C 62950 - 3 en 1201 / MAH 1 (26)

AIR END AND PNEUMATIC CIRCUIT

RANGER

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
2 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

RANGER

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. COMPONENTS OF COMPRESSOR AND PNEUMATIC CIRCUITS . . . . . . . . 3
3.1. Pneumatic circuit diagram and components . . . . . . . . . . . . . . . . . . . . . 3
3.2. Location of pneumatic circuit components . . . . . . . . . . . . . . . . . . . . . . 6
4. AIR END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2. Air end main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3. Compressing principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. OPERATING PRINCIPLE OF COMPRESSOR CIRCUIT . . . . . . . . . . . . . . . . . . 10
5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2. Description of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3. Air circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4. Oil circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.5. Compressor circuit regulating system . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.5.1. Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.5.2. Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5.3. Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.5.4. Throttling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.5.5. Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.5.6. Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. CONTROL INSTRUMENTS OF THE PNEUMATIC CIRCUIT . . . . . . . . . . . . . . 20
6.1. Compressor circuit control instruments and warning lights . . . . . . 20
6.1.1. Compressor output air thermal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1.2. Air filter service indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2. Oil circuit control instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.1. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.2. Oil filter service indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7. ADJUSTING PRESSURE AND VALVE BLOCK CONNECTIONS . . . . . . . . . . 22
8. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.1. Compressor overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.2. Oil consumption too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.3. Insufficient air output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.4. Pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 3 (26)

AIR END AND PNEUMATIC CIRCUIT

RANGER

1. GENERAL
This document describes the components, operating principle and troubleshooting of the
Ranger pneumatic circuit.
Control instruments and warning lights are described in operator’s manual (chapter
control instruments).

2. SAFETY

Always follow the safety instructions and be careful with your work.

CAUTION

Service and adjustment procedures are only allowed to persons who

have been given specific service training. Read the instructions before
any adjusting or repairing.
CAUTION

Hazardous moving and rotating parts. Do the service and repair work
only when the rig is not running. Make sure that accidental starting or
moving of the rig is prevented during service.
WARNING

High pressure air injection hazard. Can cause severe injury. Relieve
pressure before removing filler plug or fittings.

WARNING

3. COMPONENTS OF COMPRESSOR AND PNEUMATIC CIRCUITS

3.1. Pneumatic circuit diagram and components

Ranger rigs are equipped with pneumatic circuit which produces pressurized air for the
following purposes:
-- flushing of drill holes
-- lubrication of shank
-- cleaning of dust collector filters
-- dust collector cut--off cylinder is air--operated
-- rod greasing device (option)

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
4 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

RANGER
25

21 18
20 19
23
22
24

9
15
10
3 16 14 8
6 12
7

17 11
13

39
29

30 28
40

31
26 27

32
35
34 33 37 36 38

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 5 (26)

AIR END AND PNEUMATIC CIRCUIT

RANGER
1. Air pre---cleaner*
2. Ejector*
3. Air filter
4. Air filter service indicator*
5. Air end, screw compressor
6. Intake valve
7. Oil/air receiver
8. Oil separator elements
9. Minimum pressure valve
10. Safety relief valve
11. Thermostat
12. Oil cooler
13. Oil filter
14. Strainer (in the oil regeneration line)
15. Orifice (in the oil regeneration line)
16. Non---return valve (in the oil regeneration line)
17. Temperature gauge
18. Pressure regulating valve
19. Blow ---down valve
20. Non---return valve
21. Non---return valve
22. Magnetic valve
23. Magnetic valve
24. Pressure accumulator
25. Pressure gauge
26. Flushing valve
27. Half flushing valve
28. Flushing regulating valve
29. Pressure gauge
30. Drill rod greasing valve
31. Suction cut off valve
32. Blow ---out valves
33. Dust collector
34. Dust collector filters
35. Air output connection and valve
36. Shank lubrication pneumatic valve
37. Water separator
38. Shank lubrication unit
39. Flushing control
40. Rock drill
41. Non--return valve of oil filling pump*
42. 3---way valve of oil filling pump*
43. Oil filling pump*

* = not in the chart

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 6 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

RANGER

3.2. Location of pneumatic circuit components

40, 30

17, 28, 29

7, 8, 9, 10

26, 27 14, 15, 16

39 12
32

11, 13
41, 42, 43

36, 37, 38
31
18, 19, 20, 21,
22, 23, 24, 25 2

35
1,3
33, 34
4
6

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 7 (26)

