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BG00198142 A.001.1 2014-05-26

Shank Lubrication Unit (SLU)


Shank Lubrication Unit (SLU)

WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and follow
operator's and maintenance manuals before installing, inspecting,
operating, servicing, testing, cleaning, transporting, storing,
dismantling or disposing of the product or a part or accessory of the
product.

Copyright © Sandvik
ID: BG00198142 en-US A.001.1 2014-05-26
Shank Lubrication Unit (SLU)

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Copyright © Sandvik
ID: BG00198142 en-US A.001.1 2014-05-26
Shank Lubrication Unit (SLU)

Table of Contents

1 Introduction ................................................................... 7
1.1 The Purpose of these instructions ......................................................7
1.1.1 Validity of the manuals ................................................................ 7
1.2 General .................................................................................................. 7

2 Safety and Environmental instructions ...................... 9


2.1 Safety precautions ................................................................................9

3 SLU main components ................................................. 11


3.1 Main components ................................................................................. 11
3.2 Technical data .......................................................................................13
3.2.1 Oil container ................................................................................ 13
3.2.2 Pump unit .................................................................................... 13
3.2.3 Shank lubricator control unit SLCU ............................................. 13
3.2.4 Tightening torques .......................................................................13

4 SLU operation instructions .......................................... 15


4.1 Operating principle ...............................................................................15
4.1.1 General ........................................................................................15
4.1.2 Operation of the pump .................................................................16
4.1.3 Control unit .................................................................................. 17
4.2 Shank lubrication system monitoring ................................................ 17
4.3 Operating principle of the shank lubrication system ........................18
4.4 Operation diagram of the shank lubrication oil pump ...................... 19
4.5 Monitoring unit ......................................................................................20
4.6 Heating circulation function ................................................................ 20

5 Operator's maintenance procedures ...........................23


5.1 SLU .........................................................................................................23
5.1.1 Checking the oil level .................................................................. 23

6 Periodic maintenance procedures .............................. 25


6.1 SLU .........................................................................................................25
6.1.1 Draining the condensed water .....................................................25
6.1.2 Cleaning the tank ........................................................................ 25
6.1.3 Replacing the breather ................................................................ 26
6.1.4 Checking the function of the monitoring system ..........................27

7 SLU repair instructions ................................................ 29


7.1 Adjustments .......................................................................................... 29
7.2 Output settings ..................................................................................... 29

Copyright © Sandvik
ID: BG00198142 en-US A.001.1 2014-05-26
Shank Lubrication Unit (SLU)

7.3 Bleeding .................................................................................................30


7.3.1 Bleeding the shank lubrication oil line ......................................... 33
7.3.2 Bleeding the shank lubrication oil pump ......................................34
7.4 Replacing seals .....................................................................................35
7.5 Replacing a faulty shank lubrication hose .........................................36
7.6 Boost switch ......................................................................................... 37

8 SLU troubleshooting .....................................................39


8.1 Troubleshooting ................................................................................... 39

Copyright © Sandvik
ID: BG00198142 en-US A.001.1 2014-05-26
Shank Lubrication Unit (SLU)

1 INTRODUCTION
1.1 The Purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
Before operating, or performing maintenance or repair procedures for the
component or system described in this manual, read and understand the
information in operator´s and maintenance manuals supplied with the
machine. Pay special attention to the safety information in chapter "2 Safety
and environmental instructions" of those manuals.
1.1.1 Validity of the manuals
This manual, and especially the safety information, is valid only if no
unauthorized changes to the product are made.
Continuing improvement and advancement of product design might have
caused changes to your product which are not included in this publication.
Note also that if a third party has made changes to the product after
delivery from the manufacturer, this publication does not include
information on these changes or their influences on the product.
Whenever a question arises regarding your product, or this manual, please
consult your local Sandvik representative for the latest available
information.

1.2 General
The purpose of shank lubrication is to lubricate the rock drill’s rotation
mechanism and shank. Lubrication is carried out using a mixture of shank
lubrication oil and compressed air. Proper shank lubrication is essential.
Inadequate lubrication rapidly causes serious damage to the rock drill.
Following these instructions will significantly increase the safety, reliability
and operating life of the rig. Sandvik Service is always willing to provide
advice and help with any problems related to the rig.

