Original instructions

GUID-0403EAA6-62A5-4789-A638-84E70B0C989B en-US 6 2020-02-28

Basic adjustment and max force

control of reels
Basic adjustment and max force control of reels

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. Keep this publication for future reference.

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Basic adjustment and max force control of reels

Table of Contents
1 Introduction.......................................................................7
1.1 The purpose of these instructions............................................................ 7
1.1.1 Validity of the manuals...................................................................... 7

2 Basic adjustment of the reeling control......................... 9

2.1 General.........................................................................................................9
2.2 With remote control for reel(s) (ERCP)................................................... 10
2.3 Without remote control for reel(s) (ERCP)..............................................14

3 Adjusting the reeling force according to cable size... 19

3.1 General.......................................................................................................19
3.2 With remote control for reel(s) (ERCP)................................................... 20
3.3 Without remote control for reel(s) (ERCP)..............................................24

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Basic adjustment and max force control of reels

1 INTRODUCTION

1.1 The purpose of these instructions

This manual contains supplementary information for operation,
maintenance and repair of a component.
These instructions must be followed along with other manuals of the rig,
any instructions given in local laws and regulations, any orders given by
local authorities, and all protective measures specific for the site.
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 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.

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Basic adjustment and max force control of reels

2 BASIC ADJUSTMENT OF THE REELING CONTROL

2.1 General
Note! The pressure values depend on the type of the cable reel used in the
machine.
Note! While tramming and reeling the cable in or out, make sure that the
cable is not totally clear of the ground. If necessary, fine-tune the
reeling pressures so that the cable lies on the ground by the distance
of approximately 5 to 7 meters from the machine. Too high reeling
pressure causes tension to the cable, which may damage the cable.
This adjustment defines the deceleration of the reel rotation during
tramming. Correct basic adjustment prevents uncontrolled rotation of the
reel when tramming speed changes. Adjustment of the control pressure
relief valves (5 and 6) set up the back pressure to the reel rotation when
reeling the cable in/out.
Following chapters describe the basic adjustment process.

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2.2 With remote control for reel(s) (ERCP)

5 12 7 9 217 A B 218
M2
MA
A 6
A B

11

2
3
1 1
Y248 1 2
2 1 3
2 2 1 1 4 Y450
P2 bar 20 bar 3 MB1
2
4

Y173 MA1
A1 B1

9
3 7 12 11
8

5
1

Control block of the cable reel, version A

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Basic adjustment and max force control of reels

A B 218
217

B 3
6 2
1

Y450
Y248
1 1 3
2 MB

P2 bar
Y173 2

Control block of the cable reel, version B

PART NUMBER COMPONENT TIGHTENING TORQUE

2 4/3 -directional valve 8,9 Nm (Coil 4,0 Nm)
3 3/2 -directional valve 33,9 Nm (Coil 6,8 Nm)
4 2/2 -directional valve 33,9 Nm (Coil 6,8 Nm)
5 Pressure relief valve 33,9 Nm
6 Pressure relief valve 33,9 Nm
7 Check valve 33,9 Nm
8 Check valve 15,0 Nm
9 Screen 10,0 Nm
11 Orifice 5,0 Nm
12 Orifice 5,0 Nm

Complete the adjusting:

Version A:

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Basic adjustment and max force control of reels

1. Remove the hoses (217) and (218) from the motor.

2. Connect the hoses (217) and (218) by adding a fitting between the
hoses.
3. Loosen the pressure relief valve (5 and 6) locking nuts by turning them
counterclockwise. Open the valve (6) adjusting screw fully open by
turning counterclockwise and turn the valve (5) adjusting screw fully
closed.
4. Connect a pressure gauge to the pressure measuring point (M2) of the
reel control block.
5. Engage the parking brakes and start the diesel engine.
6. Activate "reeling the cable out" -function with full diesel revolutions,
which activates the coil Y450 in the reel control block (1) and the coil
Y248 in the carrier control block assembly.
7. By turning the pressure relief valve (6) adjusting screw clockwise, adjust
the pressure P2 according to table Reeling the cable out.
8. Lock the adjustment of the pressure relief valve (6) with the locking nut
(clockwise).
9. Lower the diesel revolutions to minimum.
10. By turning the pressure relief valve (5) adjusting screw
counterclockwise, adjust the pressure to 20 bar.
11. Lock the adjustment of the pressure relief valve (5) with the locking nut
(clockwise).
12. Stop "reeling the cable out" -function.
13. Switch off the diesel engine.
14. Remove the fitting between the hoses (217) and (218) and connect the
hoses back to the original position (When DS421 connect hose 217 to
motor port B and hose 218 to motor port A).
15. Remove the pressure gauge from the measuring point (M2).
Version B:
1. Remove the hoses (217) and (218) from the motor.
2. Connect the hoses (217) and (218) by adding a fitting between the
hoses.
3. Loosen the pressure relief valve (6) locking nut fully open by turning it
counterclockwise.
4. Connect a pressure gauge to the pressure measuring point (MB).
5. Engage the parking brakes and start the diesel engine.
6. Activate "reeling the cable out" -function with full diesel revolutions,
which activates the coil Y450 in the reel control block (1) and the coil
Y248 in the carrier control block assembly.
7. By turning the pressure relief valve (6) adjusting screw clockwise/
counterclockwise, adjust the pressure P2 bar according to table Reeling
the cable out.

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8. Lock the adjustment of the pressure relief valve (6) with the locking nut
(clockwise).
9. Lower the diesel revolutions to minimum.
10. Stop "reeling the cable out" -function.
11. Switch off the diesel engine.
12. Remove the fitting between the hoses (217) and (218) and connect the
hoses back to the original position (When DS421 connect hose 217 to
motor port B and hose 218 to motor port A).
13. Remove the pressure gauge from the measuring point (MB).

TCR1 - TCR5 max pressure P2

Cross-sectional area of the cable
[bar]
25 mm2 40
35 mm2 40
50 mm2 / AWG 1/0 40
70 mm2 - 150 mm2 / AWG 2/0 70
185 mm2 - 240 mm2 70
Reeling the cable out

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Basic adjustment and max force control of reels

2.3 Without remote control for reel(s) (ERCP)

5 12 7 9 217 A B 218
M2
MA
A 6
A B

11

2
3
1 1
Y248 1 2
2 1 3
2 2 1 1 4 Y450
P2 bar 20 bar 3 MB1
2
4

Y173 MA1
A1 B1

9
3 7 12 11
8

5
1

Control block of the cable reel, version A

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Basic adjustment and max force control of reels

A B 218
217

B 3
6 2
1

Y450
Y248
1 1 3
2 MB

P2 bar
Y173 2

Control block of the cable reel, version B

PART NUMBER COMPONENT TIGHTENING TORQUE

2 4/3 -directional valve 8,9 Nm (Coil 4,0 Nm)
3 3/2 -directional valve 33,9 Nm (Coil 6,8 Nm)
4 2/2 -directional valve 33,9 Nm (Coil 6,8 Nm)
5 Pressure relief valve 33,9 Nm
6 Pressure relief valve 33,9 Nm
7 Check valve 33,9 Nm
8 Check valve 15,0 Nm
9 Screen 10,0 Nm
11 Orifice 5,0 Nm
12 Orifice 5,0 Nm

Complete the adjusting:

Version A:

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Basic adjustment and max force control of reels

1. Remove the hoses (217) and (218) from the motor.

2. Connect the hoses (217) and (218) by adding a fitting between the
hoses.
3. Change the place of the electric connectors Y248 / Y173 (2) vice versa.
4. Loosen the pressure relief valve (5 and 6) locking nuts by turning them
counterclockwise. Open the valve (6) adjusting screw fully open by
turning counterclockwise and turn the valve (5) adjusting screw fully
closed.
5. Connect a pressure gauge to the pressure measuring point (M2) of the
reel control block.
6. Engage the parking brakes and start the diesel engine.
7. Activate control lever S46 function "cable in" from the tramming panel,
which activates the coil Y450 in the reel control block (1) and the coil
Y248 in the carrier control block assembly.
8. By turning the pressure relief valve (6) adjusting screw clockwise, adjust
the pressure P2 according to table Reeling the cable out.
9. Lock the adjustment of the pressure relief valve (6) with the locking nut
(clockwise).
10. Lower the diesel revolutions to minimum.
11. By turning the pressure relief valve (5) adjusting screw
counterclockwise, adjust the pressure to 20 bar.
12. Lock the adjustment of the pressure relief valve (5) with the locking nut
(clockwise).
13. Stop "cable in" -function.
14. Change the place of the electric connectors Y248 / Y173 (2) back to
original position.
15. Switch off the diesel engine.
16. Remove the fitting between the hoses (217) and (218) and connect the
hoses back to the original position (When DS421 connect hose 217 to
motor port B and hose 218 to motor port A).
17. Remove the pressure gauge from the measuring point (M2).
Version B:
1. Remove the hoses (217) and (218) from the motor.
2. Connect the hoses (217) and (218) by adding a fitting between the
hoses.
3. Change the place of the electric connectors Y248 / Y173 (2) vice versa.
4. Loosen the pressure relief valve (6) locking nut fully open by turning it
counterclockwise.
5. Connect a pressure gauge to the pressure measuring point (MB).
6. Engage the parking brakes and start the diesel engine.

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Basic adjustment and max force control of reels

7. Activate control lever S46 function "cable in" from the tramming panel,
which activates the coil Y450 in the reel control block (1) and the coil
Y248 in the carrier control block assembly.
8. By turning the pressure relief valve (6) adjusting screw clockwise/
counterclockwise, adjust the pressure P2 according to table Reeling the
cable out.
9. Lock the adjustment of the pressure relief valve (6) with the locking nut
(clockwise).
10. Lower the diesel revolutions to minimum.
11. Stop "cable in" -function.
12. Change the place of the electric connectors Y248 / Y173 (2) back to
original position.
13. Switch off the diesel engine.
14. Remove the fitting between the hoses (217) and (218) and connect the
hoses back to the original position (When DS421 connect hose 217 to
motor port B and hose 218 to motor port A).
15. Remove the pressure gauge from the measuring point (MB).

TCR1 - TCR5 max pressure P2

Cross-sectional area of the cable
[bar]
25 mm2 40
35 mm2 40
50 mm2 / AWG 1/0 40
70 mm2 - 150 mm2 / AWG 2/0 70
185 mm2 - 240 mm2 70
Reeling the cable out

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Basic adjustment and max force control of reels

3 ADJUSTING THE REELING FORCE ACCORDING TO

CABLE SIZE

3.1 General
Note! The pressure values depend on the type of the cable reel used in the
machine.
Note! While tramming and reeling the cable in or out, make sure that the
cable is not totally clear of the ground. If necessary, fine-tune the
reeling pressures so that the cable lies on the ground by the distance
of approximately 5 to 7 meters from the machine. Too high reeling
pressure causes tension to the cable, which may damage the cable.
This adjustment defines the reeling force when reeling the cable in/out
during tramming and when using ERCP. Adjustment of the pressure
reducing/relieving valve (1) according to the cable size (diameter) specific
values set up the reeling force.
Following chapters describe the reeling force adjustment process.

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Basic adjustment and max force control of reels

3.2 With remote control for reel(s) (ERCP)

CABLE REEL OPTION
7 WATER HOSE
REEL
TJ 60 TJ 60
REAR / LEFT REAR / RIGHT 8 A B A B

CABLE REEL 217 218 197 194

CONTROL BLOCK MA A B

Y450
20-
30bar

A B A B
MB1 2
P2 bar

20 bar

MA1 A1 B1

3.2
3.1

A1 B1 A2 B2 A3 B3 A4 B4

P1 P2

Y146 Y144 Y248 Y247

P1 bar 80bar 4.2 S2 S1 L6

T1 Y147 Y145 Y173 T2

4.1 E
Y174

1 2

Cable reel control block and carrier control block assembly, version A

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Basic adjustment and max force control of reels
TJ 60 TJ 60
REAR / LEFT REAR / RIGHT

7 CABLE OPTION
REEL WATER HOSE
8 REEL

A B A B

197 194
217 218
2
1

Y450
A B A B 1 1 3 20-
MB 30bar
2

P2 bar
2

3.1
3.2
A1 B1 A2 B2 A3 B3 A4 B4

P1 P2

Y146 Y144 Y248 Y247

P1 bar 80bar
4.2

T1 Y147 Y145 Y173 Y174 T2

4.1

S2 S1 L6

1 2
E

Cable reel control diagram and carrier control block assembly, version B

1. Deactivate the directional valve Y450 by disconnecting the connector

from the coil.
2. Connect the pressure gauge to the measuring point (MB1 in version A,
MB in version B).
3. Activate "reeling the cable out" function, which controls the coil Y248 in
the carrier control block assembly.
4. Loosen the pressure reducing/relieving valve (1) locking nut by turning
counterclockwise.
5. By turning the pressure reducing/relieving valve (1) adjusting screw
clockwise/counterclockwise, adjust the reeling pressure P1 according to
table Reeling the cable in.
6. Lock the adjustment screw.
7. Stop "reeling the cable out" function.
8. Activate the directional valve Y450 by connecting the connector back to
the coil.
9. Remove the pressure gauge from the measuring point (MB1 in version
A, MB in version B).

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Basic adjustment and max force control of reels

TCR 1 & TCR 2.0 E TCR 2.5 E - TCR 5 TCR 6 E

Cross-sectional area of the cable max pressure max pressure max pressure
P1 [bar] P1 [bar] P1 [bar]
25 mm2 50 50 50
35 mm2 80 80 80
50 mm2 / AWG 1/0 100 100 100
70 mm2 - 150 mm2 / AWG 2/0 140 150 150
185 mm2 - 240 mm2 - - 180
Reeling the cable in

Y247
Y248

Y173

Y174

4.2 3.2

4.1

3.1

Y173 Reeling the cable in

Y174 Reeling the water hose in
Y247 Reeling the water hose out
Y248 Reeling the cable out

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Basic adjustment and max force control of reels

3.1 Flow control valve, cable in

3.2 Flow control valve, cable out
4.1 Flow control valve, water hose in
4.2 Flow control valve, water hose out

Flow control valves (3 and 4) are adjusted when diesel engine and power
packs are stopped. The adjustment procedure is as follows:
1. Loosen the cable reel flow control valve (3.1) and the water hose reel
flow control valve (4.1) locking nuts by turning counterclockwise.
2. Turn the adjusting screws of the cable reel flow control valve (3.1) and
the water hose reel flow control valve (4.1) fully open
(counterclockwise).
3. Lock the locking nuts of the flow control valves (3.1 and 4.1).
4. Loosen the locking nuts of the cable reel flow control valve (3.2) and
water hose reel flow control valve (4.2) by turning counterclockwise.
5. Turn the adjusting screw of the cable reel flow control valve (3.2) first
fully closed (clockwise), then open it by 4-5 turns (counterclockwise)
and lock the adjustment.
6. Turn the adjusting screw of the water hose reel flow control valve (4.2)
first fully closed (clockwise), then open it by 6-7 turns
(counterclockwise) and lock the adjustment.
7. Tighten the locking nuts of the flow control valves (3.2 and 4.2).