AIR END AND PNEUMATIC CIRCUIT

RANGER

4. AIR END

4.1. Technical data

Ranger 500 X, 600 X Ranger 700 X
Type Enduro 12 Enduro 25
Max. ambient temperature 40...45_C 40...45_C
Outlet air thermal switch 115_C 115_C
Output 5,8 m3/min 8,1 m3/min
Max. output pressure 10 bar 10 bar
Bearings Roller bearings Roller bearings
Male rotor dia 120 mm 155 mm
Gear ratio 1 : 2,4 1 : 1,564

4.2. Air end main components

The most important part of the Tamrock compressor is the air end, including the following
components:

5 1 2 3 4

90

1. Housing
2. Female rotors
3. Outlet cover
4. Bearing housing cover
5. Gear
E 2001 SANDVIK TAMROCK CORP., Tampere Plant,
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
8 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

RANGER

4.3. Compressing principle

Together with the housing the two meshing rotors form the compression chamber. The
rotating rotors take air into the housing through the inlet port as the grooves of the rotors
pass the inlet port.
As the rotors turn, the meshing point closes the passage to the inlet port, and the air is
trapped in the chamber.
With the progress of the rotation the volume of the chamber between the two rotors
becomes smaller, and the pressure increases.
When the desired pressure, the operationally most economical pressure, is reached the
compressed air flows through the outlet port into the oil/air receiver.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 9 (26)

AIR END AND PNEUMATIC CIRCUIT

RANGER

21
24

22

4 1 3 3.1 3.2
23
2 6.1 6.2

18

17
20
19

12 12.1
16
15 14 9 10

12.2 25

7
8

8.1

13.1 13.2

41 42

11

13
43

Components are shown under normal operating conditions, when compressed air is
being produced.
E 2001 SANDVIK TAMROCK CORP., Tampere Plant,
P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
10 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

RANGER

5. OPERATING PRINCIPLE OF COMPRESSOR CIRCUIT

5.1. General
The built--in air end (5) produces the pressurized air used by the drilling rig. The air flows
from the air end into the oil/air receiver. (7), where the oil is separated from the air.
According to the air consumption, the pressure regulator (18) adjusts the intake valve (6)
that regulates the inlet port. The temperature gauge (17) indicates the output air
temperature.

5.2. Description of components

1. Air pre-- cleaner

D The intake air gets into whirling motion inside the air filter housing, whereby the
centrifugal force separates the coarsest impurities from the air.
2. Ejector
D The diesel engine exhaust pipe is used as a venture tube to make suction in the
pipe connected to the air filter. The impurities separated in the pre--separator are
drawn through the pipe into the exhaust system and blown out with the exhaust
gases.
3. Air filter
D From the pre--cleaner the air flows through the filter unit (3), where it first passes
through the air filter (3.1) and after that through the safety filter (3.2).
4. Air filter service indicator
D The filter element must be changed always when the service indicator shows red.
The indicator must be checked daily by pressing the button on the top, whereby
the red warning colour must show. (Filter servicing: Ref. crawler base manuals and
maintenance schedules.)
5. Air end
D The filtered intake air is compressed by the rotating rotors. The oil in the rotor
housing cools the air, and simultaneously seals the clearances between the rotors
and the housing, and lubricates the unit.
6. Intake valve
D Suction opens the inlet valve when the air end is started. The intake valve also acts
as an air end underlaid valve by restricting the intake flow whenever air
consumption is less than the air end output. When the rotors are stopped the valve
acts as a non--return valve preventing the oil in the rotor chamber from entering the
intake duct.
7. Oil/air receiver
D The unit serves the purpose of an air and oil receiver including an oil separator.
8. Oil separator
D The oil separator separates the oil mixed with the pressurized air.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 11 (26)

