BOOM DB 800

BOOM DB 800
DX/DX_R

C 45660--9 en 0507/LH 1 (16)

BOOM DB 800

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. BOOM HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1. Hydraulic components DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2. Hydraulic circuit diagram DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3. Operation DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4. Hydraulic components DX_R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5. Hydraulic circuit diagram DX_R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6. Operation DX_R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. REPLACING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. CYLINDER MOUNTING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1. Removing the pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7. TURNING FEED TO HORIZONTAL DRILLING POSITION . . . . . . . . . . . . . . . . 13
8. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 (16) C 45660--9 en 0507/LH

 BOOM DB 800

1. GENERAL
These instructions describe the structure, operating principle, and the adjustments of the
DB 800 boom.
There are three alternative mounting places for feed swing cylinder in the boom cross
piece. The mounting place in the middle is meant for normal vertical drilling, the ones on
both sides for horizontal drilling to the right or to the left.
By following these maintenance instructions, it is possible to increase the life, operational
reliability, and safety considerably.
Sandvik Service is always ready to offer advice and help in all service problems.
2. SAFETY

CAUTION
Never repair a boom or boom components or cylinders by welding
(Special materials are used in booms that cannot be welded using
normal methods). A repair-- welded boom will break, and when it falls
or tips over, it can cause personal damage.

WARNING

Maintenance, adjustments or repairs are only allowed to persons with

specific training to service the rig. Read the instructions before
servicing, adjusting or repairing the rig.
CAUTION

Pressurized hydraulic hoses must not be touched by hand. The hoses

may have unnoticeable needle holes that let out high-- pressure oil
sprays that may penetrate the skin.
WARNING

Beware of moving machine parts. Do the service and repair work only
with the rig stopped. Make also sure that the rig cannot be accidentally
started during maintenance or repair work.
WARNING

Do not go under an unsupported rig. Do not disconnect hydraulic hoses

or valves unless you are certain that the system has no static load.
Remove all static load always before starting repair work by a
WARNING mechanical support or by driving a cylinder to its extreme position.

OBSERVE ABSOLUTE CLEANNESS WHEN DISMANTLING AND

REASSEMBLING HYDRAULIC EQUIPMENT. Whenever a cylinder has
been removed, the hydraulic circuit must be vented and flushed. This is
CAUTION
to prevent dirt and air in the cylinder from causing functional
disturbances.

C 45660--9 en 0507/LH 3 (16)

BOOM DB 800

3. MAIN COMPONENTS

5 2
1

8
9
7
4
3

1. Cradle
2. Boom arm
3. Rear boom
4. Cross piece
5. Feed swing cylinder
6. Feed transfer cylinder
7. Feed tilt cylinder
8. Boom knee cylinder
9. Boom lift cylinder

4 (16) C 45660--9 en 0507/LH

 BOOM DB 800

4. BOOM HYDRAULICS
4.1. Hydraulic components DX

50. Variable displacement pump

170. Overcenter valves of cylinders (5 pcs)
171. Boom control valve; the valve is used for controlling the movements of the boom,
feed and upper structure swing.
172. Control valves for boom movement speed (6 pcs); the valves are used for
restricting the maximum speed of the boom, feed and upper structure swing
movements.
175. Feed transfer cylinder lock valve with a pressure--relief cartridge at the rod side
176. Feed transfer control valve, 30 l/min
177. Boom lift control valve, 35 l/min
178. Boom arm control valve, 35 l/min
179. Feed swing control valve, 15 l/min
180. Feed tilt control valve, 25 l/min
181. Control valve for upper structure swing, 40 l/min
182. Upper structure swing cylinder
183. Feed tilt cylinder
184. Feed swing cylinder
185. Boom knee cylinder
186. Boom lift cylinder
188. Feed transfer cylinder
193. One--way restrictor; regulates the speed of upper carriage swing
194. Double pressure--relief valve of upper carriage swing cylinder
300. Feed swing double pressure--relief valve

C 45660--9 en 0507/LH 5 (16)

BOOM DB 800

4.2. Hydraulic circuit diagram DX

188 186 185 184 183 182

170

A1 B1
B2 A2 193
300
194
B1 A1 B2 A2
175

B1 A1

176 181 177 178 179 180

171

172

80 50 1 90

6 (16) C 45660--9 en 0507/LH

 BOOM DB 800

4.3. Operation DX

The boom movement speed depends on the positions of the control levers. The
movement speed remains constant because of the boom valve’s load--sensing feature.
Each control valve spool of the valve block has its own flow restrictor (172). They are used
for setting the maximum movement speeds for the boom.
The boom valve is located in the cabin. The valve block comprises six control valves
(176--181). The control valve levers are of cross--lever type which means that each lever
controls two cylinders.
The pressure--relief cartridge of the lock valve (175) restricts the pressure at the rod side
of the feed transfer cylinder.
The double pressure--relief valve (300) restricts the feed swing cylinder pressure.
Boom circuit maximum pressure is restricted by the pressure controller of the pump (50).

