radial displacement with 64 Sh A-GS ∆Kr [mm] max. angular displacement with 80 Sh A-GS ∆Kw [degrees] max. angular displacement with 92 Sh A-GS ∆Kw [degrees] max. angular displacement with 95/98 Sh A-GS ∆Kw [degrees] max. angular displacement with 64 Sh A-GS ∆Kw [degrees]
0,4
0,6
0,8
0,8
1,0
1,2
1,4
1,5
1,8
2,0
2,1
2,2
2,6
3,0
0,12
0,15
0,19
0,20
0,21
0,15
-
-
-
-
-
-
-
-
0,06
0,10
0,13
0,14
0,15
0,10
0,14
0,15
0,17
0,19
0,23
0,24
-
-
0,04
0,06
0,08
0,08
0,09
0,06
0,10
0,11
0,12
0,14
0,16
0,17
0,18
0,21
-
0,04
0,05
0,05
0,06
0,04
0,07
0,08
0,09
0,10
0,11
0,12
-
-
1,1
1,1
1,1
1,1
1,1
1,1
-
-
-
-
-
-
-
-
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
-
-
0,9
0,9
0,9
0,9
0,9
0,9
0,9
0,9
0,9
0,9
0,9
0,9
0,9
0,9
-
0,8
0,8
0,8
0,8
0,8
0,8
0,8
0,8
0,8
0,8
0,8
-
-
The indicated permissible displacement values of the elastic ROTEX® GS couplings are general guiding values, under consideration of the coupling load up to the nominal torque TKN of the coupling and an operation speed of n=1500 rpm, as well as an arising ambient temperature of +30 °C.
Urheberschutz Gezeichnet: 09.11.01 Sha/De gemäß DIN 34 Geprüft: 23.01.02 Sha
Ersatz für: KTR-N v. 15.06.93 Ersetzt durch:
W
K
V
Verteiler VA
M
KC
V 57230-3en 0803
Service
Hydraulic motors OMR, OMR C, and OMRW N series 5 and 6 Metric versions Spare parts list / service manual HN.12.O8.52 replaces HN.12.O7.52
Index
Page Cost-free repairs ....................................................................................................................... 2 Service shops ........................................................................................................................... 2 Exploded view: OMR Series 6 with separate spigot flange ...................................................... 3 Exploded view: OMR and OMR C Series 5 and 6 with separate spigot flange ... .................... 4 Exploded view: OMRW N series 5............... ............................................................................ 5 Spare parts list .......................................................................................................................... 6 Tightening torque ...................................................................................................................... 9 Dismantling ............................................................................................................................... 10 Assembly .................................................................................................................................. 14
06-1998
HN.12.O8.52
Book 2 Partition 3
1
Vederlagsfri reparation
Vi gør opmærksom på at den vederlagsfrie reparation som er omtalt i Danfoss Almindelige Leveringsbetingelser kun udføres hos Danfoss Nordborg eller hos Danfoss autoriserede service shops (side 2).
Cost-free repairs
We would point out that cost-free repairs as mentioned in Danfoss General Conditions of Sale, are carried out only at Danfoss Nordborg or at service shops authorized by Danfoss (page 2).
Kostenlose Reparatur
Wir machen darauf aufmerksam, dass die in den "Allgemeinen Lieferbedingungen" von Danfoss erwähnte kostenlose Reparatur nur bei Danfoss Nordborg oder bei den von Danfoss autorisierten Kundendienstwerkstätten ausgeführt wird (Seite 2).
Réparation gratuite
Nous faisons observer que la réparation gratuite mentionnée dans les Conditions générales de Vente de Danfoss ne devra être effectuée que dans les ateliers Danfoss à Nordborg ou dans les ateliers de dépannage agréés par Danfoss (page 2).
Authorized Service Shops
Australia : Austria : Belgium : Brazil : Canada : Denmark : Finland : France : Germany : Great Britain : Iceland : India : Italy : Japan : Korea : Netherlands : New Zealand : Norway : Republic of South Africa : Singapore : Spain : Sweden : Switzerland : Turkey : U.S.A. :
Danfoss (Australia) Pty. Ltd., Melbourne Hainzl Industriesysteme, GmbH., Linz N.V. Danfoss S.A., Bruxelles Danfoss do Brasil Ind.e Com. Ltda., São Paulo Danfoss Mfg. Ltd., Mississauga Danfoss Hydraulik A/S, Ganløse OY Danfoss AB, Espoo Danfoss S.a.r.l., Trappes (Paris) Danfoss GmbH., Offenbach/Main Danfoss Limited, Greenford (London) Hedinn Verslun HF, Reykjavik Dantal Hydraulics PVT Ltd., New Delhi Danfoss s.r.l. Division Sordella, Torino Danfoss K.K., Gotemba Unitek Corporation, Seoul Itho B.V., Schiedam Danfoss (New Zealand) Limited, Auckland Danfoss A/S, Skui Danfoss (Pty) Ltd., Johannesburg Danfoss Industries Pte. Ltd., Singapore Danfoss S.A., San Sebastian de los Reyes, (Madrid) Danfoss AB, Mjölby Danfoss Werner Kuster AG, Frenkendorf Mert Teknik A.S., Istanbul Danfoss Fluid Power Div. Racine, Wisconsin
Australia Australia Australia Australia Czech Rep. Greece New Zealand Taiwan
Danfoss (Australia) Pty. Ltd., Adelaide Danfoss (Australia) Pty. Ltd., Brisbane Danfoss (Australia) Pty. Ltd., Perth Danfoss (Australia) Pty. Ltd., Sydney Techno Trade, Olomouc A. Skoura & Co. E.E., Athens Danfoss (New Zealand) Limited, Christchurch Symbridge Machinery Co. Ltd., Taipei
Service Shops
2
HN.12.O8.52
: : : : : : : :
Exploded view OMR Metric version, series 6 with integrated spigot flange
HN.12.O8.52
3
Exploded view OMR and OMR C Metric version, series 5 and 6 with separate spigot flange
4
HN.12.O8.52
Exploded view OMRW N Metric version, series 5 and 6
HN.12.O8.52
5
Item Spare parts 1
Washer
3
Dust seal ring ∅25 mm, ∅1", 1" spl. shaft ∅25 mm, ∅1", 1" spl. shaft 28,5 mm tapered shaft ∅25 mm shaft ∅32 mm shaft,
5
7
Code no.