AIR END AND PNEUMATIC CIRCUIT

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9. Minimum pressure valve

D The valve keeps at least 3 bar pressure in the tank while the compressor is running
to ensure the oil circulation.
10. Safety relief valve
D The valve restricts the maximum pressure in the receiver to 11.7 bar.
11. Thermostat
D The thermostat directs the oil below 45_C past the oil cooler. The thermostat starts
closing when the oil temperature rises over 45_C, allowing part of the oil to flow
through the cooler. When the oil temperature is over 48_C the thermostat is fully
closed, and all the oil circulates through the oil cooler.
12. Oil cooler
D The unit includes cooling cells for the driving and drilling hydraulics, and for the
compressor oil. The cooling power can be regulated by allowing a part or all of the
oil to the fan motor (12.2) to flow through the one way restrictor valve (12.1) directly
to the tank.
13. Oil filter
D The oil filter is a full--flow in--line unit with a mechanical service indicator and a
built--in by--pass valve. The by--pass valve (13.1) opens when the pressure
difference over the unit exceeds 3.5 bar. The red top of the service indicator (13.2)
pops up when the pressure difference exceeds 2.5 bar. The indicator has a built--in
bimetallic device to prevent indicator operation until oil temperature is above 27_C.
14. Strainer
D The strainer prevents the impurities from getting to the air end.
15. Orifice
D The orifice restricts the oil flow in the oil regeneration line.
16. Non--return valve
D The non--return valve prevents the oil/air mixture from going to the air end oil/air
receiver during the stopping. The screw unit remains pressurized until the pressure
in the oil/air receiver is released.
17. Temperature gauge
D The gauge indicates the temperature of the compressor output air. The sensor
(17.1) is located under the air end.
18. Pressure regulating valve
D The pressure regulator controls the inlet valve in accordance with air consumption,
maintaining the desired pressure. By adjusting the spring the compressor output
pressure can be regulated between 4 and 10 bar.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
12 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

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19. Blow--down valve

D The blow--down valve automatically releases the pressure from the oil/air receiver
when the air end is stopped. The pressure is released out through the valve (8).
20. Non--return valve
21. Non--return valve
22. Magnetic valve
23. Magnetic valve
24. Pressure accumulator
25. Pressure gauge
26. Flushing valve
27. Half flushing valve
28. Flushing regulating valve
29. Pressure gauge
30. Drill rod greasing valve
31. Cut--off cylinder and flap
D Dust collector suction can be shut off easily and quickly by closing the valve: the
pressure stops affecting the cut--off cylinder and the exhaust port flap is closed by
the spring.
32. Blow--out valves
33. Dust collector
34. Dust collector filters
35. Air output connection and valve
36. Shank lubrication pneumatic valve
37. Water separator
38. Shank lubrication unit
D Air/oil mist is used for lubrication of the rock drill front end. Oil amount is adjusted
by an oil flow regulator valve.
39. Flushing control
40. Rock drill
41. Non--return valve of oil filling pump
42. 3-- way valve
D The 3--way valve directs the oil from the oil filling pump (43) to the compressor
receiver or to the drilling hydraulic tank.
43. Oil filling pump
D The pump is used to add oil into the compressor and the drilling hydraulic circuits.
The required circuit is selected with the valve (42). The non--return valve (41)
prevents the air circuit pressure from breaking the seals in the pump.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 13 (26)

AIR END AND PNEUMATIC CIRCUIT

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5.3. Air circulation

The ejector (2) in the diesel engine exhaust pipe generates suction that is used to draw
out coarsest impurities from the pre--filter housing (1) into the exhaust pipe and out with
the gases.
The pre--cleaned air flows through the air filter (3) into the air end (5). The intake and
non--return valve (6) on top of the compressor is controlled by the pressure from the
pressure regulator (18). The intake valve (6) opens when the compressor starts.
After compression the oil/air mixture is led into the oil/air receiver (7) where the oil is
separated. As soon as the air pressure in the receiver exceeds the opening pressure of
the minimum pressure valve (9), the clean, oil--free air starts to flow out to be used for air
flushing, shank lubrication and other pneumatic devices.

5.4. Oil circulation

While the compressor is running, the minimum pressure valve (9) keeps at least 3 bar
pressure in the oil/air receiver. This pressure forces the oil from the receiver into the oil
circuit. The oil circulation is based on the pressure difference between the receiver and
the inlet side of the compressor.
The oil flows to the thermostat (11) through the connection at the bottom of the air/oil
receiver.
Oil temperature below 45_C
The cold oil flows directly through the thermostat valve (11) into the oil filter (13), and then
into the air end (5).
Oil temperature between 45--48_C
The bimetallic spring in the thermostat valve (11) starts closing the thermostat valve and
part of the oil flows through the oil cooler (12).
Oil temperature above 48_C
The thermostat valve is fully closed, and all the oil flows through the oil cooler (12).
From the oil cooler the oil flows to the oil filter (13). The filter has a built--in by--pass valve
(13.1) which lets the oil flow past the filter if the filter is plugged or if the oil is too thick while
it is not yet in operating temperature. The opening pressure of the by--pass valve is 3.5
bar. The filter unit also includes a mechanical indicator (13.2) with a red button that pops
up when the filter element is plugged (pressure difference over 2.5 bar).
From the filter the oil flows into the lubricating ducts at the inlet side of the air end (5). At
the beginning of the single phase compression, oil is injected onto the rotors to cool down
the air and to seal the clearances between the rotors and the housing. Oil flows also
through the other ducts to lubricate the bearings and the shaft gasket.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
14 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

