370 0 en 2009-02-16

Dust collector DC 800 H

Table of Contents

1. TECHNICAL DATA ................................................................................................................ 3

2. COMPONENTS ...................................................................................................................... 4

3. USE AND OPERATING PRINCIPLE ..................................................................................... 5

4. OPERATION OF THE DUST COLLECTOR .......................................................................... 6

4.1. Dust collection .......................................................................................................................................... 6
4.2. Blow-out ...................................................................................................................................................... 7

5. HYDRAULICS ........................................................................................................................ 8
5.1. Hydraulic components ............................................................................................................................ 8

6. MAINTENANCE ..................................................................................................................... 9
6.1. Filter elements ........................................................................................................................................... 9
6.2. Blowing sound damper ........................................................................................................................... 9
6.3. Blow-out valve ........................................................................................................................................... 9
6.4. Timer unit DUCO TIMER ......................................................................................................................... 10
6.5. Repair and maintenance of the dust collector hydraulic motor .................................................. 11
6.5.1. Construction and operation ........................................................................................................... 11
6.5.2. Checking the operation .................................................................................................................. 12
6.5.3. Replacing the seal ring ................................................................................................................... 12
6.5.4. Disassembly ..................................................................................................................................... 13
6.5.5. Checking and replacing components ........................................................................................... 15
6.5.6. Assembly .......................................................................................................................................... 16

7. MOVABLE SUCTION HEAD ................................................................................................. 19

7.1. Dust collector flap closing valve (suction cut-off, optional) ........................................................ 19

8. TROUBLESHOOTING ........................................................................................................... 20

Copyright © Sandvik Mining and Construction 1 (22)

ID: 370 0 en 2009-02-16
2 (22) Copyright © Sandvik Mining and Construction
ID: 370 0 en 2009-02-16
 Dust collector DC 800 H

1. TECHNICAL DATA ID: 17374

Dust collector DC 800 H

Main components Fine separator, DC 800 H
Movable suction head, PE 100 S
Hydraulic motor, F11-05
Suction hose, 125 mm
Separation capacity 99.9 %
Fine separator Cross section, 600 x 670 mm
Height, 1550 mm
Weight, 200 kg
Hydraulic motor Power, 12 kW
Displacement, 4.88 cm³/rev
Filter Filtrating area, 10.4 m²
Filter elements, 13 pcs

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Dust collector DC 800 H

2. COMPONENTS ID: 17375

DX_R DX
S24 S46

3
3

7 5 6 2

10

4 9

ID: 17595

1 Dust collector 2 Dust collector hydraulic motor

3 Dust collector selection switch 4 Flushing valve
5 Blow-out valve 6 Dust collector timer unit
7 Cut-off cylinder and flap 8 Blowing sound damper
9 Suction head 10 Primary cyclone

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 Dust collector DC 800 H

3. USE AND OPERATING PRINCIPLE ID: 17376

Before starting to drill, start the suction fan motor with the selection switch.
During drilling when the flushing is on, the dust collector sucks the dust that comes out with flushing
air. The dust goes through the suction head to the dust collector where the heaviest particles fall down
to the ground through the closing rubber. The lighter particles will be separated by filters in the fine
separator and the clean air is blown out through the exhaust port.
Dust collector cleaning means that impulses of pressurized air are blown through five / six filtering
elements at a time. The cleaning process is electrically controlled so that the elements receive approx.
0.1 second impulses at 30 second intervals during drilling and at 5 second intervals after drilling. The
time settings depend somewhat on the drilling conditions.
When percussion is switched off, the flushing valve closes and suction in the dust collector ends. The
pressure stops affecting the cut-off cylinder, and the exhaust port flap is closed by the spring. The
cleaning of the filtering elements continues.
Unnecessary cleaning of filter elements can be prevented with the dust collector selection switch.

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Dust collector DC 800 H

4. OPERATION OF THE DUST COLLECTOR ID: 17527

4.1. Dust collection ID: 17528

When rock drill percussion is switched on, the flushing valve (4) opens. Pressure is now directed to
the rock drill flushing line and through the flap closing valve (8) to the cut-off cylinder (7) of the dust
collector flap. The pressure affecting the cut-off cylinder (7) keeps the exhaust port flap open.