M6: L = 16 mm M5: L = 16 mm M6: L = 16 mm M6: L = 25 mm
681X1989 681X1961 681X0247 681X1454
9,9 x 6,1 x 0,5 mm
684X2047
35,0 × 27,5 × 2,2 mm
633B0370
35,0 × 27,5 × 4,0 mm
151-1313
1
35,0 × 28,5 × 4,0 mm 42,0 × 35,0 × 3,5 mm
633B0010 633B3198
1
1
1 1
1 1
6 6 6 6 6
1 1
1
1
151-5588 151-5458 151-5473 151-1827 151-5589 151-1734 151-1988
1
1 1 1 1
1 1 1
O-ring ∅25 mm, ∅1", 1" spl. 28,5 mm tapered shaft ∅25 mm ∅32 mm shaft ∅35 mm tapered shaft Bearing race ∅25 mm, ∅1",1" splined. shaft ∅25 mm, ∅1",1" splined. shaft 28,5 mm tapered shaft
Axial needle bearing ∅25 mm, ∅1", 1” spl. shaft ∅25 mm, ∅1", 1” spl. shaft 28,5 mm tapered shaft
39 × 28,6 × 4,9 mm, HSN
633B0414
42,0 × 28,6 × 5,5 mm, NBR
633B3385
1
1
1
1
42,0 × 28,6 × 5,5 mm, FPM
633B0323
1
1
1
1
46 × 35 × 4,9 mm 48,0 × 35,0 × 5,5 mm, NBR
633B0415 633B3273
1 1
47,2 × 3,5 mm, NBR
633B1191
1
48,0 × 2,0 mm, NBR 53,0 × 2,0 mm, NBR
633B1333 633B1528 633B0063
1
NBR: (Buna N, Perbunan)
1
1
47,5 × 29,5 × 3,0 mm
151-1608
1
52,0 × 35,0 × 3,5 mm
151-1701
1
42 × 28,7 × 4,5
151-5709
HN.12.O8.52
1
1
1
1
1 1
1
1
1
1
1
151-1458
1
981X3198
1
HPS: High pressure shaft seal
1 1
1
151-5708
FPM: Viton (ISO 1629)
1
1
41,6 × 29 × 4
∅32 mm shaft ∅35 mm tapered shaft
6
6
Shaft seal
∅32 mm shaft ∅35 mm tapered shaft 8
Dimension
Spigot flange ∅25 mm, ∅1" 1” spl. shaft (HPS) ∅25 mm, ∅1", 1" spl. shaft ∅25 mm shaft ∅25 mm shaft ∅32 mm shaft, (HPS) ∅32 mm shaft 35 mm tapered shaft
∅25 mm, ∅1", 1" spl. shaft (HPS) ∅25 mm, ∅1", 1" spl. 28,5 mm tapered shaft ∅25 mm, ∅1", 1" splined 28,5 mm tapered shaft ∅32 mm shaft, (HPS) ∅32 mm shaft, 35 tapered shaft 6
Number per motor Series 5 and 6 with separate spigot flange OMR OMR C OMR OMR OMRW Flange Flange Flange Flange OMRW N A2 A2 A4 C
Screw
2
4
Series 6* OMR Flange A2
1
* Series 6 with integrated spigot flange
1 1
1 1
Item Spare parts 9
10
11
12
Bearing race ∅32 mm shaft, ∅35 mm tapered shaft Castellated nut 28,5 mm tapered shaft ∅35 mm tapered shaft Washer for 28,5 mm tapered shaft ∅35 mm tapered shaft Parallel key for ∅25 mm shaft for ∅25 mm shaft for ∅1" shaft for ∅32 mm shaft for 28,5 mm tapered shaft ∅35 mm tapered shaft
Series 6* OMR Flange A2
Number per motor Series 5 and 6 with separate spigot flange OMR OMR C OMR OMR OMRW Flange Flange Flange Flange OMRW N A2 A2 A4 C
Dimension
Code no.