NOTE! The pressure of the whole system is restricted by the pressure relief valve
(55) at the rotation valve.

C 45660--9 en 0507/LH 7 (16)

BOOM DB 800

4.4. Hydraulic components DX_R

50. Variable displacement pump

64. Pressure regulator; reduces pilot control pressure to Danfoss PVG directional
valve
65. Pressure relief valve; restricts pilot control pressure (safety valve) to Danfoss PVG
directional valve
175. Feed transfer cylinder lock valve with a pressure--relief cartridge at the rod side
176. Feed transfer control valve
177. Boom lift control valve
178. Boom arm control valve
179. Feed swing control valve
180. Feed tilt control valve
181. Control valve for upper structure swing
182. Upper structure swing cylinder
183. Feed tilt cylinder
184. Feed swing cylinder
185. Boom knee cylinder
186. Boom lift cylinder
188. Feed transfer cylinder
190. Pressure compensator; maintains constant oil flow irrespective of load pressure
or pump inlet pressure
191. Shuttle valve; controls LS signal of pump
194. Double pressure--relief valve of upper carriage swing cylinder
300. Feed swing double pressure--relief valve

8 (16) C 45660--9 en 0507/LH

 BOOM DB 800

4.5. Hydraulic circuit diagram DX_R

A1 B1

300 194
B2 A2 B2 A2

B1 A1 B1 A1

C 45660--9 en 0507/LH 9 (16)

BOOM DB 800

4.6. Operation DX_R

The speed of boom actuator movement depends on the position of the electric control
levers of the boom (2 levers). The levers are located on the control panel. Deviating a
control lever from the middle position affects the control voltage of the electric controller
of the actuator block in question. A change in the control voltage proportionally moves the
spool the desired amount in the desired direction, and this determines the speed and
direction of the actuator movement. The speed of movement remains constant due to the
load--sensing properties of the valve. Each actuator block of the boom valve assembly has
two screws restricting the maximum position of the spool, and they are used for limiting
the maximum speed of the actuator movements.
The boom valve assembly is located on the upper carriage. The valve assembly consists
of seven actuator blocks (spools 53, 176--181). In addition to the boom and upper carriage
swing actuator blocks the valve assembly includes the rock drill rotation actuator block.
When one boom movement is run, the variable displacement pump (50) receives
information of the load pressure level through the set of shuttle valves (63 and 191),
whereby the variable displacement pump (50) adjusts itself to the required pressure level
and the position of the spool in the actuator block adjust the required volume of oil flow.
The actuator’s speed remains constant irrespective of load variations.
If two or more boom movements are run at the same time, the pressure level of the
variable displacement pump (50) adjusts according to the highest load level. The pressure
compensator (190) in each actuator block caters for the adjustment of oil flow for the lower
level actuators, which keeps the speeds of the actuators operating at lower pressure
levels constant as long as the maximum output of the variable displacement pump (50)
is not exceeded.
Overcenter valves located at the cylinders ensure the positional stability of actuators. The
feed transfer cylinder (188) is locked in position by the lock valve valve (175).
The pressure--relief cartridge of the lock valve (175) restricts the pressure at the rod side
of the feed transfer cylinder.
The double pressure--relief valve (300) restricts the feed swing cylinder pressure.
The maximum pressure of the boom circuit is adjusted by the pressure controller of the
variable displacement pump (50).

10 (16) C 45660--9 en 0507/LH

 BOOM DB 800

5. REPLACING CYLINDERS

1. Before starting to remove a cylinder, always securely support the component

moved by the cylinder.
2. Inch the cylinder with the hydraulics in order to find the position where the cylinder
pins are not under load.
3. Open the overcenter valves enough to remove any cylinder load.
4. Disconnect the hydraulic hoses, plug them, and mark the connections.
5. Support the cylinder and remove the pins.

When a cylinder is removed, make sure that no part of the boom is left
unsupported.

WARNING

4
3
5

1. Feed swing cylinder

2. Feed transfer cylinder
3. Feed tilt cylinder
4. Boom knee cylinder
5. Boom lift cylinder

C 45660--9 en 0507/LH 11 (16)

BOOM DB 800

6. CYLINDER MOUNTING PINS

The cylinder pins are expandable pins that are tightened clearance--free to the cylinder
ears.

4
5 5
6 6

7 7

-- Check the tightening torque. The correct value is 290 Nm.

-- Check the position of the expanding slot in the pins. The slot must be at right angle
(90_ degrees) to the cylinder’s direction of movement, and in transport position
downwards, if possible.