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After compression, the pressurized oil/air mixture flows from the screw compressor into
the spiral duct of the oil/air receiver (7) where most of the oil is separated from the air to
the bottom of the receiver. The rest of the oil mixed with the air is separated when the air
flows through the oil separator element (8). The oil from the bottom of the separator
chamber is forced through the pipe to the inlet side of the compressor unit. The pipe
includes a strainer (14) and an orifice plate (15) (on top of the oil/air receiver) which must
be cleaned regularly.

5.5. Compressor circuit regulating system

5.5.1. Before starting
The system is not pressurized. The air end (5) is not running and the intake valve (6) is
closed preventing oil from the compressor from entering the intake line. The minimum
pressure valve (9) at the top of the oil/air receiver (7) is also closed.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 15 (26)

AIR END AND PNEUMATIC CIRCUIT

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5.5.2. Starting
When starting diesel engine magnetic valve (22) opens and keep open 30 seconds after
starting. Pressure of accumulator (24) keeps air intake valve (6) closed and compressor
does not load diesel engine.
When magnetic valve (22) closes it creates suction that opens the spring--loaded intake
valve (6) letting air enter the unit. At the same time air end sucks oil from the oil/air receiver
(9). The rotating screws compress oil and air into a mixture which is led to the receiver
where oil is separated from air by means of separator filters. During starting the pressure
in the receiver is below the opening pressure of the minimum pressure valve (11) which
remains closed.

22
24

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
16 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

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5.5.3. Delivery
The intake valve (6) is fully open, and pressure in the oil/air receiver (7) starts rising. When
pressure reaches 3 bar, the minimum pressure valve (9) of the receiver opens. The
pressure regulator (18) is used to adjust desired output pressure. Normally, the operation
is adjusted with the valve (18) so that the intake valve starts closing at 8 bar, and is fully
closed at 9 bar. The intake valve will operate steplessly between 8 and 9 bar. The oil that
escapes through oil separators is led to air end unit by a regeneration line which contains
a restrictor, non--return valve and strainer.

18

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 17 (26)

AIR END AND PNEUMATIC CIRCUIT

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5.5.4. Throttling
When the system pressure reaches the pressure setting of regulator (18) this opens,
letting air enter into intake valve (6). Air pressure pushes the piston forwards and closes
the air intake partly, thus restricting air flow to compressor. At the same time air flows to
compressor trough non--return valve (20). This way compressor gets extra air at the
moment when intake valve (6) is closing; this prevents noise caused by reduced intake
air flow into compressor.
Intake valve (6) operates steplessly in 1 bar area (for example starts to close at 7 bar =>
completely closed at 8 bar). Pressure setting for the system is normally 7 bar but it is
adjustable between 4 to 10 bar.

20
18

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
18 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

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5.5.5. Idling
This is the situation when air consumption is less than compressor delivers. It only differs
from ’throttling’ in the part of intake valve (6) which is now completely closed. Only oil and
air from substitution air valve (20) circulate in compressor circuit.

20

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 19 (26)

AIR END AND PNEUMATIC CIRCUIT

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5.5.6. Stopping
When compressor stops rotating, it also stops suction of air. Lack of suction makes intake
valve (6) close by the spring. Because of the pressure in oil/air receiver (7) air end (5)
becomes pressurized through the delivery line. The line from air end to blow down valve
(19) gets pressurized opening the valve. Blow down valve is pressurized in both lines but
because of different diameters in valve spools, the pressure from compressor can push
the other spool open releasing air from oil/air receiver (7).
Non--return valves in oil regeneration line (18) and regulator exhaust line (20) prevent
air/oil mixture from entering the system.
When the system pressure drops below the pressure setting of minimum pressure valve
(9) it gets closed.