52,0 × 35,0 × 3,5 mm
151-1701
1
M20 × 1,5 M20 × 1,5
681X8202 681X8235
1
44,0 × 20,5 × 4,0
684X2530
1
A8 × 7 × 32 mm, DIN 6885 A8 × 7 × 31 mm 1⁄ × 1⁄ × 11⁄ inch, B.S.46 4 4 4 A10 × 8 × 45 mm, DIN 6885 B5 × 5 × 14 mm, DIN 6885 B6 × 6 × 20 mm, DIN 6885
682L8035 682L9007 682L8036 682L8019 682L8016
1
1
1
1 1
1
1 1
1 1 1
682L8021
1
14
Cardan shaft OMR 50 OMR 50 OMR 80 OMR 80 OMR 100 OMR 100 OMR 125 OMR 125 OMR 160 OMR 160 OMP 200 OMR 200 OMR 250 OMR 250 OMR 315 OMR 315 OMR 375 OMR 375
L = 96,6 mm L = 79,7 mm L = 101,0 mm L = 84,4 mm L = 104,5 mm L = 87,8 mm L = 109,0 mm L = 92,2 mm L = 115,0 mm L = 98,3 mm L = 122,0 mm L = 105,3 mm L = 131,0 mm L = 114,0 mm L = 142,0 mm L = 125,4 mm L = 152,5 mm L = 135,6 mm
151-1812 151-2652 151-1813 151-2653 151-1814 151-2654 151-1815 151-2655 151-1816 151-2656 151-1817 151-2657 151-1818 151-2658 151-1819 151-2659 151-1820 151-2660
1
16
O-ring
90,0 × 2,0 mm, NBR
633B1301
3
3
17
Distributor plate
151-1702
1
18
Gear wheel set OMR 50 OMR 80 OMR 100 OMR 125 OMR 160 OMR 200 OMR 250
W = 9,0 mm W = 14,0 mm W = 17,4 mm W = 21,8 mm W = 27,4 mm W = 34,8 mm W = 43,5 mm
151-1182 151-1138 151-1139 151-1140 151-1141 151-1189 151-1190
OMR 315 OMR 375
W = 54,8 mm W = 65,0 mm
151-1191 151-1192
HPS: High pressure shaft seal
HN.12.O8.52
1
1
Housing + output shaft
FPM: Viton (ISO 1629)
1
1
13
NBR: (Buna N, Perbunan)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
3
3
1
1
1
1
1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1 1 1 1 1 1
1 1
1 1
1 1
1 1
1 1
1 1
1
1 1
1
1 1
1
1 1
1
1 1
1
1 1
1
1 1
1
1 1
1
1 1 1
* Series 6 with integrated spigot flange
7
Item Spare parts 19
20
21
22
Dimension
Code no.
End cover Side port motor without drain Side port motor End port motor
150-5568 151-1659 151-1833
1
Number per motor Series 5 and 6 with separate spigot flange OMR OMR C OMR OMR OMRW Flange Flange Flange Flange OMRW N A2 A2 A4 C
1 1
1
1
1
7 5
7
7 7 7 7
7 7 7 7
7 7 7 7
7 7 7 7
7 7 7 7 7
7 7 7 7 7
7 7 7 7 7
7 7 7 7 7
1
Washer Side port motor End port motor
11,9 × 8,2 × 1,0 mm 11,9 × 8,2 × 1,0 mm
684X0076 684X0076
7
Screw Side port motor OMR 50 OMR 80 OMR 100 OMR 125 OMR 160 OMR 160 OMR 200 OMR 250 OMR 315 OMR 375
M8 × 1,25 l = 40mm l = 45 mm l = 45 mm l = 50 mm l = 55 mm l = 65 mm l = 65 mm l = 75 mm l = 85 mm l = 95 mm
681X0180 681X0181 681X0181 681X0182 681X0183 681X0184 681X0185 681X0187 681X0189 681X0190
7 7 7 7 7
End port motor OMR 50 OMR 80 OMR 100 OMR 160 OMR 200 OMR 250 OMR 315 OMR 375
M8 × 1,25 l = 45 mm l = 50 mm l = 55 mm l = 65 mm l = 70 mm l = 80 mm l = 90 mm l = 100 mm
681X0181 681X0182 681X0183 681X0185 681X0186 681X0188 681X0239 681X0240
5 5 5 5 5 5 5 5
151A0411 151A0412 151A0417
1 1 1
1 1
684X2120
1
1
1
1
1
151-1524
1
1
1
1
1
151-1076 15 -1995
2
2
2
2
633B1324
4
4
4
2 2 2
2
2
7 7 7 7
7
7 5
5 5 5 5 5 5 5 5
Name plate Side port motor - aluminium Side port motor - brass End port motor - aluminium 17,5 × 13,5 × 1,5 mm
24
Washer
25
Drain plug
26
Check valve incl. item 27
5,0 × 1,5 mm, NBR
27
O-ring
28
Plug Side port motor- plastic plug End port motor - steel plug End port motor - plastic plug
NBR: (Buna N, Perbunan)
8
Series 6* OMR Flange A2
FPM: Viton (ISO 1629)
HN.12.O8.52
633X0074 631X9706 633X0074
HPS: High pressure shaft seal
1 1
1 1
2
2
* Series 6 with integrated spigot flange
4
4
2 2 2
Item Spare parts
Dimension
Code no.