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Basic adjustment and max force control of reels

3.3 Without remote control for reel(s) (ERCP)

CABLE REEL OPTION
7 WATER HOSE
REEL
TJ 60 TJ 60
REAR / LEFT REAR / RIGHT 8 A B A B

CABLE REEL 217 218 197 194

CONTROL BLOCK MA A B

Y450
20-
30bar

A B A B
MB1 2
P2 bar

20 bar

MA1 A1 B1

3.2
3.1

A1 B1 A2 B2 A3 B3 A4 B4

P1 P2

Y146 Y144 Y248 Y247

P1 bar 80bar 4.2 S2 S1 L6

T1 Y147 Y145 Y173 T2

4.1 E
Y174

1 2

Cable reel control block and carrier control block assembly, version A

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Basic adjustment and max force control of reels
TJ 60 TJ 60
REAR / LEFT REAR / RIGHT

7 CABLE OPTION
REEL WATER HOSE
8 REEL

A B A B

197 194
217 218
2
1

Y450
A B A B 1 1 3 20-
MB 30bar
2

P2 bar
2

3.1
3.2
A1 B1 A2 B2 A3 B3 A4 B4

P1 P2

Y146 Y144 Y248 Y247

P1 bar 80bar
4.2

T1 Y147 Y145 Y173 Y174 T2

4.1

S2 S1 L6

1 2
E

Cable reel control diagram and carrier control block assembly, version B

1. Deactivate the directional valve Y450 by disconnecting the connector

from the coil.
2. Connect the pressure gauge to the measuring point (MB1 in version A,
MB in version B).
3. Change the place of the electric connectors Y248 / Y173 (2) vice versa.
4. Activate control lever S46 function "cable in" from the tramming panel,
which controls the coil Y248 in the carrier control block assembly.
5. Loosen the pressure reducing/relieving valve (1) locking nut by turning
counterclockwise.
6. By turning the pressure reducing/relieving valve (1) adjusting screw
clockwise/counterclockwise, adjust the reeling pressure P1 according to
table Reeling the cable in.
7. Lock the adjustment screw.
8. Stop "cable in" function.
9. Change the place of the electric connectors Y248 / Y173 (2) back to
original position.

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Basic adjustment and max force control of reels

10. Activate the directional valve Y450 by connecting the connector back to
the coil.
11. Remove the pressure gauge from the measuring point (MB1 in version
A, MB in version B).

TCR 1 & TCR 2.0 E TCR 2.5 E - TCR 5 TCR 6 E

Cross-sectional area of the cable max pressure max pressure max pressure
P1 [bar] P1 [bar] P1 [bar]
25 mm2 50 50 50
35 mm2 80 80 80
50 mm2 / AWG 1/0 100 100 100
70 mm2 - 150 mm2 / AWG 2/0 140 150 150
185 mm2 - 240 mm2 - - 180
Reeling the cable in

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Basic adjustment and max force control of reels

Y247
Y248

Y173

Y174

4.2 3.2

4.1

3.1

Y173 Reeling the cable in

Y174 Reeling the water hose in
Y247 Reeling the water hose out
Y248 Reeling the cable out
3.1 Flow control valve, cable in
3.2 Flow control valve, cable out
4.1 Flow control valve, water hose in
4.2 Flow control valve, water hose out

Flow control valves (3 and 4) are adjusted when diesel engine and
powerpacks are stopped. The adjustment procedure is as follows:
1. Loosen the cable reel flow control valve (3.1) and the water hose reel
flow control valve (4.1) locking nuts by turning counterclockwise.
2. Turn the adjusting screws of the cable reel flow control valve (3.1) and
the water hose reel flow control valve (4.1) fully open
(counterclockwise).

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Basic adjustment and max force control of reels

3. Lock the locking nuts of the flow control valves (3.1 and 4.1).
4. Loosen the locking nuts of the cable reel flow control valve (3.2) and
water hose reel flow control valve (4.2) by turning counterclockwise.
5. Turn the adjusting screw of the cable reel flow control valve (3.2) first
fully closed (clockwise), then open it by 4-5 turns (counterclockwise)
and lock the adjustment.
6. Turn the adjusting screw of the water hose reel flow control valve (4.2)
first fully closed (clockwise), then open it by 6-7 turns
(counterclockwise) and lock the adjustment.
7. Tighten the locking nuts of the flow control valves (3.2 and 4.2).

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www.sandvik.com
 V80230-2en1017

OPERATION & MAINTENANCE MANUAL

CABLE REELS
OPERATION &
MAINTENANCE
MANUAL
CABLE REELS

DISCLAIMER Cavotec develops

Information in this document is subject to change without notice. No Part of technologies that
this document may be reproduced or transmitted in any form or by any drive
means, electronical or mechanical, for any purpose, without the express
permission of Cavotec. productivity and
contribute to
customers’
This manual is intended to give guidelines operational
to the installation and maintenance of efficiency and
CAVOTEC cable reels.
safety.
CAVOTEC SPECIMAS SpA and associated
companies do not take any responsibility
or accept any damages for damage or loss
due to wrong use or misinterpretation of
this manual.
If any questions arise please contact your
supplier or CAVOTEC directly.
Please also note the General Warnings
given in this manual.

Document OPERATION & MAINTENANCE MANUAL

Revision

A Re-Editing 12 Oct 2017 GP

- First Issue
Rev Comment Date By Approved
1
TABLE OF CONTENTS
Disclaimer ..........................................................................................................................................................................1
general warnings and safety guidelines ..........................................................................................................................3
Mechanical Hazards: .....................................................................................................................................................3
Electrical Hazards ..........................................................................................................................................................3
reel nomenclature .............................................................................................................................................................4
Technical specification ......................................................................................................................................................5
Cable reel layout................................................................................................................................................................5
Reel at Glance................................................................................................................................................................5
mounting instructions .......................................................................................................................................................7
Mechanical ....................................................................................................................................................................7
Electrical.........................................................................................................................................................................8
maintenance instructions ...............................................................................................................................................12
After First Operating Week ........................................................................................................................................12
At Regular intervals (Two Months) ............................................................................................................................12
Every Twelve Months..................................................................................................................................................13
Torque Setting .............................................................................................................................................................14
Recommended spares.....................................................................................................................................................15
Drive System Spares....................................................................................................................................................15
Collector Assembly Spares .........................................................................................................................................16
Iso certificate ...................................................................................................................................................................17
2
GENERAL WARNINGS AND SAFETY GUIDELINES

Mechanical Hazards:
· The cable/hose reel is remotely controlled by the machine which it is mounted on. If the machine moves
the cable/hose reel can start without warning.
· The cable/hose reel can also start when the machine is standing still.
· The cable/hose reel can start when the machines diesel motor is running as the reel's motor is powered
by the diesel motors hydraulic pump. This can occur also when the cable is not connected to the wall
outlet and the cable is not properly fixed to the wall with a cable grip or other mechanical fixing.
· People are not to be in the working area of the cable/hose reel during normal use.
· Maintenance people are to be informed and understand the risks involved with working with a cable
reel.
· The area around the cable/hose reel is to be off limits for people not working on the machine during
normal use.
· Emergency Stop push button must always be accessible near the cable reel and the personnel must be
informed of its location.
· Cable/hose -reels which are delivered with chain drives for the drive of the reel or for indexing of a
spooling device must be mounted with protective covers around the chain, chain wheels and sprockets.
If these protections are not in the supply of the reel they must be incorporated in the machine on which
the reel is mounted.
· Warning for squeezing Hazard in guides and indexing devices. These parts are by nature mounted on
places where they can be easily accessed.
· Personnel should be informed about the squeezing danger from these moving parts.
· Warning signs should be mounted visibly.
· Do not stand close to moving parts as the reel, chain-drives, cable-guides or the cable.

Electrical Hazards
· Before the lid of the collector (slipring) is opened be sure the power is switched off and the main cable is
removed from the wall-socket.

The tension in the collector arrives from the main cable on the drum which is
connected to a switchboard located in the tunnel or mine-tunnel. Turn-off the
power supply from the switchboard or better unplug the cable from the socket.

· It must be possible to lock the main switch in the off position during maintenance so nobody else can
apply tension during the work.
· There must be a responsible person who supervises that the tension is removed before maintenance in
the collector and that it is not possible to apply the tension during the work.
· Always check with an instrument that all phases are without tension before starting to work in the
collector. During the work it is recommended to short circuit all phases to earth with earthing cables (
e.g. start cables )
· If anti-condense heaters, end-limit switches or lid-opening switches are mounted in the collector these
could be under tension even if the main power is switched off. These could be supplied via another
source. Always check with an instrument before work is started.
3
REEL NOMENCLATURE

4
TECHNICAL SPECIFICATION
Nominal Torque On Drum Shaft : 40Nm
Max Torque : 50Nm
Rated Drum Speed : 20rpm
Gearbox : T4, Reduction : 1:15
Max Load On Drum : 800kg cable

CABLE REEL LAYOUT

Reel at Glance

FIGURE 1 RIGHT HAND SIDE VIEW

5
 FIGURE 2 LEFT HAND SIDE VIEW

FIGURE 3 VIEW WITH OPTIONAL SPOOLING DEVICE

6
MOUNTING INSTRUCTIONS

Mechanical
1. Lift the pre-mounted reel on place. Do not lift from the drum outer rim but lift from the torque unit and
around the drum inner ring or around the cable on the drum. If delivery is with gearbox and drum
separate, mount torque unit first. Fix the torque unit to the base with high tensile screws (min. class
8.8). The gearbox mounting interface shall be levelled horizontally.

2. Mount motor (adapter flange and hydraulic motor) and collector on the gearbox. (These are normally
factory mounted but could be delivered separately due to transport reasons)
3. If drum and gearbox are delivered as separate parts. Lift drum in place and fix it to the gearbox flange. If
holes do not match then it is possible to turn the gearbox shaft with a bar until holes match up.

All electric installation work must be done by qualified fitters and comply with
general electric installation rules and also comply with any local installation rules.
7
Electrical
1. Pre-wire cable from the collector rings to the terminal box on the drum – if terminal box is supplied in
the drum. If terminal box is not supplied the reeling cable will be routed all the way to the sliprings in
the slipring box.

FIGURE 4 PRE-WIRING FROM COLLECTOR RING TO FIGURE 5 REELING CABLE ROUTED DIRECTLY TO THE
TERMINAL BOX SLIPRING

2. Put cable relief sock on reeling cable and pull cable through entry on drum inner diameter.
3. Pass cable through cable gland into terminal box (cut conical cable gland to fit cable diameter). Split
cable, prepare ends with cable lugs and fix to terminals / sliprings. Seal cable gland well with two tie-
raps, and fluid gasket material if needed.
8
 Conical cable gland (cut to fit cable diameter)

Silicon is not recommended, use other type of fluid gasket if possible.

4. Stretch the cable relief sock and lock the end on the cable with a hose clamp to the cable relief sock so it
cannot slide. Cable should not be under mechanical tension or stretched at the cable entry or at the
terminals.
5. When fixing the cables to the terminals and in collector note the following:
i. Cable shoes and terminal surface must be clean.
ii. Tighten screws with nuts as recommended by cable shoe manufacturer. Cables fixed to the
rings, earth brushes or cables fixed to the phase brushes in the K460/-- collector should be
tightened to 18 Nm. These are the screws which have threading in the bronze. Other cable
fixings – with screw and nut – should be tightened to the torque recommended by the cable
shoe manufacturer.
iii. Check and respect insulation distances.
iv. Any extra length of cable should be well fixed with tie-raps so it can not interfere with the
function of the collector.
v. Check that all brush carbons are located in the grooves of the rings when finished
vi. Wind up the cable on the drum with the help of the motor. If torque is low increase it slightly at
a time, torque setting is done by the hydraulic pressure in the system. (see instructions from
machine supplier) Setting torque too high could damage the cable.
vii. Follow cable manufacturer’s instructions on how to reel on the cable the first time. Cable should
be reeled on the same way as it is delivered on the delivery drum. Do not twist cable when it is
reeled onto the drum
viii. It is important to do this well the first time as the cable life time depends on it.

9
6. The fixed cable coming from the machine is to be fixed to the brush holders. See above regarding the
fixing of cables to the terminals and the cabling. When all is ready check extra carefully that all the
carbons are lying on the rings in the correct grooves and that no carbon is outside the rings. Do this
check by feeling with the hand all around the rings. Also check that the brushes are parallel to the rings
and that they are mounted straight above the ring. (It is possible that they move due to the forces
applied when the screws to the cable shoe fixing is applied - when tightening the screws for the cable
fixing the brush holder should always be held firm).

FIGURE 6 ALIGNMENT CHECKS

7. Connect hydraulic motor according to client internal instructions.

All torque control and slip is to be done in the hydraulic system by the client.

Adjusting the hydraulic system with too high pressure will cause damage to the
cable reel as torque and pull on cable will be too high and could also cause
damage to personnel. To high oil flow might cause cable reel to rotate too fast
without control and could be dangerous to personnel.

8. Do a megger test on the collector.

i. Apply power and check that motor rotates in the correct direction.
ii. Test drive reel.
10
9. If a travel end limit switch is supplied, set the cam as follows.
- Setting of “Drum Empty” signal:
Unreel the cable from the drum until only 2 turn of cable are left and adjust the cam to switch at this
right moment.
- Setting of “Drum Full” signal:
Reel in the full length of cable on the drum and adjust the cam to switch at this right moment.

FIGURE 7 LIMIT SWITCH

11
MAINTENANCE INSTRUCTIONS

CAVOTEC cable reels are designed so that maintenance is reduced to a minimum. However, in order to
guarantee a correct and continuous function of the reel, it is necessary to follow a few simple rules,
hereafter described.

After First Operating Week

DRUM
1. Verify the tightening of all bolts and nuts including the ones fixing the gearbox onto its support, the
collector, the drum and the motor to the gearbox.
2. Verify gaskets and covers if junction box is incorporated in drum.
GEAR BOX
1. Verify the tightening of all bolts and nuts including the ones fixing the gearbox onto its support.
2. Verify bolts and keys for the torque hub between gearbox and collector. ( if supplied ) Check that keys are
in seat and the two bolts are tight.
INDEXING /SPOOLING DEVICE (IF SUPPLIED)
1. Verify the tightening of all bolts and nuts.
2. Check chain tension including tension if needed.
3. Check also that the torque hub / drive hub for the chain is seated correctly and fixed with the keys and
screws on the gearbox shaft between gearbox and collector.
4. Check protection covers around chain and chain pinions so they are in place and secured.

These are moving parts and there is a risk of mechanical hazard – stay away from
moving parts.

COLLECTOR
1. Verify tightening of all electrical connections and check ring - brush alignment. All carbon brushes must
be in the grooves of the rings.
2. Clean if needed

Always switch off current before removing collector cover.

At Regular intervals (Two Months)

The frequency of these regular checks will also depend on the severity of the environment in which the reel is
working and on the duty cycle intensity.
Do the same checks as indicated above.
DRUM
1. Check support bearings for noise or damage.
2. If cable reel is equipped with chains for the main drive or for the indexing device these must be well
greased with good quality grease. This is valid also if a screw indexing device is used.
12
 3. Check chain tension (if applicable)
4. Check for mechanical damages of the drum which can damage the cable.
GEARBOX
Check oil level through the level gauge, and, if necessary, top it up with the oil type specified below.
120° PRE-REDUCER (IF SUPPLIED)
Pre-reducer is life time lubricated. Filled with 30 grams of synthetic oil.
INDEXING / SPOOLING DEVICE (IF SUPPLIED)
1. Verify the tightening of all bolts and nuts.
2. Check chain tension including tension if needed.
3. Check also that the torque hub / drive hub for the chain is seated correctly and fixed with the keys and
screws on the gearbox shaft between gearbox and collector.
4. Check protection covers around chain and chain pinions so they are in place and secured.

These are moving parts and there is a risk of mechanical hazard – stay away from
moving parts.

COLLECTOR
Verify tightening of all electrical connections and check ring - brush alignment. All carbon brushes must be in the
grooves of the rings.

These are moving parts and there is a risk of mechanical hazard – stay away from
moving parts.