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2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS


2.1 Safety precautions
Take all safety factors into consideration and perform your work with care.
Follow all drilling site safety regulations.

WARNING
PERSONAL INJURY HAZARD!
Moving machine could cause death or severe injury.
Maintenance and repairwork should only be done when the rig is out
of operation. Make sure that it cannot be accidentally started (open
the main power switch, for instance) during the repairwork.
Unauthorized persons are not allowed near the rig during the repair
work.

WARNING
IGNORING INSTRUCTIONS HAZARD!
To avoid death or injury you MUST read, understand and obey
following instructions before operating the equipment.
Service and adjustment procedures must be carried out by
personnel with specialized operation and service training.
Carefully plan your work beforehand to minimise risk of damage or
injury.

WARNING! HIGH PRESSURE INJECTION HAZARD!


Compressed air jets could cause death or severe injury.
Allow the pressure to be released before opening the filling cap or
the compressed air connector.

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3 SLU MAIN COMPONENTS


3.1 Main components

5
CT1 CT1 CT1
9 8
CT5
4 1
12
CT5 CT5 11
P P
2

CT7
CT4
CT2

14
18
1
11
7
15
10 16
13 17

B
L L
CT3

CT3 CT4

SLU Lubrication unit 22L / 0,85 / 3 pump


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 Unit main block (master)
B Auxiliary blocks (slave max.
2)
7 Level guard 8 Regulating unit
9 Boost switch 10 Breather / filler cap
11 Drain valve 12 Fine adjustment switches
13 Oil dipstick 14 Lubrication pump
15 Level switch (cable) 16 Pump solenoid (cable)
17 Flow indication (cable) 18 Flow control valve CT 8

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5 CT1 CT1

CT5
1 CT5

8 P
12
CT3 CT3
11
9 2

3 4
CT7

CT4 CT2

14

18 15
1
11 16

17
13
7
B
10
L L

CT2

SLU Lubrication unit 14L / 0,85 / 2 pump


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 Unit main block (master)
B Auxiliary blocks (slave max.
2)
7 Level guard 8 Regulating unit
9 Boost switch 10 Breather / filler cap
11 Drain valve 12 Fine adjustment switches
13 Oil dipstick 14 Lubrication pump
15 Level switch (cable) 16 Pump solenoid (cable)
17 Flow indication (cable) 18 Flow control valve CT 8

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3.2 Technical data


3.2.1 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

3.2.2 Pump unit

standard 0.85 cm³ (7.5 mm stroke)


Displacement
(max. 1.25 cm³, 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

3.2.3 Shank lubricator control unit SLCU

• EMC approved
• 3 alarm outputs
• Boost function
• Operating voltage 24VDC
3.2.4 Tightening torques

Monitoring switch 7 Nm
Pump unit mounting screws 20 Nm

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4 SLU OPERATION INSTRUCTIONS


4.1 Operating principle
1
7

8
3

5
11

12
6
9

10

1 Breather / filler cap 2 Oil container


3 Boost-switch 4 Pump unit
5 Pump operating pressure 6 Pressure line
7 Level switch 8 SLCU - control unit
9 Tank 10 Hydr. oil tank line
11 Air 12 Rock drill

4.1.1 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.

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4.1.2 Operation of the 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.

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4.1.3 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 drill 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
NOTICE and the drilling function is disabled. Correspondingly, if the ball does
not open over four working cycles, alarm is switched on. Alarm is
removed when normal pumping is resumed.

Pump block flowchart


Master Slave

SG

D DG

PC PG

CT5

CT1 monitoring switch


CT2 intake side non-return valve
CT3 working piston
CT4 hydr. bleed screw
CT5.1 directional valve
CT5 non-return valve
CT6.1 non-return valve
CT7 bleed screw
CT8 flow control valve

4.2 Shank lubrication system monitoring


The shank lubrication system monitors air pressure, oil flow and oil level in
the oil tank. If the air pressure drops, oil flow decreases too much (or stops
completely) or the tank runs out of oil, the shank lubrication system goes
into alarm state. In the alarm state, drilling is stopped, the joystick is
automatically centered and the red indicator light turns on.