Spar parts bag for motors with HPS and ∅25 mm, ∅1", 1” spl. shaft (Series 5/6) 3 5 6 6 16 16 20
1 pcs. Dust seal 1 pcs. Shaft seal (Series 7/8) 1 pcs. O-ring 1 pcs. O-ring 3 pcs. O-ring 3 pcs. O-ring 7 pcs. Washer
151-1286
35 x 27,5 x 2,2 mm NBR 39 x 28,6 x 4,9 mm HSN 47,2 x 3,5 mm NBR 48 x 2 mm NBR 75,9 x 1,8 mm NBR 90 x 2 mm NBR 11,9 x 8,2 x 1 mm
Spar parts bag for motors with standard shaft seal and ∅25 mm, ∅1", 1” spl. shaft (Series 4/5 and 6) 3 5 5 6 6 16 20 24
32 x 27,0 x 4,0 mm 42 x 28,6 x 5,5 mm 48 x 28,6 x 6,0 mm 47,2 x 3,5 mm 48 x 2,0 mm 90,0 x 2,0 mm 11,9 x 8,2 x 1,0 17,5 x 13,5 x 1,5
NBR NBR NBR NBR NBR NBR
Spare part bag for motors with ∅35 mm shaft (Series 4/5 and 6) 2 3 5 6 6 16 20 24
6 pcs. Washer 1 pcs. Dust seal 1 pcs. Shaft seal 1 pcs. O-ring 1 pcs. O-ring 3 pcs. O-ring 7 pcs. Washer 17,5 x 13,5 x 1,5 mm
NBR: (Buna N, Perbunan)
FPM: Viton (ISO 1629)
1
1
1
1**
1
1
1
151-1313 633B3385 633B3209 633B1191 633B1333 633B1301 684X0076 684X2120
151-1166
9,0 x 6,1 x 0,5 mm 42 x 35 x 3,5 mm NBR 48 x 35 x 5,5 mm NBR 53 x 2 mm NBR 74,0 x 2,0 mm NBR 90,0 x 2,0 mm NBR 11,9 x 8,2 x 1,0 17,5 x 13,5 x 1,5 mm
Number per motor Series 5 and 6 with separate spigot flange OMR OMR C OMR OMR OMRW Flange Flange Flange Flange OMRW N A2 A2 A4 C
633B0370 633B0414 633B1191 633B1333 633B1173 633B1301 684X0076
151-1277
1 pcs. Dust seal 1 pcs. Shaft seal (Series 5/6) 1 pcs. Shaft seal (Series 4) 1 pcs. O-ring 1 pcs. O-ring 3 pcs. O-ring 7 pcs. Washer 1 pcs. Washer
Series 6* OMR Flange A2
1
1
1
684X2047 633B3198 633B3273 633B1528 633B0063 633B1301 684X0076 684X2120
HPS: High pressure shaft seal
* Series 6 with integrated spigot flange ** Excl. dust seal ring 633B0010
Tightening torque
Item 1
10 21 25 28
Code Number 681X1989 681X0247 681X1961 681X1454
Torque (daNm) 0,5 - 0,8 0,5 - 0,8 0,5 - 1,0 1,2 - 1,5
681X8202 681X8232 631X9706
9,0 - 11 19 - 21 3,0 - 3,5 3,0 - 6,0 5,0 - 7,0
Torque (lbf in) 45 - 70 45 - 70 45 - 90 110 - 130 800 -1000 1680 - 1860 270 - 315 270 - 540 445 - 620
NBR: (BUNA N, PERBUNAN).
HN.12.O8.52
9
Special tools
Main holding tool (horse hole): Code No.: SJ 151-9000-1. SJ 151-9000-12
SJ 151-9000-14 Mandrel: Code No.: SJ 151-0414
Mandrel: Code No.: SJ 151-9000-7 or SJ 151F9000-7
Holding tool for motor with square mounting flange: Code No.: SJ 151-9000-12. Holding tool for OMRW N. Code No.: SJ 151-9000-14.
Dismantling
Item
Part to remove
10
Castelated nut
11
Washer
12
Parallel key
28
Seal plugs
Comments
Placer motor i holdeværktøj med udgangsaksel nederst. Ved endeportsversion benyttes 10 mm unbrakonøgle. Put the motor in a holding tool, with the output shaft downward. For end port version use 10 mm hexagon socket spanner. Den Motor mit der Abtriebswelle nach unten im Haltewerkzeug anbringen. Bei der Ausführung mit Endanschlüssen 10 mm Sechskantstiftschlüssel verwenden. Placer moteur dans l’outil arbre de sortie vers le bas. Pour la version avec orifice à l’arrière, utiliser une clé Allen de 10 mm.
25, 24
Drain plug, washer
Benyt 19 mm topnøgle.
(If present)
Einen 19 mm Steckschlüssel verwenden
Use a 19 mm spanner socket. Utiliser clé à douille 19 mm.
10
HN.12.O8.52
Dismantling
Item
Part to remove
21, 20 Screws, washers
Comments Benyt 13 mm topnøgle. Use a 13 mm spanner socket. Einen 13 mm Steckschlüssel verwenden. Utiliser clé à douille 13 mm.
19
End cover
Fjern endedækslet sideværts. Remove end cover sideways. Den Enddeckel seitwärts entfernen. Enlever le couvercle latéralement.
18, 16 Gear wheel set O-rings (2 off)
Hold fingrene under tandhjulssættet for at forhindre delene i at falde ud. Keep fingers under the gearwheel set to prevent the parts from falling out. Die Finger unter dem Zahnradsatz halten, um zu verhindern, daß Teile herausfallen. Tenir le jeu d’engrenages par dessous pour ne pas perdre de pièces.