Expanding slot

6.1. Removing the pins

Remove the screws (7) and the washers (6). Remove the sleeves (5) using an M24 screw
as an extractor. Pull the pin (4) out.

12 (16) C 45660--9 en 0507/LH

 BOOM DB 800

7. TURNING FEED TO HORIZONTAL DRILLING POSITION

1. Turn the upper carriage in line with the tracks.

2. Run the rock drill and the feed to the extreme forward position.
3. Move the boom forwards to the position shown below.

Make sure that the centre of gravity is forward of the point x.

WARNING

Keep the feed stinger against the ground to make sure that the feed
cannot move.

WARNING

4
3
2
1

C 45660--9 en 0507/LH 13 (16)

BOOM DB 800

4. Move the feed swing cylinder so that there is no load on the pin.
5. Remove the screw (1) and the washer (2) from the upper end of the pin at the piston
rod end of the swing cylinder.
6. Remove the sleeve (3) using an M24 screw as a puller. Pull the pin (4) out from
below and drive the sleeve (5) off upwards from below.

3 4 5
2

5
a

2
1

7. Drive the piston rod forwards up to the ear (a) for horizontal drilling, and insert the
pin. Tighten to the specified torque of 290 Nm.
8. Lift the stinger up from the ground.
9. Turn the feed to the horizontal drilling position by driving the swing cylinder
inwards.

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 BOOM DB 800

8. MAINTENANCE

Each shift:
D Lubricate the 17 boom greasing nipples:
-- cylinders
-- joints
D Visually check the condition of the boom.

Each week:
D Wash the boom.
D Tighten all bolts and nuts.
D Check all adjustable cylinder pins and their correct tightness (290 Nm).
Every 600 hours:
D Check the weldings of the boom.

2X

2X

2X

C 45660--9 en 0507/LH 15 (16)

BOOM DB 800

Notes:

16 (16) C 45660--9 en 0507/LH

 HYDRAULIC CYLINDERS

REPAIR AND ADJUSTMENT

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. OVERCENTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2. Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.4. Replacing of bearings bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6. ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1. Assembling of cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7. TESTING OF CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.1. Line A, inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.2. Line B, inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

C 47150--5 en 1207 / AR 1 (8)

HYDRAULIC CYLINDERS

1. GENERAL
1.1. Structure
The main structural differences between hydraulic cylinders are:
D single and double acting
D cylinder bore
D stroke
D overcenter valve equipment
Stroke can be limited with a spacer mounted either to the piston side or the piston rod side.
Correct type of spacer is given in the spare parts list.

2. SAFETY
Acquaint yourself with the service and user instructions before starting
to work on a cylinder. Learn to know all the components that you will be
working on.
CAUTION

Follow the installation instructions issued by Sandvik

CAUTION

Installation, adjustment and repair work can only be carried out by a

person who has the necessary qualifications and knows the equipment.

CAUTION

Proper use and service guarantee longer life of the hydraulic cylinder.

CAUTION

Use all necessary safety devices and check their condition.

CAUTION

Before starting the rig, make sure that nobody is working close to, or
under the rig

WARNING

Never disconnect any hydraulic hoses or valves before making sure that
there is no static load in the system.

WARNING

2 (8) C 47150--5 en 1207 / AR

 HYDRAULIC CYLINDERS

3. OVERCENTER VALVE
3.1. Operation
Most hydraulic cylinders are equipped with an overcenter valve. They are either built--in
or connected to the hydraulic circuit via hydraulic hoses.

Overcenter valves are one--piece components and they cannot be readjusted. Sets of
seal rings (1) are provided. The four tasks of an overcenter valve are:
-- If a hose connected to the hydraulic cylinder breaks, the overcenter valve acts as
a safety valve.
-- During drilling, the overcenter valve prevents oil flow from the cylinder to the oil
tank. The boom maintains accurately the position to which it was moved to by using
the boom control valves.
-- When the boom is moved, the overcenter valve does not allow oil to flow from the
return side until the pressure on the pressured side rises high enough. Boom
movements are smoother and more accurate, and the boom’s own weight cannot
accelerate the speed movement.
-- If an external force raises the pressure in the cylinder higher than the set value of
the overcenter valve, the valve opens and lets oil out of the cylinder. This enables
the boom to yield under external force, and mechanical damage to the boom can
be avoided.
The set value of the overcenter valves for different purposes are
different. Therefore, you must not replace an overcenter valve with one
from a other cylinder. The set value of the valve is punched on the top of
CAUTION the valve.