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4.3 Operating principle of the shank lubrication system

1 5

6
3

4
8
7

P
9 10

1 Breather / filler cap 2 Oil tank


3 Pump unit 4 Hydraulic oil pressure line
5 Level switch 6 Shank lubrication oil line
7 Hydraulic oil tank line 8 Compressed air line
9 Pressure switch (air) 10 Rock drill

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4.4 Operation diagram of the shank lubrication oil pump

SG

DG

PG

CT5

CT1 Control switch CT2 Suction side non-return valve


CT3 Operating piston CT4 Flow control valve
CT5.1 Directional valve CT5 Non-return valve
CT7 Bleeding screw CT8 Flow control valve (heating circuit)

The lubrication pump is a hydraulic, elctrically controlled piston pump. The


lubricant dosage is determined electrically by changing the operating
frequency of the pump.
The main block has its own lubrication control switch CT1. The control is
always operational when the operating voltage is switched on.
The directional valve (CT5.1) guides the hydraulic oil pressure to the piston
side and the piston rod side alternately. When valve (CT5.1) receives the
control voltage, it prevents the pressure from entering the piston side,
whereupon the pressure on the piston rod side forces the oil on the piston
side into the tank line. At the same time, the lubrication oil is sucked from
the tank through port S into the operating piston chamber. When the control
voltage is cut off from the valve (CT5.1), the higher pressure is directed to
the piston side, and the oil on the piston rod side re-enters the circulation.
The lubrication oil is pumped to the rock drill through port L.

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4.5 Monitoring unit


The shut-off ball of the lubrication pump output port non-return valve
operates as a control switch (CT1) against the valve seat. The oil flow
through the non-return valve removes the ball from the seat surface and
shuts off the circuit. The control switch non-return valve ball is electrically
connected to the pump (and rock drill) frame. The voltage is directed to the
ball via a spring isolated from the pump frame.
If the ball remains against the seat or remains open for four
NOTICE operational cycles, an alarm is switched on and drilling functions
stop.

4.6 Heating circulation function

TC

The performance of the SLU pump decreases in cold conditions. This is


due to the increased viscosity of both the shank lubrication oil and the
hydraulic oil that drives the pump. The increase in viscosity causes
problems in, for example, the ON/OFF valve (CT5.1) controlling the pump
and pump intake valve (CT2).
The heating circulation function is based on circulating the hydraulic oil
driving the pump through the pump. The oil circulates through an 0.6 mm
orifice and flow control valve (CT8) directly into the tank. The volume

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flowing through the orifice is about 1–2.5 l/min. The heating circulation
function can be enabled and disabled (factory setting is enabled). The
heating circulation is used only in the master pump unit.

Heating circulation components

3
1

1 Locking nut
2 Heating circulation orifice, 0.6 mm
3 Plug screw
4 Seal
5 Cap

Enabling/disabling the heating circulation function


Disabling the heating
Enabling the heating circulation
circulation

1.Unscrew the cap (5) 1.Unscrew the cap (5)


2.Loosen the locking nut (1) but do not 2.Loosen the locking nut (1)
remove the nut but do not remove the nut
3.Turn the plug screw (3) 2.5 turns 3.Turn the plug screw (3) 2.5
counterclockwise turns clockwise
4.Tighten the locking nut (1) 4.Tighten the locking nut (1)
5.Reinstall the cap (5) 5.Reinstall the cap (5)

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5 OPERATOR'S MAINTENANCE PROCEDURES


5.1 SLU
5.1.1 Checking the oil level
NOTE! To avoid problems caused by air bubbles in the oil, fill the tank after
drilling. DO NOT fill the tank during drilling.
1. Check the oil level from the dipstick. Fill the tank as necessary.

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6 PERIODIC MAINTENANCE PROCEDURES


6.1 SLU
6.1.1 Draining the condensed water
1. Drain the condensation water from the oil tank to the receptacle using the
drain valve.

6.1.2 Cleaning the tank


1. Empty the oil tank into the receptacle using the drain valve.

2. Clean the receiver from the inside.

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6.1.3 Replacing the breather


1. Replace the breather.

Replace the breather at the intervals specified in the maintenance


instructions or earlier as required e.g. in the event that breather has
become wet.