If necessary clean collector inside noting the following:

i. Never use water when cleaning. Use vacuum cleaner, brush or lint-free cloth.
ii. Sliprings must be dry, clean and free from oil or other covering stains.
iii. If any part is found to be damaged it must be replaced as soon as possible with a new original spare part.
iv. After cleaning the rings remount the collector housing ensuring that the drainage holes are downwards.
Also make sure the rubber gasket is in place with its joint downwards as well. This will ensure a good
sealing.
HYDRAULIC MOTOR (IF ANY)
Check fittings.

Every Twelve Months

Carry out all the operations described in the previous section along with following.
GEARBOX
1. Change oil in the gearbox. The oil to be used for ambient temperatures between: 10°C and +40°C is Esso
GX 80W-90 or similar and for higher or lower temperatures please contact the manufacturer or one of
his representatives.
2. Recheck the torque. If torque adjustment is needed decrease or increase the torque setting for a lower
or higher torque requested by the application.
13
 Adjusting the hydraulic system with too high pressure will cause damage to the
cable reel as torque and pull on cable will be too high and could also cause
damage to personnel. To high oil flow might cause cable reel to rotate too fast
without control and could be dangerous to personnel.

3. Limit switch (if any): check cam positions and that switches are operating.
4. Heaters (if any): check that they are operating.
5. Lid opening switches (if any): check function. Check that the main power supply is cut off when switch is
activated.

Always switch off current before removing collector cover.

Read carefully the chapter General warnings and safety precautions.

Gearbox Oil Capacity(kg)

T4 3
120° Pre-Reducer 9 life time oil immersed

Torque Setting
Torque setting is done by the clients hydraulic system.
Note that the reels are not intended to work as winches and drag the cable/hose over the ground. The torque is
to be set so the reels lift and recover the cable/hose and keep them tensioned when the machine is moving in the
direction of the cable/hose. When the machine is moving away from the cable/hose the cable/hose is pulled off
the drum against the set torque. Normally two torque levels are used, one higher when reeling in, one lower when
the machine is pulling out the cable (just braking torque).
A too high torque setting could damage the cable or the reels.

Adjusting the hydraulic system with too high pressure will cause damage to the
cable reel as torque and pull on cable will be too high and could also cause
damage to personnel. To high oil flow might cause cable reel to rotate too fast
without control and could be dangerous to personnel.
14
RECOMMENDED SPARES

Drive System Spares

Qty
Item Number Part Description
Inst’d Spares

1 Motor 1 1

7 Chain 1 1

Not Illustrated Oil Synthetic 3kg

15
Collector Assembly Spares

Qty
Item Number Part Description
Inst’d Spares

2 Collector housing seal 1 1

3 Slip Ring pack 1 1

4 Brushgear - Power 4 4

5 Brushgear – Control Ring 2 2

6 Belt 1 1

16
 Original instructions
GUID-DA678D64-B36F-4560-A785-C25F94B70310 en-US 2 2020-02-28

Cabin air conditioner

Cabin air conditioner

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. Keep this publication for future reference.

Copyright © Sandvik
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Cabin air conditioner

Table of Contents
1 Introduction.......................................................................7
1.1 The purpose of these instructions............................................................ 7
1.1.1 Validity of the manuals...................................................................... 7

2 Safety and environmental instructions.......................... 9

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

3 Main components........................................................... 11
3.1 Technical data............................................................................................11
3.2 Cabin air conditioner main components................................................ 12

4 Cabin air conditioner operation.................................... 13

4.1 Electrical diagrams (basic circuit arrangements).................................. 13
4.2 Operation................................................................................................... 15

5 Cabin air conditioner maintenance and repair............ 19

5.1 Periodic maintenance............................................................................... 19
5.1.1 Maintenance procedures.................................................................19
5.1.2 Cleaning the filters...........................................................................19
5.1.3 Adding oil.........................................................................................20
5.1.4 Adding refrigerant............................................................................22
5.2 Repair instructions................................................................................... 27
5.2.1 Dryer................................................................................................27
5.2.2 Coupler............................................................................................27

6 Cabin air conditioner troubleshooting......................... 29

6.1 Troubleshooting table...............................................................................29

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Cabin air conditioner

1 INTRODUCTION

1.1 The purpose of these instructions

This manual contains supplementary information for operation,
maintenance and repair of a component.
These instructions must be followed along with other manuals of the rig,
any instructions given in local laws and regulations, any orders given by
local authorities, and all protective measures specific for the site.
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 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.

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Cabin air conditioner

2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1 Safety

WARNING
ELECTRICAL HAZARD!
The power supply switch must be turned off and secured with a
locking device before any maintenance is performed inside the
electrical cabinet or on electrical powered equipment on the product.

PERSONAL INJURY HAZARD!

All refrigerant related service must be performed by authorized
refrigeration technicians.
NOTICE Avoid contact between liquid refrigerant and eyes or exposed skin.
Wear safety goggles and gloves.
Before removing a hose or component, make sure that it is not
pressurized.

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Cabin air conditioner

3 MAIN COMPONENTS

3.1 Technical data

Air conditioner / heater

EHE-59214 (Cabin EHE-610217K (Cabin

TYPE
7) 2000)
Cooling capacity 5000 W 6300 W
Heating capacity (electric
2100 W 2100 W
heating)
Heating capacity (water
9000 W 10000 W
heating)
Amount of air (max.) 700 m³/h 700 m³/h
Power consumption (24V) 13 A 13 A
Weight 27 kg 28 kg

Condenser / compressor unit

TYPE KSD 9313

Condensing capacity (ATMOSPHERIC AIR +28 °C) 8600 W
Amount of air 1100 m³/h
Number of fans 3
Secondary condenser yes
Power consumption (24V) 8A
Weight 51 kg

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Cabin air conditioner

3.2 Cabin air conditioner main components

15

13
13

Cabin 7 Cabin 2000

9 11

3.1 4 5
12
1
2 10

3.2 6
7

14

1 Compressor 2 Hydraulic motor and control

valve
3 Condenser 4 Dryer
5 Pressure regulator 6 Vaporizer cell
7 Expansion valve 8 Fan
9 Thermostat 10 Heating resistors (electric
heating)
11 Electric heating switch and 12 Heater cell (water heating)
thermostat (optional)
13 Fresh (atmospheric) air filter 14 Air filter for internal air circu-
lation (metal)
15 Cabin bleed valve 16 Electric resistor control box

12 (32) Copyright © Sandvik

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 4

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
4.1
F453.1 INTERIOR LIGHT, CD-PLAYER AND SOCKET
F453.2 AIR CONDITION-/HEATER DEVICE
F453.3 SCREENS WIPERS AND WASHERS
F453.4 AIR CONDITION CONDENCER FANS

FOR CABIN
F453.5 24VDC OPTION

24V DC SUPPLIES
101a
Cabin air conditioner

X450 10/29
F453.110A X42
451b X451 451 1 2 F453.1 1 1 W42 1 101
8/29 31/11
F453.2 X42
10A 1 2 F453.2 2 2 W42 2 102
31/11
F453.3 X42
10A 1 2 F453.3 3 3 W42 3 103
32/12
F453.4
16A 1 2 F453.4
540
F453.5 31/11
16A 1 2 F453.5 MINI SSE
541
OPTION 31/11

W2202 1 W2202 3 W2202 4

AIR CONDITION S1
1 CONDENCER 3 4
X2202 X2202 X2202
RIG-LP RD 1 (+24VDC) (HEATER) 3 (DIRECT) 4 Under 2,3 bar

Copyright © Sandvik
RD
BU
YE

1(87) 1(87) 2,3 bar - 27 bar

K1 K2 1
2(30) 2(30) RD S1 p
Over 27 bar
2
F1 F2 F3 BU
7,5A 7,5A 7,5A BU
1 1 1
(86) (86) COLOURS

ID:GUID-DA678D64-B36F-4560-A785-C25F94B70310 en-US 2 2020-02-28

1 BU = BLUE
M M M K1 K2 BR = BROWN
CABIN AIR CONDITIONER OPERATION

Y560 (85) (85) BK = BLACK

M1 M2 M3 WH = WHITE
2 GY = GRAY
2 2 2
BK PK = PINK
TR = TRANSPARENT
Electrical diagrams (basic circuit arrangements)

VI = VIOLET
BK YE = YELLOW
2 (BAT -) GR = GREEN
Y/G = YEL/GRE
X2202 2 RD = RED

W2202 2

501b 0VDC X500 501 501c

8/29 10/12

NOTICE! This document is the exclusive

property of Sandvik and it must be
DATE NAME MSA/E-2JH-6/7-CAB-1000V SHEET 9 / 33
SANDVIK returned on request. The document must
DRAWN BY 2008-05-29 HKO MAIN CIRCUIT DIAGRAM
not be copied, reproduced, disclosed to 24VDC SUPPLY TO CABIN
any third party or used in manufacture CHECKED 2008-05-29 TMR DWG NR 3-55157896-D
of subject matter thereof without the
Copyright © Sandvik Mining and Construction prior written consent of Sandvik. APPROVED 2008-05-29 TIN MAIN MP 55157896-@
POSITION ID-CODE

13 (32)
 14 (32)
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

CD PLAYER
CD PLAYER

CABIN HEATER
12VDC SOCKET
12VDC SOCKET
24VDC SOCKET

HEATER DEVICE
AIR CONDITION /
POWER SUPPLY FOR
POWER SUPPLY FOR
101 24VDC X1 101 X1 101
9/29
102 24VDC X1 102
9/29
Cabin air conditioner

CAB-
1 GR YE CAB- E510
RD
CAB- RD 4 A510
C
A500 HEATER 18-32V 18-32V
EM-130-IN
ON/OFF SW- 13.6V SW- 13.6V
1 CD-
RD BK BU THERMOSTAT
A501 PLAYER A502
1 3 2 FAN SPEED 0V CAB- 0V

0 1 2 3 B C E511
OVERTEMP C

2 1 AIR COND. 1
0 L M H
ON/OFF
YE THERMOSTAT BU
C 0-1
RD OR SWITCH
WH
5 6
OR
X1 104 X1 105 X1 107

Copyright © Sandvik
WATER W42 4 W42 5 W42 7
VALVE BK
2 FAN
M 4 5 7
MP-X42 MP-X42 MP-X42
1 4 5 7
BK
2 MP-X500 539 MP-X500 540 X500 541

ID:GUID-DA678D64-B36F-4560-A785-C25F94B70310 en-US 2 2020-02-28

+ +
MP-
K430 CAB- CAB-
20/13 6
A1
X502 X503
K451 if heater MP-
AUS option also - -
K451
540 A2
9/29
541
9/29
X1 106 0VDC X1 106 106
32/12
0VDC 501s
W42 6 33/11
1 2
6/27
6 MP- 3 4
MP-X42 K451 5 6
6
13 14

501r MP-X500 501

30/29 B21 B22
B13 B14

NOTICE! This document is the exclusive

property of Sandvik and it must be
DATE NAME MSA/E-2JH-6/7-CAB-1000V SHEET 31 / 33
SANDVIK returned on request. The document must
DRAWN BY 2008-05-29 HKO MAIN CIRCUIT DIAGRAM
not be copied, reproduced, disclosed to CABIN AC, HEATER AND SOCKETS
any third party or used in manufacture CHECKED 2008-05-29 TMR DWG NR 3-55157896-D
of subject matter thereof without the
Copyright © Sandvik Mining and Construction prior written consent of Sandvik. APPROVED 2008-05-29 TIN MAIN SW 55157896-@
POSITION ID-CODE
Cabin air conditioner

4.2 Operation

15

13
13

Cabin 7 Cabin 2000

9 11

3.1 4 5
12
1
2 10

3.2 6
7

14

Pressurizes and circulates the refrigerant.

1 Compressor The compressor is positioned so that it is connected
with the condenser, and it derives its driving force
from the hydraulic motor via the coupler.
When not energized, the valve directs the oil past
the motor and stops the compressor. When ener-
2 Hydraulic motor and control valve gized, the valve switches the compressor on.
The solenoid valve is controlled by the thermostat,
pressure switch, and air conditioner fan switch.
Gives warmth to external air, changing the gaseous
refrigerant into liquid.
The condenser part consists of the cell (3.1) and the
3 Condenser
fans (3.2).
Located on the rear surface of the cabin or on top of
the carrier.

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Cabin air conditioner

The purpose of the dryer is to remove any remaining

humidity from the system after filling (danger of
freezing).
The refrigerant passes through the filter and dryer
material; there is a sight glass in the dryer cover for
4 Dryer
checking the flow.
The dryer must be replaced every time the system
has been empty for more than 30 minutes, because
it cannot withstand prolonged exposure to air (the
dryer absorbs humidity from the air).
Functions as a pressure switch and disconnects the
flow going from the hydraulic motor to the solenoid
valve if the system pressure becomes too low or too
5 Pressure regulator high.
Located in the condenser housing and is connected
to the dryer.
Absorbs warmth and humidity from the ambient air –
in other words, cools the air inside the cabin.
6 Vaporizer cell
Converts liquid refrigerant into a gas.
Located in the cabin.
Regulates the refrigerant flow to the vaporizer.
Located in the vaporizer housing in the line coming
from the dryer.
Inside the valve, there is a spool controlled by a dia-
7 Expansion valve phragm to regulate the flow to the vaporizer on the
basis of a sensor’s output and the pressure.
If there is too much refrigerant flowing through the
vaporizer, the valve closes. If there is not enough re-
frigerant, the operation is reversed.
Sucks air through the vaporizer-heater cell and the
electric heating resistors to the cabin.
8 Fan
Located in the air conditioning housing inside the
cabin.
The thermostat is used to turn on the heating and to
adjust the temperature of the air blown into the cabin
when the heating is not turned on. It also prevents
the vaporizer cell from freezing.
The thermostat is located in the air conditioning
9 Thermostat
housing or on a separate panel.
Controls the operation of the solenoid valve of the
hydraulic motor: stops the hydraulic motor and the
compressor when the pre-selected air temperature
has been reached.
Provide warmth via the air blown through the cabin.
10 Heating resistors (electric heating)
Located in the heater housing.

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Cabin air conditioner

The switch is used for turning on the power of the

electric heating resistors.
Electric heating switch and ther- The thermostat is used to adjust the temperature of
11
mostat the air blown into the cabin.
Both components are located in the heater housing
or on the adjustment panel.
There is engine coolant circulating in the cell, which
gives warmth to the air blown through the cell to the
cabin.
Heater cell (water heating) (op-
12 Located in the air conditioner housing.
tional)
The cabin temperature is changed with a control lo-
cated in the heater housing or on the adjustment
panel.
Removes the dust from the incoming air.
Located on the outer wall of the cabin.
13 Fresh (atmospheric) air filter The air filter must be cleaned with compressed air
(the coarse filter may also be washed in soap solu-
tion) and replaced regularly. The maintenance inter-
val depends on the quality of the external air.
Removes impurities from the air circulating in the
cabin.
Air filter for internal air circulation Located in front of the air conditioner air intake, in-
14
(metal) side the cabin.
The filter must be cleaned regularly by washing or
by blowing with compressed air.
15 Cabin bleed valve
16 Electric resistor control box Contains the control contactor and fuels.

Function
The gas pressurized by the compressor is guided through the condenser
(3.1). Because the gas temperature is higher than the external air
temperature, the gas gives warmth to the ambient air. This causes the gas
to condense. The condenser fans (3.2) create the necessary condensing
capacity.
The liquid refrigerant flows through the dryer (4). Humidity is the biggest
threat to the air conditioning unit, so it must be removed as carefully as
possible. A damp system will freeze!
The liquid refrigerant flows on through the expansion valve (7) to the
vaporizer (6). The expansion valve controls the amount of refrigerant that
flows through the vaporizer by restricting flow to the cell.
The refrigerant reaching the vaporizer absorbs ambient heat. The air in the
cabin is absorbed through the vaporizer (fan 8), and the warmth and
moisture from the air transfers to the cold vaporizer surface. In the
vaporizer, the low boiling point liquid refrigerant reverts to a gas state.