20
19

5
16 7

The line from the oil/air container remains pressurized when the
minimum pressure valve has closed, unless air is used for some
function, e.g. to blow clean the dust collector filters.
WARNING

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 20 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

RANGER

6. CONTROL INSTRUMENTS OF THE PNEUMATIC CIRCUIT

6.1. Compressor circuit control instruments and warning lights

6.1.1. Compressor output air thermal switch

The compressor output air

temperature gauge (in operating
panel) indicates the output air
temperature. The gauge includes a
built--in thermal limit switch that
stops the diesel engine, and puts on
the warning light and the engine
stops if the output air temperature
exceeds 115_C.

6.1.2. Air filter service indicator

4
The air filter element must be
cleaned whenever the service
indicator (4) shows red. The air filter
element must be replaced at least
every 600 hours of operation or
every six months. The safety filter
must be replaced in connection with
every third air filter replacement or
at least every 1200 hours.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 21 (26)

AIR END AND PNEUMATIC CIRCUIT

RANGER

6.2. Oil circuit control instruments

6.2.1. Thermostat
The thermostat (11) controls the amount of oil flow through the oil cooler.
Oil temperature below 45_C thermostat fully open
above 48_C thermostat fully closed

6.2.2. Oil filter service indicator

The compressor oil filter has a

mechanical service indicator 13
(13.2). The filter element (13) must
be replaced if the red indicator 13.2
button stays up when the
compressor is running and the oil
has reached normal operating
temperature (above 48_C).

For operating principle and

operating range refer to chapter
”description of components/Oil
filter”.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
22 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

RANGER

7. ADJUSTING PRESSURE AND VALVE BLOCK CONNECTIONS

1. Pressure is adjusted when the compressor is running.

2. Select flushing off.
3. Use valve (18) to adjust the pressure to 8 bar. See pressure from gauge (25) (if
you want to adjust pressure lower open ball valve a litle during adjusting).

22

21

23
4

18

20
5

19
6

25

18 Pressure regulating valve 22 Magnetic valve

19 Blow---down valve 23 Magnetic valve
20 Non--return valve 25 Pressure gauge
21 Non--return valve

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 23 (26)

AIR END AND PNEUMATIC CIRCUIT

RANGER

4 25

5 21 18 1
20 19
24 23
22

6 3 5 6
2
1 1

1 From the air receiver

2 To pressure accumulator
3 To the inlet valve
4 Plucked
5 To the air end
6 Out--blow from the air receiver

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 24 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

RANGER

8. TROUBLESHOOTING
8.1. Compressor overheats

POSSIBLE REASON CHECK / OPERATION

Oil level too low. Check oil level and fill up if necessary.
Avoid overfilling (1/3 of the sight glass
height is sufficient).

Faulty thermostat (11). Check operation and condition of the ther-

(Oil circulation through the cooler partly or mostat (11).
completely obstructed.)

Dirty oil cooler (12). Clean the oil cooler.

Plugged oil filter (13). Replace the filter element (13). Also check
(Poor oil circulation -- poor cooling effi- the air filters (3.1 and 3.2) and inlet duct for
ciency) leaks.

Low output pressure. Raise the pressure by adjusting the pres-

(Low pressure -- poor oil circulation) sure regulator (18). Low pressure may also
be caused by excessive air consumption.

Oil viscosity too high (oil too thick). Check oil grade. Refer to oil recommenda-
(Poor oil circulation -- poor cooling effi- tions.
ciency)

Air in oil cooler. Bleed oil cooler, and change oil type if
(Poor circulation) foaming occurs.

Incorrectly adjusted/leaking/faulty pres- First check that one way restrictor valve
sure relief valve (84) of the pump (80) (12.1) at fan motor is not open; all oil
for the oil cooler. should go through fan motor (12.2).
(Fan rotates slowly -- poor cooling effi- (Ref. Drilling hydraulics instructions).
ciency) Check / adjust the pressure relief valve.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 C 62950 - 3 en 1201 / MAH 25 (26)

AIR END AND PNEUMATIC CIRCUIT

RANGER

8.2. Oil consumption too high

POSSIBLE REASON CHECK / OPERATION

Plugged return line. Clean orifice plate (15) (ø 1.0 mm), filter
(Too much oil in the separator chamber -- (14) and non--return valve (16) located on
oil mixes with output air) top of the oil/air receiver.