14 17,16
13
Cardan shaft Distributor plate O-ring Output shaft
Motorer med integreret styreflange: Motorhus placeres på arbejdsbord og akslen presses ud af motorhuset. Akslen og lejer bør normalt ikke tages ud af OMRW N. Ønskes dette alligevel for inspektion og rengøring, føres akslen forlæns ud af huset. Det bagerste leje, kan derved forblive i huset. Vend herefter motoren. Motors with integrated spigot flange: Place the motor housing on the work bench and press the shaft out of the motor housing. Shaft and bearings should normally not be removed from OMRW N. However, if necessary for inspection and cleaning, remove the shaft from the housing front end. The rear bearing can thus remain in the housing. After this, turn the motor. Motoren mit integrietem Dichtungsflansch: Das Motorgehäuse auf dem Arbeitstisch legen und die Welle aus dem Motorgehäuse pressen. Welle und Lager sollten normalerweise nicht von OMRW N entfernt werden. Wenn aber notwendig zwecks Inspektion und Reinigung, die Welle vorwärts aus dem Gehäuse führen. Das hintere Lager kann somit im Gehäuse bleiben. Hiernach den Motor wenden. Moteur avec plaque porte joint intégrée: Placer le carter moteur sur l’établi et poussez sur l’arbre pour la faire sortir du carter moteur. Normalement, il ne faut pas enlever l'arbre et les paliers de l'OMRW N, mais au besoin, pour permettre l'inspection et le nettoyage, faire sortir l'arbre du carter par l'avant. Le palier arriére peut ainsi rester dans le carter. Retourner ensuite le moteur.
HN.12.O8.52
11
Dismantling
Item
Part to remove
Comments
1
Screws (6 off)
Anvend Torx-nøgle type T30, 9 mm skruetrækker eller 4 mm unbrakonøgle. Use Torx-spanner type T30, 9 mm screwdriver or 4 mm hexagon socket spanner. Werkzeug: Torx-Schlüssel Typ T30, 9 mm Schraubenzieher oder 4 mm Sechskantschlüssel. Utiliser: Clé Torx type T30, tournevis de 9 mm ou clé 'Allen de 4 mm.
2
Washer (6off)
Kun OMRW N Only OMRW N Nur OMRW n S’applique seulement aux OMRW N
4
Spigot flange
6, 7
O-ring, bearing race
Motorer med integreret styreflange: Fjern leje og løbeskive fra motorhuset. Motorer med separat styreflange: Anvend 2 mm skruetrækker Motors with integrated spigot flange: Remove bearing and bearing race from the motor housing. Motors with separate spigot flange: Use a 2 mm screwdriver. Motoren mit integriertem Dichtungsflansch: Lager und Scheibe aus dem Motorgehäuse entfernen. Motoren mit separatem Dichtungsflansch: Einen 2 mm Schraubenzieher verwenden. Moteur avec plaque porte joint intégrée: Retirer les butées et la butée à billes du carter moteur. Moteur avec plaque porte joint séparée: Utiliser un tournevis de 2 mm.
8
Needle bearing
5 3
Shaft seal Dust seal
Motorer med integreret styreflange: Slå pakdåsen forsigigt ud med dorn og plasthammer. Motorer med separat styreflange: Slå akselpakning / Støvtætningsring ud med plasthammer. Brug dorn SJ 151-9000-7 eller SJ 151F9000-7. Motors with integrated spigot flange: With mandrel and plastic hammer, carefully knock out the shaft seal. Motors with separate spigot flange: Knock out the shaft seal / dust seal with a plastic hammer. Use mandrel SJ 151-9000-7 or SJ 151F9000-7. Motoren mit integrietem Dichtungsflansch: Die Dichtung vorsichtig mit Dorn und Plasthammer herausschlagen Motoren mit separatem Dichtungsflansch: Die Wellendichtung / Staubdichtung mit Kunststoffhammer herausschlagen. Verwenden Sie Dorn SJ 151-9000-7 oder SJ 151F9000-7.
12
HN.12.O8.52
Dismantling
Item 5 3
Part to remove
Comments
Shaft seal Dust seal
Moteur avec plaque porte joint intégrée: A l’aide d’un marteau en plastic et d’un emporte-pièce, chassez délicatement le joint d’arbre Moteur avec plaque porte joint séparée: Faites sortir les joint d’arbre/anti-poussiére à l’aide d’un marteau plastique. Utilisez l’outil SJ 151-9000-7 ou SJ 151F9000-7.
9
Bearing race
Kun OMR/OMRW N med ∅32mm/28,5 mm konisk aksel. Anvend 2 mm skruetrækker. Only OMR/OMRW N with ∅32 mm/28,5 mm tapered shaft. Use a 2 mm screwdriver. Nur OMR/OMRW N mit ∅32 mm/28,5 mm kegelige Welle. Einen 2 mm Schraubenzieher verwenden. Seulement OMR/OMRW N avec ∅32 mm/arbre conique de 28,5 mm. Utiliser tournevis de 2 mm.
26
Check valves (2 off)
Kun OMR med kontraventiler Træk kontraventilerne ud med fx en nedslebet (afkortet) 3,5 mm snittap. Only OMR with check valves Pull the check valve out with, for example, a ground (shortened) 3.5 mm screw tap. Nur OMR mit Rückschlagventilen Die Rückschlagventile herausziehen, z.B. mit einem abgeschliffenen (verkürzten) 3,5 mm Gewindebohrer. Seulement OMR avec des clapets anti-retour Pour les sortir, utiliser par ex. un taraud 3,5 mm (raccourci).