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The gaseous refrigerant returns to the suction side of the compressor, and
circulation continues in the same manner.

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5 CABIN AIR CONDITIONER MAINTENANCE AND REPAIR

5.1 Periodic maintenance

5.1.1 Maintenance procedures

There is dangerous voltage (110 V or 220 V) in the heater resistors.
Before maintenance procedures, make sure that power supply to the
resistors has been prevented (e.g. by opening the main switch; see
the Sandvik manual for electrical safety instructions).

• Keep the condenser clean. Remove dirt from between the cells
cautiously with a soft brush or similar to avoid damaging the cells. A
clean condenser works efficiently and keeps the cabin air comfortably
cool.
• Make sure that the refrigerant or hydraulic hoses do not come in contact
with any sharp edges or hot surfaces.
• Check both the compressor fastening and the tightness of the hydraulic
motor and hoses on a monthly basis. Operate the unit also during winter
at least once a week for approximately five minutes. This ensures the
compressor remains lubricated and the moving parts remain clean and
do not become oxidised.
• Never disconnect the hose connectors except in an emergency. If a
hose connector is disconnected, the refrigerant flows out of the system
and the system has to be refilled.
• Keep the heater’s fresh air-filter and the internal air circulation filter
clean.
• Do not weld or steam-clean anything in the vicinity of the air conditioning
lines or components.

5.1.2 Cleaning the filters

Fresh (atmospheric) air filter

The fresh-air filter on the outer wall of the cabin removes dust from the
incoming air.

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4
3
2
1

1 Detachable cover
2 Coarse filter
3 Fastening plate
4 Two separate fine filters
5 Housing

The air filter must be cleaned with compressed air (the coarse filter may
also be washed in soap solution) and replaced regularly. The maintenance
interval depends on the quality of the external air.

Air filter for internal air circulation (metal)

Removes impurities from the air circulating in the cabin.
Located in front of the air conditioner air intake, inside the cabin.
The filter must be cleaned regularly by washing or by blowing with
compressed air.

5.1.3 Adding oil

Note! Oil and refrigerant refills may only be carried out by trained
professionals. The procedure requires professional skill and special
equipment.

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Compressor oil is added through the filler plug (A). Normally, oil is added in
connection with compressor installation. All new compressors are delivered
ready-filled, but if oil has leaked from the system or any parts are replaced,
oil must ALWAYS be added to the system following the instructions below.

Location of the filler plug

Only the following oil grades may be used in the Sanden compressors
(refrigerant R-134a):
1. Sanden PAG SP-20 and SP-10 or a corresponding PAG (polyalkylene
glycol) ISO-100 (high-viscosity) or ISO-46 (low-viscosity) oil.
2. Corresponding ISO-100 and 46 ‘Ester’ oils can also be used in the
compressor, e.g. Castrol Icematic 100 and 46 or equivalent.
Naturally, the amount of oil to be added depends on the size of the parts,
i.e. the capacity of the system, so some variation from the values given
above will occur.

Part to be replaced Oil to be added

Vaporiser cell approx. 0.6 dl
Condenser cell approx. 0.4 dl

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Part to be replaced Oil to be added

Dryer-charger approx. 0.2 dl
Hose approx. 0.07–0.1 dl per 2 metres of hose

Amount of oil added into the compressor at the factory: SD7H15 – 1.35 dl,
sufficient for systems containing less than 1050 g of refrigerant.
If the amount of refrigerant in the system exceeds that mentioned above,
the amount of oil needed is calculated as follows:
SD7H15: (0.06 x refrigerant quantity (g) + 60) : 0.9 = amount needed (cm 3)
For example, amount of refrigerant (1400 (g) x 0.06 + 60) : 0.9 = 160 cm 3
= 1.6 dl
Oil to be added: 1.60 – 1.35 = 0.25 dl

5.1.4 Adding refrigerant

Follow the instructions below, where:
1. (a.) = work phase using a measuring cylinder
2. (b.) = work phase using a scale
In the service meter set, blue indicates the suction side and red indicates
the pressure side.

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2 1

Adding refrigerant, equipment

1 Vacuum pump
2 Service valves
3 Pressure side hose
4 Suction side hose
5 Service meter set and valves

Do as follows:
1. Attach the blue filling valve of the service meter set to the suction side
service valve (13 mm) of the system, and the red filling valve to the
pressure side service valve (16 mm).
2. (a.) Attach one end of the yellow (middle) hose of the service meter set
to the refrigerant tank, and the other end to the measuring cylinder valve.
Open the liquid valve of the refrigerant tank or turn the refrigerant tank
upside down (with the valve facing downward). Bleed the air from the
yellow hose by loosening the end on the cylinder side cautiously. Open the
cylinder valve and add liquid refrigerant to the measuring cylinder. If the
liquid refrigerant does not flow properly to the cylinder, heat the refrigerant
tank e.g. by immersing it in hot water or by letting some gas out from the
valve on the top end of the measuring cylinder. When the cylinder is filled
with at least the minimum amount of refrigerant, close the cylinder and

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refrigerant tank valves fully. Disconnect the yellow hose at both ends, and
then attach one end to the service meter. Switch on the measuring cylinder
heating.
3. Screw the middle (yellow) hose of the service meter set to the vacuum
pump. Open both filling valves by carefully turning clockwise all the way to
the bottom if you are not using quick connectors.
4. Turn on the vacuum pump. First open the blue valve of the service meter
and check that the pressure starts to drop slowly on the blue meter, and
after a while also on the red meter. If not, turn off the vacuum pump, close
the filling valves, and make sure they are properly connected to the service
valves. Restart the vacuum pump and repeat the procedure (if the pressure
on the red meter still does not drop, the system might be clogged). Once
the pressure on both meters has started to drop, open the red valve of the
service meter.
Create a vacuum in the system for at least 40 minutes, depending on
the length of the hoses (less than 6 m = at least 40 min. – 25 m = at least
80 min.).
5. First, close both service meter valves; then shut down the vacuum pump.
Let the system remain in this state for at least 15 minutes (if you are using
a vacuum gauge with a wider scale, e.g. 1000–0.0 mbar – 5 min.). If the
underpressure has remained unchanged, go to step 6. (a.) or (b.). If the
underpressure has decreased during this time, there is a leak in the
system. Repair the leak, and start again from step 4 (if the system is still
not tight, the leak must be located as described in steps 6–8, and then the
procedure restarted from step 3.)
6. (a.) Disconnect the yellow hose from the vacuum pump, attach it to the
valve below the measuring cylinder, and open the cylinder valve. Bleed the
air from the yellow hose by carefully loosening the end on the service meter
side. Set the measuring cylinder scale correctly in keeping with the
pressure gauge reading, and set the gauge line to the level of the liquid.
Write down the reading, and determine the sight glass reading which
indicates how much refrigerant must be added to the system.
(b.) Place the refrigerant tank on the scale upside down (valve facing
downward). Disconnect the yellow hose from the vacuum pump and
connect it to the refrigerant tank. Open the tank valve (if the tank is
equipped with two valves, do not turn it upside down, but open the red
liquid valve). Bleed the air from the yellow hose by carefully loosening the
end on the service meter side. Reset the scale, or write down the scale
reading if it cannot be reset, and determine the scale reading at which the
system will be full.
7. Open the red (pressure side) valve of the service meter. Add
approximately half of the total amount of refrigerant into the system.
Ensure that the pressure increases on both meters. Close the red valve. If
the pressure does not increase in the blue valve, or if it increases very
slowly, there is a clog in the system that must be cleared.
8. Check the system for leaks. Move the leak detector sensor very slowly at
each of the connecting points. Check also the cells and connections made

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by the manufacturer. Check the seal of the compressor shaft. The

refrigerant is heavier than air, so it sinks if there is leakage. Leak detection
spray (soap solution) is also a viable means of finding leaks, especially in
warm conditions (near a hot engine), because heat can cause the
electronic leak detector to give false readings.
IF INFORMATION ON THE AMOUNT OF REFRIGERANT FOR THE
SYSTEM IS NOT AVAILABLE or if you are adding refrigerant, FOLLOW
THE INSTRUCTIONS BELOW. Otherwise, go to step 11.
9. Start the vehicle's engine. Set the air conditioner to full capacity (fan at
maximum speed and thermostat at full power). Check via the sight glass
that the refrigerant is flowing in the system. If the sight glass is completely
clear and no flow is visible, there is a clog in the system. In that case,
switch off the air conditioning immediately (checking first, however, that the
compressor has been switched on). Locate the clog and clear it. Place a
thermometer in the air blast nozzle of the vaporiser. Use the air conditioner
until the pressures and the vaporiser blast air temperature are stable.
10. Check the reading of the pressure gauge (red) and the temperature of
the vaporiser air blast. If you are using a scale, add the refrigerant to the
system as gas (with the tank valve facing up or through the ‘GAS-VAPOR’
valve). Open theblue (suction side) valve of the service meter (very little
and very carefully when adding liquid refrigerant from the measuring
cylinder, in order to avoid liquid refrigerant entering the compressor). Add
50–100 g (depending on the hose lengths) of refrigerant into the system,
and close the suction side (blue) valve. The pressure side pressure (red
meter) should rise slightly, and the vaporiser air blast temperature should
fall. Wait for the pressure and temperature to stabilise, then again add 50–
100 g of refrigerant into the system from the suction side (blue valve).
Note! Depending on external conditions, the pressure increases very little
between doses!
Draw a curve, such as that shown below, to describe the ratio between the
pressure and the amount of refrigerant. Continue filling 50–100 g at a time.
When the pressure on the pressure side (red meter) no longer increases
(and the air blast temperature no longer decreases), close the blue valve of
the service meter.

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Refrigerant filling curve

1 Pressure on the pressure side

2 Refrigerant amount (g)
3 Optimal refrigerant amount

The optimal amount of refrigerant is the middle point on the curve.

Go to step 13.
11. Open both valves of the service meter (blue and red), and add the
remaining refrigerant to the system. If the required amount of refrigerant
does not flow into the system, close both valves (blue and red) of the
service meter set. Start the vehicle engine and set the air conditioner to
operate at full capacity (fan at maximum speed and thermostat at full
power). Raise the engine speed to approximately 1000 rpm.
12. (a.) Open the blue valve (suction side) of the service meter very
cautiously so that the liquid refrigerant cannot enter the system. When the
system contains the correct amount of refrigerant, close the blue valve of
the service meter. Close the measuring cylinder valve, and switch the
heating off.
(b.) Turn the refrigerant tank the right way up (with the valve facing up, or
first close the LIQUID valve and open the GAS–VAPOR valve). Open the
blue valve (suction side) of the service meter, and add the remaining
refrigerant into the system. When the system contains the correct amount
of refrigerant, close the blue valve of the service meter and the tank valve.
13. The pressure on the suction side should be 0.1–2.0 bar (blue meter),
and the pressure on the pressure side should be 7.0–18.0 bar (red meter)
when the engine operating speed is approximately 1500 rpm. Check the

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vaporiser blast air temperature at the minimum fan speed. The temperature
should be 2–8 °C. If necessary, ‘fine-tune’ the thermostat (via the small
screw) to adjust the temperature.
14. Close the filling valves of the service meter set by turning them anti-
clockwise, and remove them from the service valves of the system. Check
that there are no leaks in the service valves, and attach protective caps on
them.
Note! ALWAYS write down the amount of refrigerant added (e.g. in the
warranty information or in the place reserved on the manufacturer's
type plate).

5.2 Repair instructions

5.2.1 Dryer
When replacing the dryer, take into consideration that the cover plugs of the
new dryer must be removed and the hoses installed immediately before
filling the system! The dryer material loses its effect if it comes into contact
with air for more than 30 min. For this reason, the dryer must always be
replaced whenever the system is drained completely.

5.2.2 Coupler
If the coupler between the air conditioning compressor and hydraulic motor
must be detached during maintenance or repair work, the following points
must be observed:
1. When reinstalling the coupler, make sure that there is no end strain in
the connection, as this might damage the compressor and the engine.
2. The clearance between the coupler elements must be 2 mm +/– 0.5
mm.

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Compressor coupler

See separate instructions (v463) for spacer ring replacement.

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6 CABIN AIR CONDITIONER TROUBLESHOOTING

6.1 Troubleshooting table

FAULT CAUSE
– The automatic fuse of the main switchgear
has tripped.
Fan is not working. – The air conditioner fuse has blown.
– The fan switch is broken.
– The fan motor is broken or jammed.
– The automatic fuse of the main switchgear
has tripped.
– The pressure of the refrigerant in the system
has decreased.
Air conditioning is not working. – The air conditioner fuse has blown.
– The compressor is not rotating.
– The system is frozen. Check the operation
of the expansion valve and the condition of the
dryer.
– The automatic fuse of the main switchgear
has tripped.
– The heater is on.
– The water valve is leaking.
– The intake air filter is clogged.
Air conditioning lacks efficiency.
– The condenser cell is dirty.
– The vaporiser cell is dirty.
– The refrigerant is low.
– The expansion valve is frozen.
– The dryer is clogged or frozen.
– The automatic fuse of the main switchgear
has tripped.
– The automatic fuse of the main switchgear
Heating is not working. has tripped (feed for the heating resistor).
– The air conditioner fuse has blown.
– The water valve is broken.
– The fan motor (in the cabin) is faulty.
– There is not enough oil in the compressor, or
the compressor is faulty (bearing fault).
– There is not enough refrigerant in the sys-
Operation is noisy.
tem (noisy vaporiser).
– There is excess humidity in the system
(noisy expansion valve).
– The air filter is clogged.

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www.sandvik.com
 v463-1en0911

Replacement instructions for spacer ring

Compressor / condenser unit; Finnklima KSD-9313H-T

Manufacturer; Wihuri Oy Technical Trade
Description of work; Replacement of the red spacer ring in
the clutch between the compressor and hydraulic motor
Note; Replacement is recommended as the too hard
material of the red spacer ring may break the compressor
shaft in some circumstances

- Sandvik code for compressor / condenser unit; 55040122

- Wihuri code for compressor / condenser unit; FKK16 931301

Equipment needed:
• Spacer ring
- Sandvik code: 55208028
- Wihuri code: FK24 800104
• Hose binding 50 – 65 mm

JKo 9/11
KSD-9313H-T

Note! Before starting, make sure that there is

no pressure in the hydraulic system.
The air conditioning refrigerant hose
connections need usually not be opened.
However, if you must open the connections,
the refrigerant system must be emptied before
any actions. Pay attention to the refrigerant
handling safety instructions!

Clutch element replacement:

Remove the air conditioning compressor / Picture 1
condenser unit cover.
Disconnect hydraulic hoses above the
compressor bracket flange (picture 1).
Plug the disconnected hydraulic lines.

Remove the end plate and hydraulic hoses

aside (picture 2).
If the hydraulic line is attached to the end
plate side of condenser unit, remove the end
plate as much as possible aside.

Picture 2

Remove the compressor mounting bolts

(picture 3).

Picture 3

2
KSD-9313H-T

Pull the compressor away from the clutch and

remove the red spacer ring from the clutch
(picture 4).

Picture 4

Switch the yellow spacer ring into the clutch.

Set a 50 – 65mm hose binding around the
clutch (picture 5).

Set the clutch elements opposite each other

and mount the compressor back in the
bracket. Do not tighten bolts yet!

Picture 5

Tighten the hose binding around the clutch

(picture 6).

Tighten the compressor mounting bolts and

remove the hose binding.

Picture 6

3
KSD-9313H-T

Measure the clearance between the clutch

elements using a feeler gauge (picture 7).
Measure the clearance from the top and
bottom.
The clearance should be between 1-2 mm!