10 8
13

12
6 5 1

3 11 2 7

ID: 17599

1 Filter elements 2 Dust collector hydraulic motor

3 Air/oil receiver 4 Flushing valve
5 Blow-out valves 6 Timer unit
7 Cut-off cylinder 8 Flap closing valve (optional)
9 Air end 10 Rock drill
11 Air receiver 12 Half flushing valve
13 Flow control valve

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 Dust collector DC 800 H

4.2. Blow-out ID: 17529

When rock drill percussion is switched on the timer unit (6) activates each of the blow-out valves (5)
in turn every 30 seconds for 0.1 second. Impulses of pressurized air remove the heaviest dust layer
from the filtering element. When rock drill percussion is switched off, the flushing valve closes, the
pressure affecting the cut-off cylinder (7) ends and the exhaust port flap is closed by a spring. The
timer unit (6) is now activated and gives a 0.1 second current impulse every 5 seconds to the blow-
out valves (5) in turn. When the blow-out valve opens it lets an impulse of pressurized air to five filters
at a time. These impulses will clean the filters and after 10 impulses the timer unit stops the blow-out
process.

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Dust collector DC 800 H

5. HYDRAULICS ID: 17530

5.1. Hydraulic components ID: 17531

82 81

A B
84

81
E
84

82
83
A D B

80 50 1 90

ID: 17615

80 Gear pump; output for the dust collector

81 Dust collector selection valve; switches the dust collector on and off.
82 Dust collector hydraulic motor (number 2 on the component list); rotates the fan.
82 Intake valve for the dust collector hydraulic motor; supplies oil to the motor (82) intake side.
84 Dust collector circuit pressure relief valve
E 1.0 mm
The dust collector motor (82) is driven by oil from the gear pump (80). The maximum pressure of the
circuit is determined by the pressure relief valve (84) which is set to 210 bar.
The dust collector is switched on and off with the switch S17 in the cabin. The switch controls the
directional valve (81). The valve directs oil flow either to the dust collector or to the tank.
The intake valve (83), connected in parallel with the motor (82), allows the oil flow to the intake side
of the motor when the selection valve (81) is closed. This arrangement removes cavitation problems.

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 Dust collector DC 800 H

6. MAINTENANCE ID: 17533

6.1. Filter elements ID: 17534

Dust coming out of the exhaust port of the dust collector indicates a damaged filter element. Replace
the element immediately since dust passing through the damaged element quickly wears
down the blower fan. The elements have threaded fittings at the upper end.
The elements can be checked and if necessary, blown clean with compressed air from the hatch
provided on the side of the dust collector. The compressed air nozzle must be kept at a safe distance
from the elements to prevent them from becoming damaged.

6.2. Blowing sound damper ID: 17535

There is a sound damper (1) in the dust collector blow-out opening. It is lined with wool. Replace the
lining, if necessary.

ID: 17616

6.3. Blow-out valve ID: 17536

ID: 17617

The dust collector cleaning line includes blow-out valves (2 pcs) for 16 bar pressure.

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Dust collector DC 800 H

6.4. Timer unit DUCO TIMER ID: 17537

ID: 17618

The timer unit is a separate module and it is located in a terminal box at the rear end of the rig.
Adjustments are only allowed when the ignition key is in the STOP-position.
The adjusting screw T1ON is used to adjust the length of the current impulses for the blow-out valves
(e.g. 0,5 s).
The adjusting screw T1OF is used to adjust the intervals between impulses (e.g. 5 s).
The adjusting screw T3DOF is used to adjust the intervals between impulses during drilling (e.g. 30
s).

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 Dust collector DC 800 H

6.5. Repair and maintenance of the dust collector hydraulic motor ID: 17538

6.5.1. Construction and operation ID: 17622

4 2

6
3

ID: 17627

The F11 is a piston-type motor consisting of an upper and a lower chamber. The spherical pistons
(1) and piston rings (2) act at a 40° angle to the drive shaft (3).
When oil is introduced to the pressure coupling, the pistons are pushed down in the cylinder barrel
(4) and rotate the shaft. A spring element pushes the cylinder barrel (4) valve plate (5) against the
connecting end. Since the gear ring (6) connects the cylinder barrel to the drive shaft, they rotate at
the same speed. The drive shaft is supported with two taper roller bearings (8).