Rensning Rengør omhyggeligt alle dele i aromatfattig petroleum. Kontrol og udskiftning Kontroller omhyggeligt alle dele og skift dem ud hvis nødvendigt. Smøring Smør alle enkeltdele ind i hydraulikolie før samling og indfedt gummidele med vaseline. Cleaning Clean all parts carefully with low aromatic kerosine. Inspection and replacement Check all parts carefully and replace if necessary. Lubrication Before assembly, lubricate all parts with hydraulic oil and grease rubber parts with vaseline. Reinigung Alle Teile sorgfältig in aromatarmem Petroleum reinigen. Kontrolle und Auswechslung Alle Teile sorgfältig kontrollieren und falls notwendig, auswechseln. Schmieren Alle Einzelteile vor der Montage mit Hydrauliköl einschmieren, und die Gummiteile mit Vaseline einfetten. Nettoyage Nettoyer soigneusement toutes les pièces dans du pétrole à faible teneur en additifs. Vérification et remplacement Vérifier soigneusement toutes les pièces et les remplacer s’il y a lieu. Lubrification Avant le remontage, enduire toutes les pièces d’huile hydraulique, et graisser les pièces de caoutchouc avec de la vaseline. HN.12.O8.52
13
Assembly
Item
Part to mount
Comments Placer motorhuset i holdeværktøjet med flangen øverst. Place the motor housing in the holding tool with the flange upwards. Das Motorgehäuse mit dem Flansch nach oben im Haltewerkzeug anbringen. Placer le carter du moteur dans l’outil, bride vers le haut.
26
Check valves (2 off)
Kun OMR med kontraventiler Indfedt kontraventilerne (med nye O-ringe) og monter dem i boringerne med lette slag af en plasthammer. Only OMR with check valves Grease the check valves (fitted with new O-rings) and fit them in their bores with light blows using plastic hammer. Nur OMR mit Rückschlagventilen Rückschlagventile (mit neuen O-Ringen) einfetten und mit leichten Schlägen mit einem Kunststoffhammer in den Bohrungen anbringen. Seulement OMR avec des clapets anti-retour Enduire de graisse les clapets antiretour avec nouveaux joints toriques et les mettre en place dans les alésages en tapant légèrement avec un marteau plastique.
9
Bearing race
Kun OMR/OMRW N med ∅32mm/28,5 mm konisk aksel. Only OMR/OMRW N with ∅32 mm/28,5 mm tapered shaft. Nur OMR/OMRW N mit ∅32 mm/28,5 mm kegelige Welle. Seulement OMR/OMRW N avec ∅32 mm/arbre conique de 28,5 mm.
5
Shaft seal
Motorer med integreret styreflange: Smør pakdåsen med hydraulikolie indvendig og udvendig. Placer pakdåsen korrekt på montagedorn SJ 151-0414 og pres den forsigtig på plads i motorhuset. Motorer med separat styreflange: Slå pakningen på plads i styreflangen. Kontroller at pakningen lægger an mod dækslets reces. Brug dorn SJ 151-9000-7 eller SJ 151F9000-7. Motors with integrated spigot flange: Lubricate the shaft seal on the out side with hydraukic oil. Fit the shaft seal correctly onto mandrel SJ 151-0414 and carefully press the shaft seal into position in the motor housing. Motors with separate spigot flange: Knock the seal into position in the spigot flange. Check that the seal lies against the cover recess. Use mandrel SJ 151-9000-7 or SJ 151F9000-7. Motoren mit integrietem Dichtungsflansch: Die Wellendichtung mit Hydrailiköl auf Innen- und außenseite schmieren. Die Dichtung korrekt auf Dorn SJ 151-0414 anbringen und vorsichtig an ihren Platz im Motorgehäuse drücken. Motoren mit separatem Dichtungsflansch: Die Dichtung im Steuerflansch an ihren Platz schlagen. Kontrollieren, ob die Dichtung an der Vertiefung des Deckels anliegt. Verwenden Sie Dorn SJ 151-9000-7 oder SJ 151F9000-7. Moteur avec plaque porte joint intégrée: Lubrifier le joint d’arbre sur sa contour extérieur avec de l’huile hydraulique. Positionnez-le sur correctement l’outil SJ 151 0414 et positionnez délicatement le joint d’arbre dans le carter moteur. Moteur avec plaque porte joint séparée: Placer le joint dans la bride de centrage et taper pour le mettre en place; s’assurer qu’il est blotti dans le recès. Utiliser pointenau SJ 151-9000-7 ou SJ 151F9000-7.
14
HN.12.O8.52
Assembly
Item
Part to mount
Comments
3
Dust seal ring
Anbring støvtætningsringen i styreflangen og bank den på plads med en plasthammer og passende dorn. SJ 151-9000-7 eller SJ 151F9000-7. Place the dust seal ring in the spigot flange and knock it into position with a plastic hammer and appropriate mandrel. SJ 151-9000-7 or SJ 151F9000-7. Den Staubdichtungsring im Steuerflansch anbringen und mit einem Kunststoffhammer und passendem Dorn an seinen Platz schlagen. SJ 151-9000-7 oder SJ 151F9000-7. Placer le joint anti-poussière dans bride de centrage et le taper en place avec marteau plastique et pointeau adéquat. SJ 151-9000-7 ou SJ 151F9000-7.