Picture 7

If the measured clearance is more than

2mm or less than 1mm, proceed as
follows:
Remove the compressor as described above.
Move the compressor (hoses attached) above
the condenser unit (picture 8).
If there is no space above the condenser unit,
move the compressor so that you can reach
the tightening nut of the clutch element.

Picture 8

Remove the tightening nut of the clutch

element. Remove the clutch element from the
compressor shaft. If necessary, use an
extractor (picture 9).

Picture 9

4
KSD-9313H-T

Remove the locking wedge from the shaft

(picture 10).

Picture 10

Add (or remove) the shim plates on the shaft

based on the measured clearance (picture
11).

Mount back the locking wedge.

Install the clutch element back on to the Picture 11

compressor shaft (picture 12).
The torque for the tightening nut is 35Nm.

Install the compressor back and measure the

clearance between the clutch elements.
If the clearance is still not within the margins,
repeat the previous steps.

When the clearance is right, install the end

plate of the condenser unit and hydraulic
hoses back in place.

Install the cover of the condenser unit and test

the operation of the air conditioning system. Picture 12

5
 V464-1en0813

Instruction guide for

air conditioning system refrigerant’s
recovery and refilling

Air conditioning system: Finnklima

Manufacturer: Wihuri Oy Technical Trade
Description of work: Recovery of the refrigerant from an AC
system, vacuuming and refilling
Reason for the work: The AC system of a machine must be
empty when the machine is transported outside the country
of manufacture. The AC system must also be vacuumed to
avoid moisture condensing in the AC loop.
The work has to be performed by a person who is authorizied
by officials to work with AC refrigerant systems.
Refrigerant in AC system: R134a

This instruction guide must be applied to all Finnklima AC

systems.

Equipment needed:
• Air conditioning service device
• Protective gloves and eye-classes

JKo 6/13
AC system refrigerant’s recovery

Always use protective gloves and safety

glasses when working with the AC system
refrigerant loop!

1. Connect the hoses of the air conditioning

service device in the high and low
pressure service ports.
The ports are located in the fittings
situated towards the cabin in the
condenser / compressor unit (picture 1
and 2).

Picture 1
2. Open the high and low pressure valves
from the air conditioning service device
and start the loop recovery (picture 3).

3. Write down the amount of the compressor

oil removed from the system.
Hint: Take a print from air conditioning
service device!
Mark the oil amount into the service
document delivered with the machine. The
same amount of oil must be added into the
AC loop when refilling refrigerant system.

4. Vacuum the AC loop to prevent moisture

condensing in the loop. Start the Picture 2
vacuuming and wait until the operation is
finished.

5. When finished the vacuuming, disconnect

the hoses from the air conditioning service
device from the high and low pressure
service ports. Put the protective caps back
into the service ports.

Picture 3

2
Refilling the AC system

1. Connect the hoses of the air conditioning

service device in the high and low
pressure service ports.
The ports are located in the fittings
situated towards the cabin in the
condenser / compressor unit.

2. Check the end-result of the loop

vacuuming from the gauges in the air
conditioning service device.
If there is no vacuum in the loop, find the Picture 4
leakage and repair the system. Also the
receiver/drier must be replaced in case of
a loop leakage.

3. Start the AC loop refilling by vacuuming

the loop.
Open the high pressure valve from the air
conditioning service device. Keep the low
pressure valve closed (picture 4).

4. Check the amount of oil to be refilled from

the machine’s service document. Use
PAG 100 oil.
Set the oil amount value in the air
conditioning service device and start filling Picture 5
(picture 5).

5. Check the amount of refrigerant to be

refilled from the machine’s service
manual. The amount of refrigerant needed
in the AC loop depends on the type of the
machine.
Set the refrigerant amount value in the air
conditioning service device and start filling
(picture 6).

If the needed amount of the refrigerant

does not enter into the AC loop, open the
low pressure valve and fill the system via
both the high and low pressure ports. Picture 6

3
6. A small amount of liquid refrigerant will
remain in the air conditioning service
device hoses after filling. Empty the hoses
into the machine AC loop as follows:
• Close the high and low pressure valves
from the air conditioning service device.
• Disconnect the high pressure hose from
the service port of the machine.
• Start the engine of the machine.
• Open the high pressure valve from the air
conditioning service device.
• Open slightly the low pressure valve
(picture 7). Do not open it totally at once! Picture 7
Wait approx. 1 min. and then open the low
pressure valve slowly entirely. Watch all
the time the low side pressure of the AC
loop!

The AC compressor is sucking refrigerant

from the hoses of the air conditioning service
device while the engine is running.
After the low side pressure of the AC loop is
stabilized in the pressure between 1 – 3 bar,
the hoses are empty from the refrigerant. After
that:
• Remove the low pressure hose from the
service port of the machine.
• Test the function of the AC system.

For additional information on the air

conditioning service device, please contact
the official distributor of the unit.

4
 Original instructions
GUID-BF6DC075-9347-4009-8E70-E6AEDBCBD883 en-US 1 2020-03-24

Resin shooting automatics for

DS400/DS500
Resin shooting automatics for DS400/DS500

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. Keep this publication for future reference.

Copyright © Sandvik
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Resin shooting automatics for DS400/DS500

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Resin shooting automatics for DS400/DS500

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 Resin shooting automatics main components.............. 9

2.1 Connecting diagram................................................................................... 9
2.2 Operating principle..................................................................................... 9

3 Resin shooting automatics operation.......................... 11

3.1 Filling cassette drum with resin cartridges............................................ 11
3.2 Resin shooting and cleaning of shooting line....................................... 12

4 Resin shooting automatics adjustments and

lubrication....................................................................... 15
4.1 Adjustment of cassette drum functions................................................. 15
4.1.1 Positioning of cassette drum to shooting line.................................. 15
4.1.2 Adjusting cassette drum turning lever............................................. 16
4.2 Lubrication.................................................................................................16

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Resin shooting automatics for DS400/DS500

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ID:GUID-BF6DC075-9347-4009-8E70-E6AEDBCBD883 en-US 1 2020-03-24
Resin shooting automatics for DS400/DS500

1 INTRODUCTION
1.1 The purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
These instructions must be followed along with other manuals of the rig,
any instructions given in local laws and regulations, any orders given by
local authorities, and all protective measures specific for the site.
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 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 equipment is used in mechanized reinforcing of rock, with resin
cartridges as the grouting medium. The operator can set the equipment to
shoot 1–5 resin cartridges successively.
The equipment is designed for control from cabin while the cartridge
cassette is outside the cabin. The control box sends input data to the logic
system that sends the respective output data to the on/off valves of the
equipment.

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Resin shooting automatics for DS400/DS500

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ID:GUID-BF6DC075-9347-4009-8E70-E6AEDBCBD883 en-US 1 2020-03-24
Resin shooting automatics for DS400/DS500

2 RESIN SHOOTING AUTOMATICS MAIN COMPONENTS

2.1 Connecting diagram
Turning cylinder

Relesing
cylinder Sealing cylinder

Water valve,
shooting line

Air reservoir

Reserving Air valve,

outer pipe

Sealing
Air valve,
inner pipe
Turning

Resin shooting connecting diagram

2.2 Operating principle

Cassette drum Turning lever pin Turning lever
Turning cylinder
Release
cylinder

Wash
connection
Sealing
cylinder

Connecting
pipe Slide locking sleeve Slide

Main components of the system

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Resin shooting automatics for DS400/DS500

When the equipment is ready to shoot, the cassette drum is in the rear
position, the slide locking sleeve in the inner circle pipe, and the turning
lever pin in the outer circle pipe.
When the shooting button SH1 is pushed, pressurized air enters the piston
side of the sealing cylinder through the valve Y402, and the cassette drum
moves to the front position for sealing. Sealing stays on all the time when
pressurized air is led to the shooting line (valve Y400 or Y401 live). After
sealing (0.5 s), the logic control lets pressurized air for 1.5 seconds through
the valve Y400 and the slide into the outer pipe of the drum, whereupon
pressurized air drives a resin cartridge along the shooting line into the
drilled hole. When the valve Y400 is closed, sealing is released. The logic
unit waits 5 seconds for the pressure containers to be filled, and then it lets
pressurized air flow through the valveY403 for 1 second to the piston side
of the release cylinder, whereupon the drum moves to the rear position and,
at the same time, the turning lever pin is inserted into the outer pipe of the
drum.
Note! The locking sleeve is still in the inner pipe of the drum and prevents
the drum from turning while it is moving in the longitudinal direction.
When shooting of two cartridges is selected (without turning the cassette),
sealing is carried out as above. After this, the valve Y400 opens for 0.3
seconds and immediately after that the valve Y401 opens for 1.5 seconds.
In this way, two cartridges can be driven into the shooting line.
The cassette drum is turned so that when the working stroke of the release
cylinder is completed, the valve Y404 is activated and pressurized air is
simultaneously directed to the piston rod side of the sealing cylinder and to
the piston head side of the turning cylinder (with spring return). The
pressure on the piston rod side of the sealing cylinder pulls the slide into
the rear position and releases locking, whereupon the turning lever turns
the cassette to the next position. As the cassette moves during sealing to
the front position, the turning lever pin is released and the spring of the
turning cylinder turns the lever into the initial position.
The cassette drum is not turned although the cartridges on both inner and
outer circle have been shot. The reason is that if the shooting line is to be
blown or washed clean, the outer circle is now empty for this purpose.

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Resin shooting automatics for DS400/DS500

3 RESIN SHOOTING AUTOMATICS OPERATION

3.1 Filling cassette drum with resin cartridges

WARNING
PERSONAL INJURY HAZARD!
Avoiding these instructions could cause death or severe injury.
Always turn the switch S4 into 0 position to turn off power to resin
cartridge shooting automatics before working on the cassette.

WARNING
FALLING OBJECT HAZARD!
Machine movements could cause death or severe injury.
Never go close to the cassette drum while shooting is in progress.
Never go under the boom to load the cassette drum.

Casette drum Turning lever pin

Filling door
Latch Turning cylinder
Control box

Sealing
cylinder

Slide Rubber of drum

locking
sleeve Slide SwitchS4

The maximum capacity of the cassette is 48 resin cartridges with a max.

length of 550 mm. Recommended cartridge diameter is 23 mm. For best
results, firmly packed, tight cartridges should be used.
1. Switch off power to the equipment by turning the switchS4 into the 0
position. If necessary, lift up the rubber cover of the drum.
2. Pull the sealing cylinder slide into the rear position. Turn the filling door
latch upwards and open the door by turning it backwards.

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Resin shooting automatics for DS400/DS500

3. Push the cassette drum forwards to release the drum from the pin of the
cassette turning lever so that the cassette can rotate freely.
4. Push the resin cartridges into the cassette pipes so that the rear ends of
the cartridges are flush with the rear surface of the cassette drum. If the
resin cartridges are provided with plastic 'brakes', push the cartridges
'brake' end first into the cassette.
5. Having filled the cassette, close the filling door and secure it by turning
the latch downwards.
6. Position the drum correctly by turning it and pushing the sealing cylinder
slide forwards so that the locking sleeve at the front end of the slide
goes into one of the inner pipes of the cassette drum.
7. Lower the drum rubber cover back into place and turn the switch S4 into
position 1.
8. Reset the system by turning the selector switch S2 on the control box
into position 0 and depressing the shooting push button SH1 and the
acknowledging push button S3 simultaneously.

3.2 Resin shooting and cleaning of shooting line

WARNING
PERSONAL INJURY HAZARD!
Exposing to the shooting line could cause death or severe injury.
Never aim the shooting line at a person, an electric cabinet or other
corresponding objects during shooting or the blowing/washing of
shooting line. Never go near the cassette drum when shooting is in
progress.

Resin shooting
The shooting push button SH1 on the control box is used for shooting resin
cartridges, and for blowing or washing the hose clean. Warning light
illuminates during operation.
The selector switch S2 is used for selecting the number of cartridges to be
shot (1–5), after which shooting is started by depressing the shooting push
button SH1. If there are less than the selected number cartridges left in the
cassette, the warning light SH1 starts flashing and shooting is prevented.
The cassette can be shot empty by depressing the acknowledging push
button S3 and then, again, the shooting push button SH1.

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Resin shooting automatics for DS400/DS500

Control box
Push button S3 can be used for interrupting a shooting sequence if some
disturbance is observed during shooting. When the shooting push button
SH1 is then depressed again, the selected shooting sequence starts again
from the beginning.

Cleaning of shooting line

• When you want to blow the shooting line clean, turn the selector switch
S2 to position 6 (blowing of shooting line) and depress the shooting push
button SH1. Pressurized air is blown in for a preset time.
• To wash the shooting line turn the selector switch S2 to position 7 and
depress the shooting push button SH1. Water is now first let into the
shooting line and then blown out with pressurized air.
Note! Blowing/washing of shooting line cannot be done immediately after
filling the cassette but only after shooting at least one resin cartridge.
Otherwise one resin cartridge will be lost when blowing/washing the
shooting line.

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ID:GUID-BF6DC075-9347-4009-8E70-E6AEDBCBD883 en-US 1 2020-03-24
Resin shooting automatics for DS400/DS500

4 RESIN SHOOTING AUTOMATICS ADJUSTMENTS AND

LUBRICATION
4.1 Adjustment of cassette drum functions

WARNING
PERSONAL INJURY HAZARD!
Avoiding these instructions could cause death or severe injury.
Always turn the switch S4 into 0 position to turn off power to resin
cartridge shooting automatics before working on the cassette.

WARNING
HIGH PRESSURE HAZARD!
Maintenance work in the pressurized system could cause death or
severe injury.
Before starting any maintenance, repair, or adjustment work release
the pressure in the system (after stopping the compressor) by
running the blowing of shooting line (selector switch S2 in position
6) so many times that the pressure in the system drops to zero.

4.1.1 Positioning of cassette drum to shooting line

1. To adjust the cassette drum to the shooting line, first remove the
connecting pipe at the front end of the equipment.
2. Push the slide to the front position to lock the drum with the locking
sleeve of the slide.
3. Loosen the four mounting screws of the slide body and turn the drum
and the slide body into a position where the drum pipes align with the
holes of the sealing rubber at the front end of the drum.

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4. Tighten the mounting screws of the slide body and install the connecting
pipe.
Cassette drum Turning lever pin Turning lever
Turning cylinder
Adjusting screw
lever movement

Slide
body

Connecting
pipe Slide Adjusting screw,
Slide body
lever return
Slide locking sleeve mounting
Sealing screw

4.1.2 Adjusting cassette drum turning lever

The extreme positions of the drum turning lever are adjusted using the two
M10 screws against which the turning lever stops. The lever is operated by
a pneumatic cylinder with a return spring.
1. With the slide adjusted as described above, move the drum to the rear
position while the drum is locked by the slide locking sleeve, and turn
the turning lever at the same time so that the pin on the lever is
accurately inserted into the pipe on the drum.
2. Adjust and secure the lower adjusting screw of the lever (lever return)
into this position.
3. Pull the slide to the rear position where the drum can be turned
counterclockwise with the lever.
4. Turn the drum enough to be able to accurately push the slide locking
sleeve into the next pipe. Adjust and secure the upper adjusting screw
(lever movement) into this position.
5. Before actual shooting, check the operation by running one round of 5
cartridges to verify correct operation of the turning lever.

4.2 Lubrication
The lubrication points of the equipment are both ends of the cassette drum
axle. The release cylinder end has a ø 12 mm ball that acts as a thrust
bearing when the cassette drum is rotating.
• The ball housing and the axle shall be lubricated at least once a month
by removing the release cylinder.
• There is a grease nipple at the rear end of the cassette drum, and the
rear baring of the axle shall be lubricated through it once a week.