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Dust collector DC 800 H

6.5.2. Checking the operation ID: 17539

The condition of the motor can be checked by measuring the drain oil flow.
1. Detach one of the drain oil hoses and place its end in a measuring can. Plug the open connection.
2. Detach the other drain oil hose, and plug the connection as well as the hose end.
3. Run the unit at normal speed and pressurize the system with about 150–200 bar.
4. Check that there is no leakage at the shaft seal and the housing halves.
5. Measure the drain oil running out during one minute. If the drain flow exceeds the values indicated
when the unit is pressurized, the unit is worn and must be replaced.

Drain flow limits (Liters/minute):

Normal: 0.2 l/m
Maximum: 1.0 l/m

ID: 17619

6.5.3. Replacing the seal ring ID: 17540

1. Remove the lock ring securing the seal ring

and the support ring.
2. Drive a screwdriver inside the seal’s sheet
metal cover and pull the seal ring out. Be
careful not to damage the shaft sealing
surface!

ID: 17631

3. An installation tool made from a pipe can be

used for the installation of the seal ring.
35

T ~~ 3
ID: 17632

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 Dust collector DC 800 H

6.5.4. Disassembly ID: 17541

Before disassembly, clean the outside of the motor carefully. Remove any coupling components from the shaft
journal.
1. Remove the Allen screws (4 pcs) attaching
the chamber halves together. Separate the
halves by prising with two screwdrivers. Be
careful not to loose the shim between the
chamber and the guide bushing.
2. Mark the pistons and the corresponding ball
seats so that you can place each piston back
into its own ball seat during re-assembly.

ID: 17648

3. Pull the pistons out in the drive shaft direction.

ID: 17649

4. Push the bearing assembly out from the lower

chamber by placing the chamber on, for
example, a pipe and pushing the shaft
journal. An alternative method for removing
the bearing assembly: Hold the lower
chamber with both hands and hit the shaft end
against a wooden block. Do not damage the
shaft journal!

ID: 17650

5. Remove the seal ring by removing the lock

ring and the support ring.
6. The bearing assembly should be
disassembled only if the bearings are
damaged, as the re-assembly of the bearings
will require careful adjustment of bearing and
gear clearances.

ID: 17651

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Dust collector DC 800 H

7. Bearing disassembly: Place the bearing

assembly on a pipe so that it rests on its gear
ring. Open the shaft nut and push from the
end of the shaft.

ID: 17652

8. The cylinder barrel is removed by hitting the

chamber against a wooden block.

ID: 17653

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 Dust collector DC 800 H

6.5.5. Checking and replacing components ID: 17542

After disassembling the F11 motor, clean all parts carefully with naphtha.
If the leakage rate was too high, the following parts are probably damaged or worn:
• piston rings
• the end of the cylinder barrel and the slide plate
• the upper chamber valve plate and the connecting end surface that connects to the cylinder barrel

Any scratches or marks on these parts impair the operation of the motor. Replace the parts, if nec-
essary.
1. Replace all seals, seal rings, and O-rings.
2. Replace the piston rings that have signs of
50% Max
wear on over 50% of their surface. The piston
rings can be removed with circlip pliers. The
piston rings are fitted so that they form a
continuous spherical surface with the piston
head.
3. If necessary, the valve plate and the end of
the cylinder barrel may be sanded carefully.
Clean the parts carefully after sanding.

ID: 17654

4. The motor’s drive shaft bearing clearance is

adjusted with the shaft nut, if necessary. The
spacer separating the bearings may not be
loose but it must move sideways by hand.

ID: 17655

5. Check the sealing surface between the drive

shaft and seal ring for damage. Replace the
drive shaft, if necessary.

ID: 17656

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Dust collector DC 800 H

6.5.6. Assembly ID: 17543

Before assembly, wash the parts carefully and lubricate them with hydraulic or motor oil. The motor
is assembled in reverse order to disassembly.
1. Attach the upper chamber to a vice so that the
valve plate surface is horizontal.

ID: 17657

2. Install the valve plate in the upper chamber in

the position shown in the figure.