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6.1.4 Checking the function of the monitoring system

Check the operation of the monitoring unit as follows:


• Disconnect the directional valve (CT5) plug: the alarm must activate after
four operational cycles.
• Disconnect the flow monitoring cable from the monitoring unit (CT1): the
alarm must activate after four operational cycles.
• Short-circuit the flow monitoring cable to the pump body: the alarm must
activate after four operational cycles.

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7 SLU REPAIR INSTRUCTIONS


7.1 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 in chapter
7.2 Output settings (Page 29).

7.2 Output settings


Range Fine [ g / h ] Rock drill type
0 80–150 HE 122, HEX1, HLX1, HSX1
1 100–200 HL 300
HLX5, HFX5 -series, RD300 -series,
2 150-300
RD500 -series
3 200-400 HL 510
4 300-600 HL 560, HL 600
HL 700, HL 1000, HL 710, HL 800, HL
5 400-850
1010
6-F 600-1200 HL 1500, HL 1560

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


Adjust correct output according to the information on this page.

Depending on the drilling conditions (hole depth, type of rock, etc.)


the required amount of lubrication may vary in the given range and
more. For small hole sizes (for the rock drill in question) and in
NOTICE upwards drilling and bolting, we recommend to choose low Fine
settings. For larger hole sizes and high temperature surface
applications, we recommend to choose higher Fine setting.

Chart reading example:


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

Lubricant metering curves

7.3 Bleeding
Bleeding of SLU TANK is based on gravity, and it is carried out by opening
the bleeding screw (4) (CT7) 1–2 turns and then waiting until the oil no
longer contains any bubbles. During the bleeding the diesel engine/power
pack must be stopped. When bleeding the PUMP (14), connect an extra
hose (04-JIC) from port L to a suitable reservoir, start the power pack and
put the rotation on. Open the bleeding screw (4) (CT7) 1/2 turn and the
bleeding screw (2) (CT4) 1 turn. Leave them open for about 1 minute.
Close the bleeding screw (4) (CT7). Wait until the oil no longer contains any
bubbles. Close the bleeding screw (2) (CT4). Remove the extra hose from
line L and connect the original hose to port L. Start the compressor. Switch
on the Booster switch (position 1) approx. for 10 minutes to make sure that
there is shank lube oil in the hose all the way to the rock drill and to make

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sure that the rod side of the SLU pump is bled. After boosting remember to
switch off (position 0) the booster switch (9). Turn off the rotation and stop
the power pack.

2
CT7
CT4
CT2

L
14

RISK OF EQUIPMENT DAMAGE!


Hydraulic bleeding screw (CT4) is used only for bleeding the pump.
NOTICE Remember to bleed all pump blocks in same time!
Remember to turn off the boost switch after the service operations!

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Pump block flowchart


Master Slave

SG

D DG

PC PG

CT5

CT1 monitoring switch


CT2 intake side non-return valve
CT3 working piston
CT4 hydr. bleed screw
CT5.1 directional valve
CT5 non-return valve
CT6.1 non-return valve
CT7 bleed screw
CT8 flow control valve

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7.3.1 Bleeding the shank lubrication oil line

CT4 CT7

1. Turn off the engine.


2. Open the bleeding screw (CT7) 1–2 revolutions.
3. Close the bleeding screw (CT7) when the oil bleeding out no longer
contains air bubbles.
Note! If there is air left in the oil pump, it must be bled separately. See
more information in chapter: 7.3.2 Bleeding the shank lubrication oil
pump (Page 34).

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7.3.2 Bleeding the shank lubrication oil pump

CT4 CT7

1. Disconnect the hose from port L.


2. Connect a separate hose to port L and place the other end of the hose in
a receptacle.
3. Start the power pack and put the rotation on.
4. Open the bleeding screw (CT7) half a turn and the bleeding screw (CT4)
one turn.
Leave the screws open for about one minute.
5. Close the bleeding screw (CT7).
6. Close the bleeding screw (CT4) when the oil bleeding out no longer
contains air bubbles.
7. Turn off the power pack.
8. Disconnect the bleeding hose from port L and reconnect the original
hose.
9. Start the diesel engine.
10. Start the forced shank lubrication by pressing the forced operation
button (Boost).
Leave the forced operation on for about 10 minutes.
11. Ensure that the rock drill receives shank lubrication oil.
12. Stop the forced shank lubrication.