16 (18) Copyright © Sandvik

ID:GUID-BF6DC075-9347-4009-8E70-E6AEDBCBD883 en-US 1 2020-03-24
www.sandvik.com
 Original instructions
en-US 4 2020-06-23

Screen handler SB60RSH /

SB93RSH

GUID-1EF98092-688C-4E47-8F82-5E125557D1C1
Screen handler SB60RSH / SB93RSH

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. Keep this publication for future reference.

Copyright © Sandvik 3 (40)

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Screen handler SB60RSH / SB93RSH

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Screen handler SB60RSH / SB93RSH

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 instructions......................................................................................9

3 SB60RSH / SB93RSH Main components...................... 11

3.1 Screen handler main components...........................................................11
3.1.1 Gripper............................................................................................ 12
3.1.2 Rotary actuator................................................................................13
3.1.3 Functional diagram of the screen handling device.......................... 14
3.2 Roll mesh handler main components (optional) ...................................15
3.2.1 Roll mesh handler........................................................................... 16
3.2.2 Rotary actuator................................................................................17
3.2.3 Functional diagram of the roll mesh handler boom......................... 18
3.3 Component/system description.............................................................. 19
3.3.1 Lifting instructions............................................................................19
3.3.2 Technical data................................................................................. 20
3.3.3 Model and serial number.................................................................22

4 Operator's maintenance instructions........................... 23

4.1 Screen handler SB60RSH/SB93RSH....................................................... 23
4.1.1 Checking the hoses, pipes and couplings....................................... 23
4.1.2 Checking the bolts...........................................................................23
4.1.3 Greasing the boom..........................................................................23
4.1.4 Checking the roll mesh handler gripper jaws (optional).................. 27
4.1.5 Checking the roll mesh handler wheel extension assembly (optional)
........................................................................................................ 28
4.1.6 Checking the roll mesh handler frame (optional).............................29
4.1.7 Greasing the roll mesh handler gripper jaws (optional)...................30

5 Periodic maintenance instructions...............................31

5.1 General.......................................................................................................31
5.2 Parking position........................................................................................ 32
5.3 Screen handler SB60RSH/SB93RSH....................................................... 32
5.3.1 Tighten the bolts and hose couplings..............................................32
5.3.2 Cleaning the boom.......................................................................... 33
5.3.3 Checking the clearance of the swivel pin bushes........................... 33
5.3.4 Checking the roll mesh handler (optional) sprocket wheels............ 33
5.4 Central greasing system maintenance................................................... 34

6 SB60RSH / SB93RSH repair instructions.....................35

6.1 Tightening torques of the control valve block....................................... 35

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Screen handler SB60RSH / SB93RSH

7 Troubleshooting............................................................. 37
7.1 The proportional movements of the boom are inoperative.................. 37
7.2 Single functions can not be controlled...................................................37
7.3 Pressure too low or nil............................................................................. 37
7.4 Varying pressure or oil flow..................................................................... 37
7.5 Hydraulic slewing is not working............................................................ 38
7.6 Slew motor rotational speed is insufficient............................................38

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Screen handler SB60RSH / SB93RSH

1 INTRODUCTION
1.1 The purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
These instructions must be followed along with other manuals of the rig,
any instructions given in local laws and regulations, any orders given by
local authorities, and all protective measures specific for the site.
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 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
This manual gives you a good understanding of the equipment,
maintenance, service information and technical specifications. Read this
manual before installing or maintaining the SB60RSH / SB93RSH screen
handler for the first time.
In this manual, the units of measurement are metric. For example, weights
are given in kilograms (kg). In some cases the other unit follows in
parenthesis (). For example 28 liters (7.4 US gal).

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Screen handler SB60RSH / SB93RSH

2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1 Safety instructions
WARNING! TIPPING HAZARD!
Machine tip over could cause death or severe injury.
Lower the hydraulic jacks fully before using screen handler. Make
sure that there is nobody in the rig hazard zone when using screen
handler.

WARNING! PERSONAL INJURY HAZARD!

Falling grid plates could cause death or severe injury.
Grid plates should not be transported on top of the screen handler
boom.

WARNING! FALLING LOAD HAZARD!

Falling load could cause death or severe injury.
Do not go under the boom unless it is supported. Always before
starting any repair work, move the boom parking position. Do not
disconnect hydraulic hoses or valves before making sure that there
is no static pressure in the system.

WARNING! HIGH PRESSURE OIL SPRAY HAZARD

There could be pinhole leaks in the hoses, and the high-pressure oil
expelled could penetrate the skin.
Do not touch pressurized hydraulic hoses with bare hands.

RISK OF PROPERTY DAMAGE

Ensure absolute cleanliness whenever performing disassembly or
assembly of hydraulic equipment
NOTICE After removing the cylinders, the hydraulic circuit should be vented
and flushed. This is done to prevent malfunctions caused by dirt or
air trapped in the cylinders.

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Screen handler SB60RSH / SB93RSH

3 SB60RSH / SB93RSH MAIN COMPONENTS

3.1 Screen handler main components
1 2 3 4 5
A

A SB60RSH B SB93RSH
1 Gripper 2 Rotary actuator
3 Hose support assembly 4 Extension boom
5 Lift boom 6 Pedestal

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Screen handler SB60RSH / SB93RSH

3.1.1 Gripper

4
3

1 Claw
2 Cylinder
3 Pad
4 Mounting point

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Screen handler SB60RSH / SB93RSH

3.1.2 Rotary actuator

1 Rotary actuator (screen handler swing)

2 Rotary actuator (screen handler lift/lowering)
3 Rotary actuator (screen handler rotation)
4 Screen handler zoom

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 3.1.3

14 (40)
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
2
TO CARRIER UNPRESSURIZED
BOOM SWING 3 4 5 6 7 8 9 10
COLLECTOR PORT 6 6 6

JIB BOOM SCREEN STEEL

6 BOOM EXTENSION ROLL-OVER SCREEN SWING SCREEN TILT
1 BOOM LIFT SCREEN GRIP SCREEN ZOOM SIZE SELECTOR
CYLINDER CYLINDERS
D D

C 6 C
A B A B

A B A B 3:1 3:1 3:1 3:1 B

B B

PIPE
16x2
A A A

PIPE
16x2
4

PIPE
16x2
4

PIPE
16x2
C2 C1 3:1 3:1 3:1
C2 C1 4.5:1 4.5:1

60bar
60bar

60bar
60bar
P2 P2 P2

A B A B

230bar

230bar
230bar

230bar

230bar
4.5:1 V2 V1

210bar
V2 V1
P1 P1 P1

3:1 3:1 3:1

230bar
230bar

230bar
4 4 4 4 4 4 4 4 4 4

5 6 1 2 7 8 3 4 9 10

6 6 6 6 6 6 6 6 6 6 6 4 4 4 4 4 4 4 4 4 4 4 4 4 4

11 12 5 6 1 2 7 8 3 4 9 10

4 4 4 4 4 4 4 4 4 4 4 4
Screen handler SB60RSH / SB93RSH

15 16 13 14 11 12 5 6 1 2 7 8 3 4 9 10

Copyright © Sandvik
6 6 6 6 4 4 4 4 4 4 4 4 4 4 4 4

15 16 13 14 11 12 5 6 1 2 7 8 3 4 9 10

6 6 66 4 4 4
4 4 4 4 4 4 4 4 4

Screen handler boom hydraulic diagram

Functional diagram of the screen handling device

MA MB

A B

ID:GUID-1EF98092-688C-4E47-8F82-5E125557D1C1 en-US 4 2020-06-23

4:1 4:1

200bar 200bar
MA MB MA MB
C
a A B b a A B b a A B b a A B b a A B b a A B b A B A B A B
4:1 4:1 4:1 4:1 4:1 4:1

50bar 50bar 100bar 100bar 50bar 50bar

Z

200bar 180bar 225bar 120bar 210bar 210bar 210bar 40bar 80bar 40bar
"b" "b" "b" "b" "b" "b" "b" "b" "b" "b"

40bar 200bar 180bar 180bar 100bar 210bar 210bar 210bar 40bar 60bar 40bar

"a" "a" "a" "a" "a" "a" "a" "a" "a" "a"

Y221
Y222
Y224
Y223
Y227
Y228
Y238
Y237
Y225
Y226
Y231
Y232
Y233
Y234
Y235
Y236
Y230
Y229
Y449
Y448

LS
LS
T

FROM PRESSURE
CONTROL BLOCK
PORT P1 8
P R

TO PRESSURE MP
CONTROL BLOCK 8
PORT T1 Updated Change
Date by not. Date Was before Pos. Rev.

NOTICE! This document is the exclusive DATE NAME

property of Sandvik and it must be Sandvik DS411 SHEET 1 / 1 A1
SANDVIK returned on request. The document must DRAWN BY 2017-08-25 JHK Hydraulic diagrams
not be copied, reproduced, disclosed to Screen handler boom
any third party or used in manufacture CHECKED 2017-08-25 JN DWG NR BG00965033-A
of subject matter thereof without the
Copyright © Sandvik Mining and Construction prior written consent of Sandvik. DS411_421
APPROVED POSITION ID-CODE BG00965033
Screen handler SB60RSH / SB93RSH

1 Boom lift 2 Boom swing

3 Jib boom cylinder 4 Boom extension cylinders
5 Roll-over 6 Screen swing
7 Screen tilt 8 Screen grip
9 Screen zoom 10 Screen steel size selector

3.2 Roll mesh handler main components (optional)

2
1

5 6

1 Roll mesh handler 2 Rotary actuator

3 Hose support assembly 4 Lift boom
5 Extension boom 6 Pedestal

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Screen handler SB60RSH / SB93RSH

3.2.1 Roll mesh handler

4 5 6 7 8

1 Mesh end plate 2 Spindle

3 Wheels 4 Mounting point
5 Wheel extension 6 Gripper jaws
7 Gripper locking pin 8 Gripper cylinder

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Screen handler SB60RSH / SB93RSH

3.2.2 Rotary actuator

1 Rotary actuator (screen handler swing)

2 Rotary actuator (screen handler lift/lowering)
3 Rotary actuator (screen handler rotation)

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 3.2.3

18 (40)
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

2
TO CARRIER UNPRESSURIZED
BOOM SWING
COLLECTOR PORT 6 6 6 3 4 5 6 7 8 9
MESH ROLL LOCK MESH FEED ROTATION
6 JIB BOOM BOOM EXTENSION ROLL-OVER MESH SWING MESH TILT
1 BOOM LIFT
CYLINDER CYLINDERS
D D 4
B 4 B
C 6 C
4
A B A B 4 4 A B A B
A A
A B A B 3:1 3:1 3:1 3:1

PIPE
16x2
PIPE
16x2

PIPE
16x2
3:1 3:1 3:1 4 4

PIPE
16x2
C2 C1
C2 C1 4.5:1 4.5:1 4 4 MESH FEED LOCK

60bar
60bar

60bar
60bar
P2 P2 P2

A B A B C1 C2 C1 C2

230bar

230bar
230bar

230bar

230bar
B
4.5:1 V2 V1

210bar
V2 V1
10
P1 P1 P1
A
V1 V2

3:1 3:1 3:1

230bar
230bar

230bar
V1 V2
4 4 4 4

4 4 4 4 4 4

5 6 1 2 7 8 3 4 9 10

6 6 6 6 6 6 6 6 6 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

11 12 5 6 1 2 7 8 3 4 9 10

4 4 4 4 4 4 4 4 4 4 4 4
Screen handler SB60RSH / SB93RSH

15 16 13 14 11 12 5 6 1 2 7 8 3 4 9 10

Copyright © Sandvik
6 6 6 6 4 4 4 4 4 4 4 4 4 4 4 4

15 16 13 14 11 12 5 6 1 2 7 8 3 4 9 10

6 6 6 6 4 4 4 4 4 4 4 4 4 4 4 4
Functional diagram of the roll mesh handler boom

MA MB

Roll mesh handler boom hydraulic diagram

A B

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4:1 4:1

200bar 200bar
MA MB MA MB
C
a A B b a A B b a A B b a A B b a A B b a A B b a A B b a A B b A B
9bar 4:1

50bar
Z

200bar 180bar 225bar 120bar 210bar 210bar 210bar 40bar 100bar 40bar
"b" "b" "b" "b" "b" "b" "b" "b" "b" "b"

40bar 200bar 180bar 180bar 100bar 210bar 210bar 210bar 40bar 100bar 40bar

"a" "a" "a" "a" "a" "a" "a" "a" "a"

B "a"

Y221
Y222
Y224
Y223
Y227
Y228
Y238
Y237
Y225
Y226
Y231
Y232
Y233
Y234
Y235
Y236
Y230
Y229
Y449
Y448

LS
LS LS
T
Z
P
FROM PRESSURE R
CONTROL BLOCK
PORT P1 8
P R

TO PRESSURE MP
CONTROL BLOCK 2017-12-11 JHK Added Y numbers. 1 B
8
PORT T1 Updated Change
Date by not. Date Was before Pos. Rev.

NOTICE! This document is the exclusive DATE NAME

property of Sandvik and it must be Sandvik SB60RSH / SB93RSH SHEET 1 / 1 A1
SANDVIK returned on request. The document must DRAWN BY 2017-08-28 JHK Hydraulic diagrams
not be copied, reproduced, disclosed to Roll mesh boom
any third party or used in manufacture CHECKED 2017-08-28 JN DWG NR BG00965561-B
of subject matter thereof without the
Copyright © Sandvik Mining and Construction prior written consent of Sandvik. DS411_421
APPROVED POSITION ID-CODE BG00965561
Screen handler SB60RSH / SB93RSH

1 Boom lift 2 Boom swing

3 Jib boom cylinder 4 Boom extension cylinders
5 Roll-over 6 Mesh swing
7 Mesh tilt 8 Mesh roll lock
9 Mesh feed rotation 10 Mesh feed lock

3.3 Component/system description

3.3.1 Lifting instructions

Lifting points of the machine are marked with the

following decal.

Use a hoist when lifting components which weigh 23 kg (50 lbs.) or more to
avoid back injury. Make sure all chains, hooks, slings, etc., are in good
condition and are of the correct capacity. Be sure hooks are positioned
correctly. Lifting eyes are not to be side loaded during a lifting operation.
Lifting devices must safely carry the working weight of the product.
Pay special attention to placing chains and slings so that these will not
damage vulnerable components (pipes, hoses, bearings, pins and
cylinders) of the product.

Centre of gravity (1)

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3.3.2 Technical data

ITEM SPECIFICATION
Hydraulic power supply From the carrier
PEDESTAL
Structure Welded steel plate structure
Slew Slewing ring with internal gear
Boom swing Two high-torque hydraulic motors
Slew angle 264°
Recommended working angle 250°
BOOM SYSTEM
Lift boom and two extension booms
Lift boom structure Welded steel plate structure
Lift boom swiveling Reinforced swivel points
Extension boom structure Welded steel square pipe structure
Lift boom length 2000 mm (SB60RSH) / 2500 mm (SB93RSH)
5600 mm (SB60RSH) / 6400 mm (SB93RSH) from
Minimum boom length
slew centre to screen handler
7800 mm (SB60RSH) / 9200 mm (SB93RSH) from
Maximum boom length
slew centre to screen handler
Maximum boom length with screen handler 8200 mm (SB60RSH) / 9600 mm (SB93RSH) from
manipulator zoom slew centre to screen handler
Pins Expander® pins
Bushings Special bronze bushings with grease depots
CYLINDERS
Double-acting cylinders with self-aligning bearings
Cylinder type
and easily replaceable seals
Lift cylinder (piston / rod - stroke) mm 140 / 80 - 380
Maximum pressure 25.0 MPa
Stick cylinder (piston / rod - stroke) mm 120 / 70 - 650
Stick cylinder (piston / rod - stroke) mm with
120 / 70 - 625 (limited stroke)
roll mesh option
Maximum pressure 25.0 MPa
SB60RSH Extension cylinders (piston / rod - 63 / 40 - 1400 (Inner cylinder) , 63 / 40 - 1100 (out-
stroke) mm er cylinder)
SB93RSH Extension cylinders (piston / rod -
Both 63 / 40 - 1400
stroke) mm
Maximum pressure 7.5 MPa

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ITEM SPECIFICATION
OTHER SPECIFICATIONS
Boom weight (with screen handler) 1750 kg (SB60RSH) / 1800 kg (SB93RSH)
Rotary actuator weight 170 kg (screen handler) / 195 kg (roll mesh)
Screen handler gripper 25 kg
Roll mesh handler (optional) 235 kg
Hydraulic lifting force 310 kNm (at pedestal base)

Coverage

A B

A SB60RSH
B SB93RSH

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3.3.3 Model and serial number

The equipment model and serial numbers are stamped on the legend plate
which is located on the pedestal body. It is important to refer to the correct
serial number of the boom system when making repairs or ordering spare
parts. The identification of the serial number is the only proper means of
maintaining and identifying parts for a specific product.