7, 6
Bearing race, O-ring
Motorer med integreret styreflange: Leje og løbeskive placeres på akslen og monteres sammen med denne. Motorer med separat styreflange: Indfedt O-ring i vaseline og monter løbeskiven og O-ringen i styreflangen. Motors with integrated spigot flange: Fit bearing and bearing race onto the shaft and mount together with the shaft. Motors with separate spigot flange: Grease the O-ring with vaseline and fit the bearing race and O-ring into the spigot flange. Motoren mit integrietem Dichtungsflansch: Lager und Scheibe auf die Welle platzieren und zusammen ein bauen. Motoren mit separatem Dichtungsflansch: O-Ring mit Vaseline einfetten und Laufscheibe und O-Ring im Zentrierflansch montieren. Moteur avec plaque porte joint intégrée: Monter les butées et la butée à billes sur l’arbre et monter l’ensemble dans le carter moteur. Moteur avec plaque porte joint séparée: Enduire le joint torique de vaseline et monter la butée à billes et le joint torique dans la plaque porte joint.
8
Needle bearing
4
Spigot flange
Drej så hullerne flugter. Turn so that the holes line up. So drehen, daß die Löcher fluchten. Ajuster pour aligner les trous.
2
Washer
Kun OMRW N Only OMRW N Nur OMRW N Seulement OMRW N
HN.12.O8.52
15
Assembly
Item
Part to mount
Comments
1
Screws (6 off)
Tilspændingsmoment Torx skruer M6 : 0,5-0,8 daNm Kærvskruer M6 : 0,5-0,8 daNm Unbrakoskruer M5 : 0,5-1,0 daNm Unbrakoskruer M5 : 1,2-1,5 daNm Vend herefter motoren. Tightening torque Torx screws M6 : Slotted screws M6 : Hexagon socket screws M5: Hexagon socket screws M5:
0,5-0,8 daNm(45-70 lbf in (in-lbs)) 0,5-0,8 daNm (45-70 lbf in (in-lbs)) 0,5-1,0 daNm (45-70 lbf in (in-lbs)) 1,2-1,5 daNm (45-70 lbf in (in-lbs))
After this, turn the motor. Anzugsmoment Torx Schrauben M6 : Schlitzschrauben M6 : Sechskantstift-Schrauben M5: Sechskantstift-Schrauben M5:
0,5-0,8 daNm 0,5-0,8 daNm 0,5-1,0 daNm 1,2-1,5 daNm
Hiernach den Motor wenden. Couple de serrage vis Torx M6 : vis à encoche M6: vis Allen M5 : vis Allen M5 :
0,5-0,8 daNm 0,5-0,8 daNm 0,5-1,0 daNm 1,2-1,5 daNm
Retourner ensuite le moteur. 13
Output shaft
Akselsølerne smøres med hydraulikolie. På akselenden skal der markeres et punkt lodret over et kommuteringsspor der har forbindelse til forreste ringkanal. Akslen på OMRW N føres bagfra ind i motorhuset med det bagerste nåleleje monteret på akslen. Slå med lette slag med plasthammer på akslen til den flugter med husets bagside. Kontroller at akslen nemt drejer rundt. Grease the journals with hydraulic oil. The rear shaft end must be marked before fitted. The mark must be positioned vertically above a commutation slot leading up to the front annular channel. For OMRW N, guide the shaft into the motor housing back with the rear needle bearing fitted on the shaft. Bring the shaft in line with the back of the motor by gently tapping the shaft with a plastic hammer. Check that the shaft rotates easily Die Gleitlager mit Hydrauliköl einschmieren. Am Wellenende muß senkrecht über eine Kommutierungsrille, die Verbindung mit dem vorderen Ringkanal hat, eine Markierung gemacht werden. Bei OMRW N, die Welle von hinten in das Gehäuse einführen, indem das hintere Nadellager auf der Welle montiert ist. Der Welle leichte Schläge eines Kunststoffhammers zufügen, um sie mit der Rückseite des Gehäuses zu fluchten zu bringen. Kontrollieren, daß die Welle unbehindert dreht. Enduire les tourillons de l’huile pour systèmes hydrauliques. Pour arbres marquer au bout de l'arbre arrière la position qui se trouver verticalement à une voie de commutation liée au canal annulaire placé en tête. Pour l'OMRW N, faire entrer l'arbre par l'arrière dans le carter du moteur, la butée à aiguilles arrière étant montée sur l'arbre. Faire affleurer l'arbre et l'arriére du carter en frappant légèrement sur l'arbre avec un marteau plastique. Vérifier que l'arbre tourne facilement.
16
HN.12.O8.52
Assembly
Item 16
Part to mount
Comments
O-ring
Indfedt O-ring og læg den i husets O-ringsrille. Grease the O-ring and put it in the O-ring groove of the housing. Den O-Ring einfetten und in die O-Ring-Rille des Gehäuses legen. Graisser le joint et le placer dans sa rainure dans le carter.
17
Distributor plate
Drej fordelerpladen, så hullerne flugter. Turn the distributor plate so that the holes line up. Die Verteilerplatte so drehen, daß die Löcher fluchten. Ajuster la plaque de distribution pour aligner les trous.