C 47150--5 en 1207 / AR 3 (8)

HYDRAULIC CYLINDERS

4. COMPONENTS
10
1
2
9
8
5
3
6
7
4

10

Components of a typical cylinder

1. Socket screw 6. Locking plate

2. Cylinder cover 7. Rod nut
3. Piston 8. Piston rod
4. Overcenter valves 9. Spacer
5. Cylinder tubes 10. Bearing bushing

10
2
9
8
5
3
6
7
4

10

Components of a typical cylinder (threaded cylinder cover)

4 (8) C 47150--5 en 1207 / AR

 HYDRAULIC CYLINDERS

5. DISMANTLING
Before starting to remove the cylinder, make sure that the boom is properly supported, and
all static loads of the cylinder are removed. Disconnect the hydraulic hoses to the cylinder
and plug the open hose ends and cylinder adapters.
Remove the locking rings of the cylinder pins, support and secure the cylinder so that it
cannot fall down. Tap the pins out.
Wash the cylinder externally and mount securely before starting to dismantle it.

5.1. Cylinder
If you can use hydraulic pressure, connect the hoses to the cylinder and run the piston
rod (8) out, remove the overcenter valves (4). Unscrew the socket screws off of the cover
(2) or, if the cover is thread mounted, open the cover with a suitable tool. Screw the
overcenter valves (4) back, and run the piston rod (8) and the cylinder cover (2) out. When
pressing out, support the piston rod (8) properly to get it out smoothly.
Be aware of oil spilling

WARNING

5.2. Piston
Mount the piston rod firmly from the eye end, and tap out the locking washer lug from the
groove of the nut, and remove the nut (7). Remove the piston (3) together with the seals.
Pull the cylinder cover (2) off the piston rod and remove the cylinder cover seals and the
wiper and replace them. Unscrew the overcenter valves (4) from the cylinder tube and
visually check their condition. Wash all components.

5.3. Inspection
Replace all seals and wipers. Check all sliding surfaces. If scratches, big enough to feel
with a fingernail are found, the components should be replaced because the sealing ability
of the surfaces is no longer good. Also check the piston rod for straightness. If the rod is
distorted, check that it is not caused by a incorrect spacer. Check the condition of the
bearing bushings (10), and replace them if there are any marks of wear.

5.4. Replacing of bearings bushing

If the cylinder already has been removed from the rig, support the cylinder well and tap
the old bearing bushings out using a suitable drift and a copper hammer.
The new bearing bushings are easier to install if they are cooled in a freezer, and the
cylinder eye is warmed up with a torch.

C 47150--5 en 1207 / AR 5 (8)

HYDRAULIC CYLINDERS

6. ASSEMBLING
If the stroke of the cylinder is limited with a spacer and it is left out, the
cylinder can be damaged in use. Check that you install the correct type
spacer.
CAUTION

6.1. Assembling of cylinder

2
Grease the seal grooves and install the
9 O--rings, the lip seal and the guide rings on
the cylinder cover (2). Install the cover of
the piston rod (8). If a spacer (9) is used to
limit the maximum stroke of the cylinder,
install the bushing on the piston rod before
8 installing the piston.

Grease the seal grooves and install the

11 piston seal (10). When installing the
6
piston’s O--ring (11), be careful not to
7 damage it in the piston rod thread. Install
the locking plate (6) and the locking nut (7).
Tighten the nut and lock it in a place by
turning a tang of the locking plate into its
10 groove.

The piston rod and the cover assembly

6 (8) C 47150--5 en 1207 / AR

 HYDRAULIC CYLINDERS

Check if the minimum stroke of the cylinder is limited. If it is, the spacer must be inserted
into the cylinder first. Push the piston assembly into the cylinder. Remember to lubricate
the seals before assembling!

Push the cylinder cover (2) in and insert the socket screws (1) through the cover and
tighten them. If the cylinder cover is thread--mounted, use a special tool for tightening.
Install the overcenter valves (4) and the adapters, and test the cylinder.

2 1

Assembled cylinder

C 47150--5 en 1207 / AR 7 (8)

HYDRAULIC CYLINDERS

7. TESTING OF CYLINDER

11
12
10

13
14

Testing of cylinder

7.1. Line A, inspection

Run the piston rod completely out. Disconnect line A, and pressurize line B. Check line
A for leaking oil. If oil leaks out, one of the seals (10, 11 or 12) or overcenter valve is faulty.

7.2. Line B, inspection

Run the piston rod completely in. Disconnect line B, and pressurize line A. Check line B
for leaking. If oil leaks out, one of the seals (10, 11 or 12) or the overcenter valve is faulty.
If oil comes out from between the cylinder cover and the cylinder tube, the cylinder cover
O--ring (13) is faulty. If oil comes out from between the cylinder cover and the piston rod,
the cylinder cover O--ring (14) is faulty.

8 (8) C 47150--5 en 1207 / AR