ID: 17658

3. If the motor is equipped with a mounting ring,

it is installed as shown in the figure. The
cylinder barrel is pressed into place so that
the cut in the mounting ring is aligned with the
lug on the upper chamber.

ID: 17659

4. Fit the guide ring slot so that the tooth contact

can be checked.

ID: 17660

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 Dust collector DC 800 H

5. Install the shims as shown in the figure. The

thickness of the shims is adjusted so that the
tooth clearance is 0.05–0.15 mm. The shims
might need to be replaced if the shaft
bearings are replaced.

ID: 17661

6. The teeth of the cylinder barrel and gear ring

have marks to ensure that tooth contact is
correct and that the pistons are placed to the
cylinders in the correct position. Align the
marked tooth gap in the cylinder barrel with
the guide ring slot. Emphasise the marking
with a small dot of paint to make the
installation easier.

ID: 17662

7. One tooth of the drive shaft gear ring has a

mark.

ID: 17663

8. Install the drive shaft with pistons in the

cylinder barrel so that the marks on the gear
rings are aligned and the pistons are placed
into the correct cylinders.

ID: 17664

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Dust collector DC 800 H

9. If the timing marks do not align, pull the drive

shaft with pistons out and align again.

ID: 17665

10. Install a new shaft seal in the bearing housing.

Be careful not to damage the seal when
installing the bearing housing. Tighten the
screws in a crosswise pattern. Tighten first to
an initial tightening torque of 20 Nm and then
to the final tightening torque of 25 Nm.
11. To check for proper assembly, rotate the shaft
quickly back and forth; a clinking sound
indicates that the clearance between the gear
ring and cylinder barrel is correct. If there is
no sound, the clearance is too small and a
thicker shim should be installed. The correct
clearance is 0.05–0.15 mm.

ID: 17666

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 Dust collector DC 800 H

7. MOVABLE SUCTION HEAD ID: 17544

The suction line in good condition is a prerequisite for effective dust collection. The movable suction
head makes drilling easier in a slope or uneven terrain. In addition, it can be used to prevent water
from entering the filters when drilling wet holes.
The suction head can be turned for 180 degrees.

ID: 17668

1. Ground support
2. Movable suction head
3. Hydraulic cylinder
4. Feed

The movable suction head is installed at the lower end of the feed beams. The suction head can be
moved with the hydraulic cylinder within a range of 250 mm.

7.1. Dust collector flap closing valve (suction cut-off, optional) ID: 17545

The valve is installed in the power pack. When the valve is closed the pressure ceases to affect the
cut-off cylinder, and the dust collector valve closes. The system prevents dust collector operation
when drilling a water hole, for instance.

Copyright © Sandvik Mining and Construction 19 (22)

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Dust collector DC 800 H

8. TROUBLESHOOTING ID: 17546

Air flows continually along the blow-out line to the filter elements

Blow-out magnetic valve does If the magnetic valve spool is stuck open, clean the valve or, if
not function. necessary, replace it.
Dust collector blow-out does not operate at all

Blow-out selector switch in the
wrong position.
Timer unit does not function.
Blow-out magnetic valve spool
stuck closed.
Dust collector is ineffective
Turn the switch to the correct position.
Check first that the timer unit is correctly adjusted. If the
adjustment is correct and the blow-out does not function,
replace the timer unit.
Clean the valve or, if necessary, replace it.

Filter element blow-out sequence too slow or blow-out Adjust timer unit.
does not function at all.
Closing valve open, causing suction air leakage
resulting in ineffectiveness of blow-out.
Closing valve stuck closed, resulting in insufficient Check the flap and cut-out cylinder
suction for the fine separator. operation. Also check the tightness of the
cylinder and the condition of the spring.
Moist dust has blocked the suction hose or the dust Clean the hose and the filters.
collector filters.
The suction hose or suction head rubbers are damaged. Replace the suction hose or suction head
rubbers.
Hydraulics does not function normally. Check the pressures, hydraulic pump, and
the amount of the hydraulic motor oil drain.
Dust comes out from the dust collector exhaust port

Some of the filter elements are damaged. Replace the damaged filter elements immediately.

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 Dust collector DC 800 H

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ID: 370 0 en 2009-02-16
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