Faulty oil separator element (8) or O-- Check oil separator element (8) and O--ring
ring (8.1). (8.1) (for example, a hole in the element).

Oil level too high. Check oil level, and remove oil to correct
level.

Foaming oil Check oil grade. Refer to oil recommenda-

tion.
Check oil level.

8.3. Insufficient air output

POSSIBLE REASON CHECK / OPERATION

Incorrectly adjusted or faulty pressure Adjust regulator for higher pressure. Check
regulator (18). regulator operation and condition.

Leaking blow--down valve (19). Clean blow--down valve.

Plugged breather hole of intake valve Clean breather hole.

connecting nipple.
(Pressure under intake valve piston not re-
leased)

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 26 (26) C 62950 - 3 en 1201 / MAH

AIR END AND PNEUMATIC CIRCUIT

RANGER

Leaking air circuit. Repair leaking

(For example, a broken hose allows air to
escape)

Faulty dust collector blow--out valve. Turn the switch to forced flushing position.
The magnetic valve (33) will be closed.
Loosen the hose coming from the air/oil re-
ceiver (9) to the dust collector while flush-
ing is on. If air comes out through the hose
connection the magnetic valve is faulty.

8.4. Pressure too high

Leaking inlet valve (6) piston seal, or If air escapes through the breather hole
faulty inlet valve. above the piston while the compressor is
(Inlet valve not closing properly) running the piston seals must be replaced.

Incorrectly adjusted or jammed pres- Adjust pressure regulator for lower pres-
sure regulator (18). sure. Check regulator operation.

E 2001 SANDVIK TAMROCK CORP., Tampere Plant,

P.O.Box 100
FIN--33311 TAMPERE, Finland
Tel. +358 205 44 121, Telex 22335 parts fi
Telefax +358 205 44 4771
 B 63250 – 7 en 0301 / TMK 1 (11)

SLU 1/2/3
Operation and maintenance

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2. Operation of pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3. Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4. Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4.1. Oil container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4.2. Pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4.3. Shank lubricator control unit SLCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4.4. Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1. Output settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2. Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3. Boost switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1. Changing the seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

E 2001 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
2 (11) B 63250 – 7 en 0301 / TMK

SLU 1/2/3
Operation and maintenace

1. GENERAL
The shank lubricator SLU 1/2/3 is one of the most important units on Tamrock drilling
equipment. Its purpose is to provide sufficient lubrication for Tamrock rock drills under
varying drilling conditions and situations. Sufficient and accurate lubrication is made
possible by regulating the working frequency of the shank lubricator pump(s).

2. MAIN COMPONENTS
7

10

8
4
9

9
4

2
12
3 2
3
6
1
11
1. Monitoring switch CT 1
2. Hydr. bleed screw CT 4
3. Directional valve CT 5.1
4. Bleed screw CT 7
5. Oil container
6. Pump unit (1 main block, max. 2 auxiliary blocks)
7. Level guard
8. SLCU regulating unit
9. Boost switch
10. Breather / filler cap
11. Drain valve
12. Fine adjustment switches
E 2001 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
 B 63250 – 7 en 0301 / TMK 3 (11)

SLU 1/2/3
Operation and maintenance

3. OPERATING PRINCIPLE

Breather / filler cap

Level switch
Oil container

SLCU – control unit

Boost–switch

Pump unit

P T

Pump operating
pressure Air
Rock drill

Pressure line Tank

Hydr.oil tank line

3.1. General
The pump unit delivers oil to the rock drill along an inserted pipe. Pressurized air is used
for distributing the oil to the lubricating points. In a recovering system, pressurized air is
used for collecting the lubricating oil into a separate receiver. The system is equipped with
an oil level switch.

3.2. Operation of pump

The lubricating pump is a hydraulically operated piston pump with electric control. The
metered amount of oil is determined by electrically altering the pump’s working frequency.
The lubricating pump is made up of blocks. The pump consists of one main block with 1–2
auxiliary blocks connected to it (depending the number of the booms). The main block and
each auxiliary block have their own lubrication monitoring switch. Electric control is for the
main block only. Monitoring is activated always when operating voltage is switched on.
E 2001 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
 4 (11) B 63250 – 7 en 0301 / TMK

SLU 1/2/3
Operation and maintenace

3.3. Control unit

The closing ball in the non–return valve of the lubricating pump outlet port operates as a
monitoring switch against its seat. Oil flow through the non–return valve lifts the ball off
the seat surface, whereby the circuit is cut. The ball in the non–return valve of the control
valve connects electrically to the frame of the pump (and the drilling rig) Voltage is
connected to the ball via a spring that is insulated from the pump frame.