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4 OPERATOR'S MAINTENANCE INSTRUCTIONS

4.1 Screen handler SB60RSH/SB93RSH
4.1.1 Checking the hoses, pipes and couplings

1. Check the condition and tightness of the hoses, pipes and couplings.

4.1.2 Checking the bolts

1. Check the tightness of the locking bolts of swivel pins (1). Tighten if
necessary.
2. Check the tightness of the mounting bolts of the boom (2). Tighten if
necessary.
1 1 1

1 1 1

4.1.3 Greasing the boom

1. Grease the boom according to the following instructions.

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Manual greasing

1. Press 4-5 strokes from a grease gun to all grease nipples presented in
the next picture.
If your boom is provided with a 360° slewing angle pedestal, do not
forget the grease nipples associated with it.

The nipples on the boom have also

been marked with the following
sticker.

Apply the grease at regular intervals. The greasing interval and the amount
of grease must be adapted to working conditions. Anyway, the intervals
may not under any circumstances be longer than eight hours.
After greasing all the boom movements must be driven to their extreme
positions to make sure the grease has properly spread to objects to be
lubricated.
It is of the primary essence that adequate purity is taken care of on every
step of the lubricating action.
Note! Insufficient greasing or use of improper grease may cause abnormal
wear of swivel pins and bushings.
Note! To avoid unintentional boom movements during lubrication, hydraulic
power from the carrier to the boom must be stopped while staying
inside the boom working area.

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Manual central greasing

To reduce the maintenance work, the boom may be equipped with a
manual central greasing system. In this case there is only one grease
nipple the user has to lubricate. The equipment automatically divides the
grease to all the grease nipples provided.
The system consists of central grease nipple, divider valves, piping and
connecting nipples. The lubricant is pumped manually to the central nipple
and forwarded to the main divider valve, which proportions the grease
further to the subdividers. The subdividers finally distribute the grease to
each lube point. They have been trimmed so, that each lube point gets just
the correct proportion of grease.
1. Press 20-25 strokes from a grease gun to the central nipple every four
hours.
Apply the grease at regular intervals. The greasing interval and the amount
of grease must be adapted to working conditions. Anyway, the intervals
may not under any circumstances be longer than four service hours.
After greasing all the boom movements must be driven to their extreme
positions to make sure the grease has properly spread to objects to be
lubricated.
It is of the primary essence that adequate purity is taken care of on every
step of the lubricating action.
Note! Insufficient greasing or use of improper grease may cause abnormal
wear of swivel pins and bushings.
Note! To avoid unintentional boom movements during lubrication, hydraulic
power from the carrier to the boom must be stopped while staying
inside the boom working area.

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Automatic central greasing

To reduce the maintenance work the boom may be equipped with an
automatic central greasing system. In this case there is only one grease
reservoir the user has to keep filled. The equipment automatically greases
all the grease nipples provided at preset intervals with the correct amount
of grease.
The system consists of central grease pump, divider valves, piping and
connecting nipples. The operation is controlled by a specific lubrication
timer, which switches the pump on at preprogrammed intervals. Electrically
driven central pump feeds the lubricant to the main divider valve, which
proportions the grease further to the subdividers. The subdividers finally
distribute the grease to each lube point. They have been trimmed so, that
each lube point gets just the correct amount of grease. The divider valves
keep on forwarding the grease as long the pump is running.
If desired, the operation of the system is monitored by a limit sensor
connected to one of the divider valves. Once the valve refuses to operate
correctly the central greasing alarm lamp lights up. In certain case the
operating must be stopped and the failure corrected immediately. The
causes of the failure:
• The reservoir runs out of lubricant.
• One of the lubricating points is clogged.
• Grease supplying pipe has broken.
• Lubricant is too stiff.
• There are disturbances in electric circuits.
The automatic control can be passed by applying the lubricant through the
grease nipple of the pressure relief valve with a manual grease gun. This is
valid also when the pump is in operation.
If one of the lubrication points is clogged (the lubricant does not get through
to the bearing), the grease will pass through the pressure relief valve
integrated to the pump when 250 bar pressure is exceeded.
Selecting the grease
Only a high quality lithium or lithium complex based grease suitable for
greasing heavily loaded sliding bearings may be used for boom joint
lubrication. The recommended temperature range for grease to be used
specified by the grease manufacturer must unconditionally cover the
temperature conditions in the actual state of use.

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4.1.4 Checking the roll mesh handler gripper jaws (optional)

There are number of components on the gripper jaw that needs to be
checked daily.

2 4

1. Check for excessive wear on wear plates (1).

2. Check grippers (2) for damage.
3. Check that all bolts are tight.
4. Check for hydraulic leaks on gripper cylinder (3).
5. Check for damaged or missing gripper inserts (4).
6. Check that the backing plate is straight (5).
7. Check all pins for excessive wear (6).
8. Ensure that retaining split pins (7) are in all pins.

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4.1.5 Checking the roll mesh handler wheel extension assembly (optional)
There are number of components on the wheel extension assembly that
needs to be checked daily.

1. Check wheels for wear and damage (1).

2. Check the hydraulic wheel motors (2) for leaks and damage.
3. Check that all nuts and bolts are tight.
4. Check hydraulic extension cylinder (3) for leaks.
5. Check extension housing (4) for excessive wear.

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4.1.6 Checking the roll mesh handler frame (optional)

It is important to check the roll mesh handler for cracks in the frame and
around the welds daily.
Any sign of cracks should be reported immediately to your supervisor.

1. Check wheel base (1) for cracks.

2. Check gripper mount welds (2) for cracks.
3. Check welds on both sides (3) for cracks.

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4.1.7 Greasing the roll mesh handler gripper jaws (optional)

1. Apply grease to all grease nipples in the gripper jaws daily.

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5 PERIODIC MAINTENANCE INSTRUCTIONS

5.1 General
This product is a precision made hydraulic machine. Therefore great care
and purity should be taken when handling any of the hydraulic components.
Dirt is the worst enemy in hydraulic systems.
Handle the parts carefully and remember to cover any cleaned and dried
parts with clean lint-free cloth. Do not use anything other than purpose
designed materials for cleaning hydraulic parts. Never use water, paint
thinners or carbon tetrachloride.
Components, gaskets and seals in the hydraulic system should be oiled
with clean hydraulic oil before assembly.
When not in use or when starting maintenance the boom has to be moved
to its parking position.
Note! Re-tighten all conical pin locking sleeves (1) a few times after the
boom start-up until they are firmly locked. See the figure below.

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5.2 Parking position

When starting maintenance or service, move the boom to the parking
position. Park also when the boom is not in use. If not parked properly,
detrimental extra stresses will be generated to the boom arms and swivels.
This may considerably reduce reliability and life time of the boom system.
Parking must be accomplished so that the boom rests on lift cylinder, and
the extension booms are retracted in. This way the base vibrations will be
forwarded to the boom arm slightly. The parking position is shown in next
picture.

5.3 Screen handler SB60RSH/SB93RSH

5.3.1 Tighten the bolts and hose couplings

1. Tighten the pin locking bolts (1), boom locking bolts (2), hose couplings
and control valve mounting bolts.
1 1 1

1 1 1

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Tightening torques
Size Torque [Nm] Torque [ft.lbs]
M8 25 18
M10 49 36
M12 85 63
M14 135 99
M16 210 155
M18 300 221
M20 425 313
M22 580 427
M24 730 538
M27 1100 811
M30 1450 1069
M36 2300 1695
Metric bolts (grade 8.8 - 12.9) tightening torques

5.3.2 Cleaning the boom

1. Clean the boom externally.

If necessary, the boom may be washed with steam or pressure washer.
When washing, pay special attention to not to harm the electrical
equipment or wiring.
All the hydraulic connectors have to be closed while washing to prevent
water and dirt from getting into the hydraulic system.
After washing all the grease nipples have to be carefully lubricated.
5.3.3 Checking the clearance of the swivel pin bushes

1. Check that swivel pins have no exessive play in their bushes. Replace
pins and bushes if necessary.

5.3.4 Checking the roll mesh handler (optional) sprocket wheels

1. Check for excessive wear in sprocket wheel tooth geometry.

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5.4 Central greasing system maintenance

If one of the divider valves malfunction, stop the greasing operation and
correct the failure. The causes of the malfunction:
• One of the lubricating points is clogged.
• Grease supplying pipe has broken.
• Lubricant is too stiff.
If one of the divider valves is not supplied with lubricant, it indicates
clogging in one of the lubricating points. Remove outputs of the deliver in
question one at a time and after each removal feed lubricant with a grease
gun into the grease nipple of the divider. When the divider starts operating
(i.e., the lubricant goes into divider) the clogging is in the output branch
which was removed last. It is also possible that the delivery pipe has got
such an impact that the lubricant can`t get through it. Repair the pipe or
remove clogging.
In case the hose or pipe must be replaced all the grease pipes must
thoroughly be filled with grease. This may happen either by filling each pipe
before installation or filling the whole system at a time through the central
nipple with a suitable grease gun. Adequate cleanliness has to be taken
care of during installation.

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6 SB60RSH / SB93RSH REPAIR INSTRUCTIONS

6.1 Tightening torques of the control valve block
Do not overtight the mounting bolts. The valves do not function
NOTICE correctly if bolts are overtighten.

End plate, a/f 13 torque 23Nm, a/f 10 torque 9,5Nm

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Socket head screws, 9,5Nm

Overcenter cartridges, 30Nm

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7 TROUBLESHOOTING
7.1 The proportional movements of the boom are inoperative
• Main power is not switched on.
- Switch the main power on.
• One of the emergency stop buttons is pushed in.
- Check all the emergency stop buttons and pull them out if necessary.
• Control voltage cable is not connected.
- Check the cable connections and see that the cable itself is not
damaged.
• The valve controlling voltage is incorrect.
- Check that the signal current is correct. Check the signal voltage in
the valves between connectors 2 and earth connection. When moving
the controller it should be 12 V and decrease to 6 V or increase to 18
V depending on the direction of the movement. Check the supply
voltage of the valves between connector 1 and earth connection.
When moving the controller it must be 24 V. When checking voltages,
the control voltage has to be on, but the main motor must not run.

7.2 Single functions can not be controlled

• Interruption in the control lead between controller and boom valve
- Check firm position of connection plug, check connection cable to
control valve and possibly check mechanical activation.

7.3 Pressure too low or nil

• Pressure relief valve does not close due to impurities, broken spring,
wear or other similar cause.
- Clean the valve and exchange faulty part.
• Faulty piston seal causing internal leak in cylinder.
- Leak can be verified by opening the connecting pipe at return side of
the cylinder. Replace seals.
• Worn-out pump which gives insufficient oil flow when ois is thin (e.g.,
warm oil).
- Contact your Sandvik dealer.

7.4 Varying pressure or oil flow

System pressure depends on load of all applications. If boom operates
without load or under light load, the pressure will naturally be low. This
should not be interpreted as an indication of a fault.

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• Impurities in control valves or restrictions or alternatively impurities in oil

- Impurities may cause uneven flow through restrictions. Clean valves
and other parts and change oil. Take care that all the impurities are
removed from the whole oil circulation.
• Air in cylinders or piping.
- Remove air.
• Large internal leak
- A large internal leak permits a large portion of the oil flow to escape
from pressure side to return side without performing useful work. In
such case a great amount of hydraulic power is dissipated. Locate
leak and repair fault.
• Heat removal from oil is reduced.
- Normal heat removal has impaired due to dirt on cooling surfaces,
poor air circulation or clogged cooler. Check and cooling equipment.

7.5 Hydraulic slewing is not working

• The boom slewing is stuck.
- Repair.
• Oil pressure low.
- Check pressure supply.
• Motor not receiving enough oil.
- Refill tank after determining. Check that the piping is alright.
• Slewing motor or gear damaged.
- Repair or replace faulty parts.

7.6 Slew motor rotational speed is insufficient

• Oil supply to motor is insufficient.
- Adjust oil flow restriction in the controlling valve.
• Internal leak in motor
- Check and repair motor.

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 Original instructions
GUID-9952D426-36EB-4E92-819F-066D4E958D62 en-US 1 2020-04-06

Hydraulic high pressure water pump

Hydraulic high pressure water pump

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. Keep this publication for future reference.

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Table of Contents
1 Introduction.......................................................................7
1.1 The purpose of these instructions............................................................ 7
1.1.1 Validity of the manuals...................................................................... 7

2 Safety and environmental instructions.......................... 9

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

3 Pump description........................................................... 11
3.1 System description................................................................................... 11

4 Pump operation.............................................................. 13
4.1 Operating HPW-PUMP.............................................................................. 13
4.2 Pump start-up............................................................................................13
4.3 Stopping HPW-pump................................................................................ 13

5 Pump maintenance.........................................................15
5.1 Maintenance.............................................................................................. 15

6 Pump troubleshooting................................................... 17
6.1 Troubleshooting........................................................................................ 17

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1 INTRODUCTION
1.1 The purpose of these instructions
This manual contains supplementary information for operation,
maintenance and repair of a component.
These instructions must be followed along with other manuals of the rig,
any instructions given in local laws and regulations, any orders given by
local authorities, and all protective measures specific for the site.
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 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.

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Hydraulic high pressure water pump

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Hydraulic high pressure water pump

2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS

2.1 Safety precautions
The pressure in both hydraulic and water circuits is considerably high.
Thereat the technical of your equipment should be under constant scrutiny.
Especially couplings, valves and hoses should be maintained tight and
clean as well as kept under constant observation. Hydraulic leakages must
be rectified immediately to avoid injuries caused by pressure and hot oil
blowouts. Follow all your local safety instructions related to the high
pressure hydraulics. Hydraulic system of a carriermachine should be
maintained according to the service program. In order to exclude possible
accidents, it is not allowed to clean or inspect HPW-pump and pressure
tools when hydraulic or/and water circuit is pressurised.
Prior to any cleaning, inspection and service hydraulic system of your
carrier machine must be stopped and both hydraulic and pumping fluid
circuits dissipated, for instance, by opening the spray gun. Always wear
appropriate clothing and safety equipment such as goggles, ear protection
and safety shoes at all times when operating the pump.When operating the
pump, beware of machinery parts warmed by hot hydraulic oil.
Never point the spray gun or end of the hose at bystanders or any
inappropriate object !

AN EXTREME CLEANLINESS MUST BE MAINTAINED WHEN

CARRYING OUT ANY SERVICE DISASSEMBLING OR REPAIR OF HPW-
PUMP AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE
SAFE, RELIABLE AND LONG-LIFE OPERATION OF YOUR EQUIPMENT.
Operators and maintenance personnel must always comply with local
safety regulations and precautions in order to close out the possibility of
damages and accidents. All installation and service of both hydraulic and
electric equipment must be performed by qualified and experienced
personnel only.