14
Cardan shaft
Før kardanakslen ned i motorhuset. Når der er forskel på splinelængden, vendes kardanakslen således, at den lange splinende monteres i udgangsakslen. Overfør markering fra udgangsaksel til kardanaksel. Guide the cardan shaft down into the motor housing. In case of different splines lengths turn the cardan shaft to ensure the long splines end is fitted in the output shaft. Transfer marking from output shaft to cardan shaft. Kardanwelle in das Motorgehäuse einführen. Bei unterschiedlichen Verzahnungslängen ist die Kardanwelle so zu richten, daß lange Verzahnungsendstück in der Abriebswelle montiert wird. Die Markierung von der Abtriebswelle auf die Kardanwelle übertragen. Glisser l’arbre à cardan dans le carter du moteur. Si les cannelures sont différentes de longeur, tourner l'arbre à cardan de façon que l'extrémité cannelée la plus longue est montée dans l'arbre de sortie. Reporter le marquage de l'arbre de sortie à l'arbre à cardan.
HN.12.O8.52
17
Assembly
Item 18, 16
Part to mount
Comments
Gearwheel set, O-rings
Placer O-ringene (indfedtet) i tandkransens O-ringsriller. I de tandhjul hvor splines ikke er gennemgående, vendes tandhjulet så fridrejning vender ned mod huset. Placer tandhjulssættet på kardanakslen, så en tandtop i tandhjulets udvendige fortanding er lodret over mærket på kardanakslen. Drej tandhjulssættet mod uret indtil kardanakslen og tandhjul går i indgreb (15°). Drej tandkransen, så hullerne til skruerne flugter. Place the O-rings (greased) in the O-ring grooves of the gearwheel. In gearwheels with non through splines place the gearwheel with the recess in the spline hole facing down towards the housing. Place the gearwheel set on the cardan shaft so that the top of a tooth in the external teeth of the gearwheel are vertically above the mark on the cardan shaft. Turn the gearwheel set counter clockwise until the cardan shaft and the gearwheel start to mesh (15°). Turn the gearwheel rim so that the holes made for the screws line up. Die O-Ringe (eingefettet) in den O-Ring-Rillen des Zahnkranzes anbringen. Einen Zahnradsatz mit Zahanrad ohne durchgehende Verzahnung so wenden daß die Seite ohne Verzahnung gegen das Motorgehäuse gekehrt ist. Den Zahnradsatz so auf der Kardanwelle anbringen, daß sich ein Zahnkopf in der Aussenverzahnung des Zahnrads senkrecht über der Markierung der Kardanwelle befindet. Den Zahnradsatz gegen den Uhrzeigersinn drehen, bis Kardanwelle und Zahnrad im Eingriff sind (15°). Den Zahnradkranz drehen, bis die Schraubenlöcher fluchten. Placer les joints toriques (graissés) dans leurs rainures dans la couronne dentée. Si les cannelures ne sont pas du type traversant, orienter la roue dentée avec la gorge de dégagement contre le carter. Placer le jeu d’engrenages sur l’arbre à cardan de façon à ce qu’un sommet de dent de la denture extérieure du rotor se trouve au-dessus de la rainure dans l’arbre a cardan. Tourner le jeu d’engrenages en sens inverse d’horloge jusqu’à engagement de l’arbre à cardan dans la roue dentée (15°). Tourner la couronne dentée pour faire aligner les trous à vis.
19
End cover
Drej endedækslet så hullerne flugter. Turn the end cover so that the holes line up. Den Enddeckel so drehen, daß die Löcher fluchten. Tourner le couvercle pour faire aligner les trous.
18
HN.12.O8.52
Assembly
Item 20, 21
Part to mount
Comments
Washer, screws
Benyt 13 mm topnøgle. Tilspændingsmoment: 3,0-3,5 daNm. Use a 13 mm spanner socket Tightening torque: 3,0-3,5 daNm (265-310 lbf in (in-lbs)). Den 13 mm Steckschlüssel verwenden. Anzugsmoment: 3,0-3,5 daNm. Utiliser clé à douille de 13 mm. Couple de serrage: 3,0 à 3,5 daNm.
24, 25
Washer, drain plug
Benyt 19 mm topnøgle. Tilspændingsmoment: 3 -6 daNm Use a 19 mm spanner socket. Tightening torque: 3-6 daNm (270-315 lbf in). Den 19 mm Steckschlüssel verwenden. Anzugsmoment: 3-6 daNm. Utiliser clé à douille 19 mm. Couple de serrage: 3 à 6 daNm.
28
Seal plugs Threaded plug (If present)
Endeportsversion Skru plastpropper i endeportene. Skru propperne i sideportene med 10 mm unbrakonøgle. Tilspændingsmoment: 5-7 daNm. Sideportsversion: Skru plastpropper i. End port version: Screw plastic plugs into end ports. Screw in the side port plugs using 10 mm hexagon socket spanner. Tightening torque: 5-7 daNm (445-620 lbf in (in-lbs)). Side port version Screw in plastic plugs. Ausgabe mit Endanschlüssen Kunststoffstopfen in die Endanschlüsse einschrauben. Stopfen in die Seitenanschlüsse mit 10 mm Sechskantstiftschlüssel einschrauben. Anzugsmoment: 5-7 daNm. Ausgabe mit Seitenanschlüssen: Kunstoffstopfen einschrauben. Version avec orifice à l’arrière Visser les bouchons dans les orifices arrières. Visser les bouchons dans les orifices latéraux avec une clé Allen de 10 mm. Version avec orifices latéraux: Visser les bouchons en place.
12
Parallel key
11
Washer
10
Castelated nut
HN.12.O8.52
Sikres med tape eller plastring. To be secured with tape or plastic ring. Mit Tape oder Kunststoffring sichern. Attacher avec du scotch ou un anneau en matière plastique.
19
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DK-6430 Nordborg Denmark 20
HN.12.O8.52