If the ball remains open over four working cycles, the alarm is switched
on. The indicator light goes on, the joystick(s) are centered and the
drilling function is disabled. Correspondingly, if the ball does not open
CAUTION over four working cycles, alarm is switched on. Alarm is removed when
normal pumping is resumed.

Pump block flowchart

CT7 CT6.2 CT1 = monitoring switch
CT2 = intake side non–return valve
CT1 CT2 CT1 CT2
CT3 = working piston
CT3
CT4 CT4 CT4 = hydr. bleed screw
CT3
CT5.1 = directional valve
CT5.1 CT5.2 = non–return valve
CT6.1 = non–return valve
CT6.1 CT5.2
CT6.2 = bleed screw
CT7 = bleed screw

3.4. Technical specifications

3.4.1. Oil container
ITEM SLU 22 SLU 14

Total oil capacity (liters) 22 14

Effective oil capacity without oil heater (liters) 18 12
Effective oil capacity with oil heater (liters) 16 –
Breather (µm) 10 10
Oil screen (mm) 1 1
Level guard yes yes

E 2001 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
 B 63250 – 7 en 0301 / TMK 5 (11)

SLU 1/2/3
Operation and maintenance

3.4.2. Pump unit

Displacement standard 0.85 cm# (7.5 mm stroke) (max.
1.25 cm#, 11 mm stroke)
Output range 80 – 1200 g/h (with standard stroke)
Max. hydr. pressure (pilot control) 210 bar
Min. hydr. pressure (pilot control) 25 bar
Max. lubricating pressure 25 bar

3.4.3. Shank lubricator control unit SLCU

– EMC approved
– 3 alarm outputs
– Boost function
– Operating voltage 24VDC

3.4.4. Tightening torques

Monitoring switch 7 Nm
Pump unit mounting screws 20 Nm

4. ADJUSTMENTS
The working frequency of the lubricator pump can be adjusted between 2 and 30 strokes
per minute using the two rotary switches on the SLCU unit. The 16 positions of the
switches are marked using numbers 0...9 and letters A...F. One of the switches selects
Range, and it is preset and sealed at the factory. The other switch is for Fine adjustment.
The metered values with different switch settings are shown in the table and graph on
page 6.

Adjusting switches

E 2001 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
 6 (11) B 63250 – 7 en 0301 / TMK

SLU 1/2/3
Operation and maintenace

4.1. Output settings

Range Fine [ g / h ] Rock drill type
0 80 – 150 HE 122
1 100 – 200 HL 300
2 150 – 300
3 200 – 400 HL 510, HLX5
4 300 – 600 HL 560, HL 600
5 400 – 850 HL 700, HL 1000
6–F 600 – 1200 HL 1500

NOTE! A circuitboard delivered as a spare part is set to maximum values.

Adjust correct output according to the information on this page.
CAUTION

Depending on the drilling conditions the required amount of lubrication

can be 1,5 – 2 times greater than the amount recommended here.
CAUTION

Chart reading example:

Range = 5
Fine adjusting = 9
Lubrication oil amount is approx. 590 g/h

range 5, fine adjusting 9

Range
Lubrication [g/h]

A B C D E F

Fine adjusting

Lubricant metering curves

E 2001 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
 B 63250 – 7 en 0301 / TMK 7 (11)

SLU 1/2/3
Operation and maintenance

4.2. Bleeding
Bleeding is based on gravity, and it is carried out by opening the bleeding screw (4) 1–2
turns and then waiting until the oil coming out no longer contains any bubbles of air. The
pump can be either running or stopped during bleeding.
When bleeding the pump with external pressure, the diesel/powerpack must be running.
Open the bleeding screw (4) 1/2 turn and the bleeding screw (2) 1/2 turn. Leave the screws
open for about 1 minute. Stop the diesel/powerpack. Close the bleeding screw (2). Open
the bleeding screw (4) 1–2 turns and wait until the outcoming oil no longer contains any
bubbles of air. Close the bleeding screw (4).