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7.4 Replacing seals

2 3 1

1 Pump unit
2 Plug
3 Piston
4 Piston seals

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1. Remove the old seals from the piston grooves.

A B C D E F G H A

B D E

2. Clean the grooves.


3. Install the guide sleeve C on to piston E as shown in the picture.
4. Lubricate the o-ring D and slide it over the guide sleeve into the groove in
the piston.
5. Lubricate the piston seal B and slide it over the guide sleeve into the
groove on top of the o-ring D.
Use the mounting sleeve A if needed.
6. Repeat the procedure with the o-ring F and the piston seal H using
corresponding tools (G and A).
7. Press the seals lightly with oily fingers to better fit them into the grooves.
8. Calibrate the seals from both ends of the piston (B, D, F and H) using
mounting sleeve A.
Calibration is performed by sliding the mounting sleeve carefully over the
piston and the piston seal, and then carefully rotating the sleeve so that
the seal is set to its groove evenly.
9. Install the piston back into the pump unit.

7.5 Replacing a faulty shank lubrication hose


When replacing a faulty shank lubrication hose with a new one, operate as
follows:
1. Change the faulty hose.

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2. Disconnect the end of the desired shank lubrication hose from the rock
drill.
3. Start the power pack (electric motor or diesel) and turn the air on.
4. Turn the boost switch on.
5. Keep the boost switched on, until oil comes out of the hose (drain it into
the overflow receptacle).
6. When system has bled, turn off the boost switch, and stop the
powerpack.
7. Re-connect the shank lubrication hose to the rock drill.

7.6 Boost switch


The boost switch is used in the following cases
• to fill the shank lubrication hose
• 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 pump(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.
RISK OF EQUIPMENT DAMAGE!
NOTICE Remember to turn off the boost switch after the service operations!

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8 SLU TROUBLESHOOTING
8.1 Troubleshooting
Problem: No oil output, green indicator light not on, drilling joystick is
centered
POSSIBLE REASON: REMEDY:
Check the rotation and percussion
No operating voltage at the
pressure switches, electrical connections
pump
and wiring

Problem: No oil output, red indicator light on, green indicator light off,
drilling joystick is centered
POSSIBLE REASON: REMEDY:
Add oil and remove air from pump
Oil level too low
through bleeding screw
Pump intake blocked Check and clean container
Remove and clean or replace delivery
Delivery pipe blocked
pipe
Oil viscosity too high Select correct oil grade
No pump operating pressure Problem in rig’s hydraulic 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 frequency Check setting
Check the oil level and bleed the
Air in pump
pump
Dirt in intake side non-return valve Clean ball of non-return valve
Dirt in control switch non-return valve Clean control switch / container
Breather blocked (underpressure) Clean breather
Return hose to collector tank blocked Clear obstruction

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Problem: Too much oil (red indicator light may turn on and drilling
joystick may be centered)
POSSIBLE REASON: REMEDY:
Hydraulics bleed screw open Close bleed screw
Timer frequency incorrectly adjusted Check adjustment
Piston seals damaged Check piston and replace seals
BOOST switch activated Check and turn off

Problem: Internal hydraulic oil leakage of pump


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

Problem: Normal amount of oil but alarm activated (red indicator light
on, green indicator light off, drilling joystick is centered)
POSSIBLE REASON: REMEDY:
Control switch wiring cut or shortcut
Check/replace wiring
to ground
Dirty oil, conducting electricity Change oil in shank lubricator tank
Worn flow monitoring device (pitted Check / replace flow switch
ball surface) assembly
Readjust the switch (correct value is
Air line pressure switch wrongly
ca. 1 bar on the switch's scale),
adjusted or faulty
replace if needed

40 Copyright © Sandvik
ID: BG00198142 en-US A.001.1 2014-05-26
www.sandvik.com

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