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3 PUMP DESCRIPTION
3.1 System description
HPW-pump is a converter, which transforms actuating fluid power, usually
hydraulic oil, into pumping fluid’s power, which is defined by flow rate and
pressure. Actuating power is supplied from hydraulic system of carrier
machine. Water or any other pumping fluid can be taken from natural
source, reservoir or pressurized supply network. Hydraulic flow moves the
piston assembly until the other water plunger reaches its extreme position,
when changes the incorporated reversal valve direction of hydraulic flow
and, by that, the piston assembly is being set to counter direction.
Vacuum is being developed into pumping fluid’s intake line and positive
pressure in delivery line accordingly. Within pumping cycle water is being
taken by water plungers through intake valves and pumped through
pressure valves into delivery line. Relation of water’s flow rate and pressure
to corresponding parameters of hydraulic fluid is linear, as shown on
diagrams below.
When hydraulic pressure and/or flow is under the value needed to achieve
the maximum output power of HPW-pump, the water pressure and flow are
decreased respectively without any harm to pump itself.
PUMPING FLUID TO HYDRAULIC FLUID RELATION IN REGARD TO
THEIR FLOW RATES AND PRESSURE.

1 3

2 4

1 Pumping fluid flow

2 Hydraulic fluid flow
3 Pumping fluid pressure
4 Hydraulic pressure

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Hydraulic high pressure water pump

4 PUMP OPERATION
4.1 Operating HPW-PUMP
Prior to starting-up the HPW-pump it is checked whether all couplings in
hydraulic and pumping fluid circuits are properly connected and there are
no leakages over the equipment. Ensure that the water tank is refilled.

4.2 Pump start-up

HPW-pump starts immediately after the hydraulic flow has been put on
either with control valve and/or by pulling the trigger of spray gun.
Immediately after opening the water pressure line, air is being vented out
from the pumping fluid circuit and high pressure washing is about to begin.
Do not try with hand the water or air coming out from high pressure
nozzle !

The nozzle, attached to a pressure tool, determines the flow rate and
pressure of water when operating parameters of hydraulic circuit meet
HPW-pump’s requirements.

4.3 Stopping HPW-pump

HPW-pump is halted by shutting off the hydraulic flow. High pressure
remains in closed water delivery line,which should be depressurized to
avoid unexpected water discharges. If spray gun or similar tool has been
used, pull the trigger for some time after the pump has halted.
In cold season HPW-pump and pumping fluid pressure line should be
dewatered after a working shift. Detach the intake hose from HPW-pump
and run it for a while until all water is moved from water circuit.
ATTENTION ! In cold season HPW-pump can be used for circulating the
water through water circuit to keep it unfrozen in transit.
Different water based solutions and special liquids can be used as pumping
fluid with HPW-pumps. The only requirement is that the pump MUST be
thoroughly cleaned and flushed with sweet water after the job to prevent
pump and its sealing from oxidation and water valves from seizing. The
procedure should be made even if such a harmless liquid as sea water has
been used.
ATTENTION! HPW-pump can be run dry unlimited time without any harm,
because self-lubricating sealings and circulating hydraulic oil prevent the
pump from overheating.

Copyright © Sandvik 13 (20)

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Hydraulic high pressure water pump

5 PUMP MAINTENANCE
5.1 Maintenance
Due to small number of moving parts, in normal operating conditions HPW-
pump does not require any other service, except replacement of sealings or
occasionally of water valves, which depends on content of abrasives in
pumping fluid, as well as on cleanliness of hydraulic oil.
Check constantly whether the fluid dropping from pump’s leakage detectors
is growing and replace sealing in proper time to exclude intermixing of
hydraulic oil and pumping fluid. If the draining from leakage detectors
exceeds rate of 10 drops per minute, pump’s sealings should be replaced.
Drain fluid can be water, hydraulic oil or their solution.

1 2

1 Leakage detectors on bottom surface

2 Leakage detectors on side faces

To enable the easy surveillance, pump should be kept clean.

WHEN CARRYING OUT ANY SERVICE DISASSEMBLING OR REPAIR
OF HPW-PUMP, ABSOLUTE CLEANLINESS MUST BE MAINTAINED TO
ENSURE RELIABLE AND TROUBLE-FREE OPERATION OF YOUR
EQUIPMENT.

Copyright © Sandvik 15 (20)

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Hydraulic high pressure water pump

6 PUMP TROUBLESHOOTING
6.1 Troubleshooting
FAULT POSSIBLE REASON / CHECK
1.1.1 1.1.1
Too small hydraulic flow or Enable or adjust the hydraulic flow.
no hydraulic flow at all. 1.1.2
1.1.2 Adjust the hydraulic pressure.
1.1
Hydraulic pressure too low. 1.1.3
HPW-PUMP DOES
1.1.3 Check and reconnect hydraulic hoses. Pres-
NOT WORK.
Hydraulic flow reversed. sure hose should be connected to P-port
1.1.4 and return hose to T-port.
Hydraulic piston damaged 1.1.4
mechanically. Replace damaged part.
1.2
1.2.1
HPW-PUMP 1.2.1
Water intake and pressure
WORKS, BUT Check water valves and clean them thor-
valves are open (jammed
DOES NOT DELIV- oughly or replace when damaged.
with debris) or damaged.
ER WATER FLOW.
1.3
1.3.1
HPW-PUMP DOES 1.3.1
Intake hose detached or
NOT RECEIVE Check and fix the hose and connectors.
hose breathes.
PUMPING FLUID.
1.4
WATER PRES- 1.4.1 1.4.1
SURE LINE Nozzle clogged. Check the nozzle and clean thoroughly.
BLOCKED.
2.1 2.1
Insufficient hydraulic flow or Adjust the hydraulic flow to the demanded
2.
pressure. level at required pressure.
WATER FLOW
2.2 2.2
RATE TOO SMALL.
Nozzle of your pressure tool Verify the nozzle sizing and replace with
undersized. proper one.
3.1
Some of water intake and 3.1
3.
pressure valves are open or Check water valves, clean thoroughly or re-
INTENSE PULSAT- damaged. pair.
ING OF WATER
3.2 3.2
PRESSURE.
Water intake line breathes Check water intake line and fix the problem.
causing pump cavitation.

Copyright © Sandvik 17 (20)

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Hydraulic high pressure water pump

FAULT POSSIBLE REASON / CHECK

4.1 4.1
Insufficient hydraulic pres- Adjust the hydraulic pressure to the demand-
sure or flow. ed level at required hydraulic oil flow.
4.2 4.2
4.
Nozzle of pressure too over- Verify the nozzle sizing and replace with
WATER PRES- sized. proper one.
SURE TOO LOW.
4.3 4.3
Wear-out nozzle. Replace the nozzle.
4.4 4.4
Insufficient water supply. Check and fix the problem.
5.
CLOSING THE WA- 5.1
TER PRESSURE Adjust the hydraulic pressure up as much as
LINE DOES NOT 5.1
necessary to enable proper operation of wa-
DROP PRESSURE Insufficient hydraulic pres- ter pressure unloader valve.
TO FREE CIRCU- sure in relation to pumping
LATION MODE. Note that the maximum hydraulic pressure
fluid pressure, adjusted with
should not be overrun !
Hydraulic system water pressure unloader
starts to run through valve. If boosting the hydraulic pressure is not pos-
the pressure relief sible, the water unloader pressure setting
valve, emitting ex- should be dropped.
cessive heat.
6.1
Check the tightness of component mating,
tighten screws.
Replace when necessary sealings of pump’s
mated surface.
6.1
Check and tighten/replace couplings.
Hydraulic oil leakages.
6.2
6.2
6. Check the tightness of component mating,
Pumping fluid leakages.
tighten screws. Replace when necessary
LEAKAGES. 6.3 sealings of pump’s mated surface.
Hydraulic-pumping fluid Check and tighten/replace couplings.
commixture dropping from
6.3
leakage detecting bores.
If the draining from leakage detectors ex-
ceeds rate of 10 drops per minute, pump’s
sealings should be replaced.
The rule applies to dropping of hydraulic flu-
id, pumping fluid and their commixture.

18 (20) Copyright © Sandvik

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www.sandvik.com
 6  EN
Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

QUICKLUB
MOBILE CHASSIS LUBRICATION SYSTEM
Timer with adjustable pause time and flow monitoring

Sandvik ref. 88627899

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

SAFETY INSTRUCTIONS

Appropriate Use
x Use of the 203 pump and progressive divider valves only for dispensing lubricants in
centralized lubrication systems. The system is designed for intermittent operation.

General Safety Instructions

x The progressive centralized lubrication system connected to the QUICKLUB pump
Model 203 must always be secured with a safety valve.
x Incorrect use may result in bearing damage caused by poor or over-lubrication.
x Unauthorized modifications or changes to an installed system are not admissible. Any
modification must be subject to prior consultation with the manufacturer of the
lubrication system.
x Use only original LINCOLN spare parts (Parts Catalog) approved by LINCOLN

Regulations for Prevention of Accidents

x Adhere to the regulations for prevention of accidents, which are effective in the country
where the system is to be used.

Operation, Repair and Maintenance

x Repair should only be performed by:
- Authorized and
- Instructed personnel who are familiar with the centralized lubrication systems.

This is a brief Owner Manual only. More detailed safety and operation instructions
are described in the following Owner Manuals that are available:

Manual Name Manual number

Quicklub Pump model 203 2.1A-30001-H07
Quicklub, Progressive Metering Devices for Oil and Grease 2.2L-20001-F06
Printed Circuit Board for Pump 203 with adjustable pausetime 2.6L-28003-B06
and flow monitoring
Quicklub Parts Catalogue 2.0A-20001-H06

For technical service contact Lincoln customer service or Lincoln web site at:

LINCOLN GmbH
Heinrich-Hertz-Str 2-8
D-69190 Walldorf-Germany
Phone +49 6227 33-0
Fax +49 6227 33-259
www.lincolnindustrial.de

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

Key components and tubing

Main (master) Divider Valve

Main Supply
Line Ø8.6x2.3

Secondary
Divider Valve
P203
Pump

Feed line to Lubrication Point

(Ø8.6x2.3 or Ø6x2)

Inductive proximity switch

x Inductive proximity switch is installed on a

SSV-divider valve. It monitors the system
operation and stops the pump when signal is
received.
x The circuit board must receive a signal from
the inductive proximity sensor within the
monitoring time (30 mins) otherwise the
system will alarm.

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

Printed circuit board 236-13870-2 for monitoring of metering device

(microprocessor control) with flashing fault indicator

x The printed circuit board is integrated in the

pump housing.

x Remove the controller cover plug to review

settings , indicator lights and to activate extra
lubrication test cycle.

x For jumper settings remove the circuit board

by opening the housing cover in the bottom.

Indicator lights and pushbuttons

1. LED is illuminated when power is switched on.

2. Rotary switch “Pause time setting”
3. LED is lit when pump operates
4. Pushbutton for additional lubrication cycle
pushing > 2 sec.

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

Pause time setting

(Pause time is pre-set by Sandvik (4 hour))

Rotary switch with 15 positions for pause time

settings

Switch
1 2 3 4 5 6 7 8 9 A B C D E F
position
Minutes 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60

Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Faults and their causes

Right hand LED on the printed circuit board and

push button light in the cabin

x Indicator light flashes in different frequencies

based on the alarmcause – See “fault
indication”.
(LED is also lit when pump operates).

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

Fault indication

A. Power failure

B. No signal from inductive sensor

C. (No signal from sensor 2)

D. (No signal from sensor 1 nor sensor 2)

E. Low level alarm

F. Fault acknowledged

Reservoir filling

x Always fill through the filling nipple. The best practice is to use standard refinery drums
or pails. Impurities in grease can create operational problem.
x NLGI 2 greases are applicable up to –20 ºC (-4 ºF)
x Do not mix two greases - Consult your grease supplier first

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

Emergency lubrication

The pump can be by-passed by feeding grease manually through the manual grease fitting
attached on the pressure relive valve. In case of system failure this fitting can be used for
trouble shooting and manual greasing (all points are lubricated from this one fitting).

Pressure relief valve with a by-pass fitting

Filling nipple

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

PRACTICAL SYSTEM INFORMATION AND TROUBLESHOOTING TIPS

System check

x Initiate an extra lubrication cycle pressing pushbutton > 2 sec.

x The stirring paddle will start to rotate and pump will start to operate
x If necessary open one feed line and verify grease flow. NOTE! Depending on the
operation sequence it may take a few minutes until the dividers will feed.

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

PUMP ELEMENT AND PRESSURE RELIEF VALVE OPERATION

Pump element operation

Suction phase Pumping phase

Pump does not feed

The main reason is impurities in the pump element check valve seat. Remove the pump
element and clean it. In case the element is damaged replace it.

System blockage
In case the system is blocked the pressure relief valve will start to bleed at 5000 psi (350
bar). Since the system piping will hold the pressure after the pump has stopped the
blockage can be detected by carefully loosing the supply line fittings between the main
SSV-valve and secondary SSV-valves (A, B, C). If necessary use manual grease gun to
apply more pressure through the by-pass fitting on over pressure valve.

x Feed line fitting on secondary SSV-valve that bleed grease is blocked.

x It is fastest to detect the blockage in a secondary valve loop by attaching a manual
grease fitting in the SSV-valve inlet. The blockage can be found with grease gun by
opening lubrication feed lines.
A

B
C

Feed lines

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

SSV divider valves and piping

The output of one SSV outlet is on 0.2 cm³. The valve pistons operate in series and the
valve simple keeps on diving the grease as long as the pumping continues. Once the
pumping stops the cycling of the SSV valve stops. Once pumping resumes the valve
starts where it last time stopped. By plugging an outlet with a short plug the grease is
directed to the next outlet. This way multiple shots of grease are obtained (2x, 3x... 0.2
cm³)

inlet

Example: SSV10, 6 outlets in service:

Plugged outlets: 3,4,5,10

Outlet 1: 0.6 cm³ per valve cycle (3x0.2)

Outlets 2,8: 0.4 cm³ per valve cycle (2x0.2)

Outlets 6,7,9: 0.2 cm³ per valve cycle

This SSV10 divider completes a full cycle when 2.0-cm³ (10x0.2) lubricant is fed through
the inlet. This corresponds approx. 30 second pumping time with a K7 pump element.

Note:
‰ Use only original, short SSV-plugs.
‰ Use only original SSV outlet fitting (with sleeves A)
‰ Never plug outlets 1 & 2 (valve stops cycling)
‰ Deleted lubrication point must always plug on SSV outlet using Lincoln original short
SSV-plugs. Don`t plug the tubing.

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Operating Instructions
Quicklub Grease Lubrication System for Sandvik Mining and
Construction.

WEEKLY WALK-AROUND INSPECTION

The Lincoln Industrial Quicklub automated lube system components are designed,
engineered, manufactured, and assembled to the highest of quality standards. This lube
system requires little or no maintenance, however, to ensure maximum reliability and to
realize maximum service life of all components, it’s highly recommended that a weekly
walk-around inspection be performed.

The weekly walk-around inspection should include the following:

x Observe lubricant level in reservoir. Fill reservoir if it is low

x Inspect high pressure relief at pump element, noting any lubricant build-up. If build-
up is observed, correct this problem by determining cause of blockage

x Inspect all valve and lube point connections to verify that no leaks are occurring
Inspect supply/feedlines to insure that no punctures or breaks have occurred since
last inspection.

x Inspect lube points to insure that all lube points have a "fresh grease appearance".
x Check pump operation by depressing push-button located in base of pump for 2
seconds to initiate a manual lube event. This will verify that pump is working (Ignition
switch must be on).

x Report or repair any problems found in this walk-around inspection immediately

NOTE: Operator to confirm operation of electric pump while machine is in service

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