Bleeding cannot be done with the bleeding screw (4) closed and the
hydraulics bleeding screw (2) opened. This prevents air from escaping
from the pump.
CAUTION

4.3. Boost switch

The boost switch is used in cases as follows:
- to fill the shank lubrication hose
- to bleed the shank lubrication line
- when higher shank lubrication is temporarily needed
When the boost switch is activated, the indicator light of the control valve of the pump(s)
starts to flash. The oil output of the pumps(s) is now 1200 g/h and the pumps’ stroke
frequency is 30 strokes / minute. The boost function is active as long as the boost switch
is on.

Remember to turn off the boost switch after the service operations!

CAUTION

E 2001 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
8 (11) B 63250 – 7 en 0301 / TMK

SLU 1/2/3
Operation and maintenace

5. MAINTENANCE
– drain condensed water every 50. h
– change the breather every 1000. h (or earlier if necessary) and clean the tank
– check the function of the monitoring system every 1000. h

D disconnect directional valve connector, alarm is switched on (wait 4

pulses), or
D disconnect flow monitoring cable, alarm is switched on (wait 4 pulses), or
D short–circuit flow monitoring cable to pump body, alarm is switched on
(wait 4 pulses)
When replacing the faulty shank lubrication hose with a new one, operate as follows:

- change the faulty hose.

- disconnect the end of the desired shank lubrication hose from the rock drill.
- start the power pack (electric motor or diesel) and turn the air on
- turn the boost switch on.
- keep the boost switched on, until oil comes out of the hose (drain it into the overflow
receptacle).
- when drained from air, turn off the boost switch, and stop the powerpack.
- re–connect the shank lubrication hose to the rock drill

E 2001 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
 B 63250 – 7 en 0301 / TMK 9 (11)

SLU 1/2/3
Operation and maintenance

5.1. Changing the seals

3
2 1

1. SLU–pump unit
2. Piston plug
3. Piston
4. Piston seals
NOTE: Before assembling the SLU–piston into the cylinder!
– After installing the seals on the piston the seals at the both ends of it need to be
calibrated using this tool below, and preferably a lubricant should be applied (oil
or grease) to prevent any damage on the seals when performing that.

1. SLU–piston
2. Piston seal
3. Calibration tool
E 2001 SANDVIK TAMROCK CORP., Tampere Plant
P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
 10 (11) B 63250 – 7 en 0301 / TMK

SLU 1/2/3
Operation and maintenace

6. TROUBLESHOOTING
Problem : No oil output, indicator on in cabin
POSSIBLE REASON: REMEDY:
Oil level too low Add oil and remove air from pump through bleeding
screw (4)
Pump intake blocked Check and clean container
Delivery pipe blocked Remove and clean or replace delivery pipe
Oil viscosity too high Select correct oil grade
No pump operating pressure Problem in rig’s hydr. system?
Faulty solenoid valve of pump Check / replace valve
Faulty pump timer Check (measure) / replace timer
Solenoid valve wiring fault Check / replace wiring
Shank lubrication pressure hose Change or fix the hose
damaged

Problem : Too little oil

POSSIBLE REASON: REMEDY:
Incorrectly set timer (13) frequency Check setting
Air in pump Check oil level and bleed pump
Dirt in intake side non–return valve Clean ball of non–return valve
Dirt in control plug non–return valve Clean control plug / container
Breather blocked (underpressure) Clean breather
Return hose to collector tank blocked Clear obstruction

Problem : Too much oil

POSSIBLE REASON: REMEDY:
Hydraulics bleed screw open Close bleed screw (2)
Timer frequency incorrectly adjusted Check adjustment
Piston seals damaged Check piston and replace seals
BOOST switch activated Check and turn off

E 2001 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120
 B 63250 – 7 en 0301 / TMK 11 (11)

SLU 1/2/3
Operation and maintenance

Problem : Internal hydraulic oil leakage of pump

POSSIBLE REASON: REMEDY:
Hydraulics bleed screw open Close bleed screw (2)
Piston seals damaged Check piston and replace seals

Problem : Normal amount of oil (but alarm activated)

POSSIBLE REASON: REMEDY:
Fault in monitoring plug wiring Check/replace wiring
Dirty oil, conducting electricity Change oil in shank lubricator container
Worn flow monitoring device (pitted ball Check / replace flow switch assembly
surface)

E 2001 SANDVIK TAMROCK CORP., Tampere Plant

P.O.Box 100
FIN–33311 TAMPERE, Finland
Tel. +358 205 44 121
Telefax +358 205 44 120