Boom & bucket system 1

T9 rev1 03.07 MY
System lay-out

Sandvik Mining and Construction

 Boom & bucket system 2
T9 rev1 03.07 MY
System description

The converter mounted variable displacement type pump (P303) delivers oil to a hydraulically controlled bucket
main valve (V204). The bucket hydraulic pilot pressure is controlled with proportional electric valves (V203)
which are controlled by the control joystick on the right--hand side in the cabin via the Control System. Control
joystick is connected to the Chair module. Control System processes the input and safety conditions.When
safe the front module controls the proportional valve to open and let the pilot pressure to enter the main valve
spool end. The hydraulic pressure is directed through bucket main valve to boom and bucket cylinders. Excess
flow from steering hydraulics (when steering is not used) flows to bucket main valve from the priority block
(V315).

Safety interlocks
If boom / bucket control is stopped because of a situation that does not occur in normal usage, remove
themalfunction that prevents the control and return the control joystick into middle position before function
control can start again. For example, when parking brake is used the boom--and bucket controls are disabled.
In that case, the parking brakemust be released and the control joystick returned into middle position. Only then
it is possible to control the boom / bucket again.
The system prevents boom and bucket control in the following situations:
• The control joystick’s direction switches are not active in the same direction as the
controlling signal
• The control joystick’s analog voltage rating is too high or low compared to the
calibrated parameters
• Both direction switches are activated at the same time
• Parking brake is engaged
• Door is open
• Emergency stop is activated
• The engine is not running
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 Boom & bucket system 3
T9 rev1 03.07 MY
Hydraulic diagram/stand-by

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 Boom & bucket system 4
T9 rev1 03.07 MY
Hydraulic diagram/boom up

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 Boom & bucket system 5
T9 rev1 03.07 MY
Hydraulic diagram/bucket up

Sandvik Mining and Construction

 Boom & bucket system 6
T9 rev1 03.07 MY
Electric diagram
RIGHT JOYSTICK
RJ3 BOOM UP / BOOM DOWN BUCKET UP / BUCKET DOWN BUCKET SHAKING
10/22
DOWN UP DOWN UP
R044 R043
SUPPLY FOR
SWITCHES

X1179 X1178 X1179 X1178 X1179 Interlock 137

RJ4 10 9 1 3 2 11 12 4 5 1 Output is active when:
10/22 - Emergency stop is not active
8 9 12 13 14
X53 X53 X53 X53 X53 -Manual /remote input XC1:23
10 11 15 2 1
+5V is not active (RC not selected)
X53 X53 X53 X53 X53
J600.1
18/13 Interlock 111
5 6 5 4 8 7 6 18 1 Output is active when:
- The boom joystick is turned from
XC2 XC2 XC3 XC3 XC2 XC2 XC3 XC1 XC2 the middle position
in in in GND in in in in +24V - The boom joystick’s direction
CHAIR MODULE switches are active in the same
direction as the controlling signal
CAN BUS
FRONT MODULE - The boom joystick’s analogy
voltage rating is inside the

FB-
FB-
137 111 112
25/11 24/11 24/11 calibrated values
XF2 XF1 XF1 XF1 XF1 XF1 XF1 - Both direction switches are not
activated at the same time
2 3 4 5 7 8 6
- Parking brake is released
GND.X221 - Door is closed
- Emergency stop is not active
1 5 4 1 5 4 1 5 4 1 5 4 1 5 4 1 5 4 - Engine is running

K2173 GND.X221 Interlock 112

2 3 K285 2 3 K286 2 3 2 3 K287 2 3 K288 2 3 K2174
Output is active when:
- The bucket joystick is turned from
the middle position
7 8 28 27 9 10 26 25 - The bucket joystick’s direction
switches are active in the same
JF109.1 X223 X223 X223 X223 X223 X223 direction as the controlling signal
7/25
1 1 1 1 - The bucket joystick’s analogy
voltage rating is inside the
Y328 2
Y325 2 Y327 2 Y324 2 calibrated values
- Both direction switches are not
activated at the same time
- Parking brake is released
- Door is closed
1 2 3 4
- Emergency stop is not active
RAISE BOOM LOWER BOOM BUCKET LOAD BUCKET DUMP - Engine is running
PUOMI YlöS PUOMI ALAS KAUHA YLöS KAUHA ALAS

Sandvik Mining and Construction

 Boom & bucket system 7
T9 rev1 03.07 MY
Electric diagram/stand-by
RIGHT JOYSTICK
RJ3 BOOM UP / BOOM DOWN BUCKET UP / BUCKET DOWN BUCKET SHAKING
10/22 -Parking brake released.
DOWN UP DOWN UP -Engine running
R044 R043 -Door closed
SUPPLY FOR
SWITCHES

X1179 X1178 X1179 X1178 X1179 Interlock 137

RJ4 10 9 1 3 2 11 12 4 5 1 Output is active when:
10/22 - Emergency stop is not active
8 9 12 13 14
X53 X53 X53 X53 X53 -Manual /remote input XC1:23
10 11 15 2 1
+5V is not active (RC not selected)
X53 X53 X53 X53 X53
J600.1
18/13 Interlock 111
5 6 5 4 8 7 6 18 1 Output is active when:
- The boom joystick is turned from
XC2 XC2 XC3 XC3 XC2 XC2 XC3 XC1 XC2 the middle position
in in in GND in in in in +24V - The boom joystick’s direction
CHAIR MODULE switches are active in the same
direction as the controlling signal
CAN BUS
FRONT MODULE - The boom joystick’s analogy
voltage rating is inside the

FB-
FB-
137 111 112
25/11 24/11 24/11 calibrated values
XF2 XF1 XF1 XF1 XF1 XF1 XF1 - Both direction switches are not
activated at the same time
2 3 4 5 7 8 6
- Parking brake is released
GND.X221 - Door is closed
- Emergency stop is not active
1 5 4 1 5 4 1 5 4 1 5 4 1 5 4 1 5 4 - Engine is running

K2173 GND.X221 Interlock 112

2 3 K285 2 3 K286 2 3 2 3 K287 2 3 K288 2 3 K2174
Output is active when:
- The bucket joystick is turned from
the middle position
7 8 28 27 9 10 26 25 - The bucket joystick’s direction
switches are active in the same
JF109.1 X223 X223 X223 X223 X223 X223 direction as the controlling signal
7/25
1 1 1 1 - The bucket joystick’s analogy
voltage rating is inside the
Y328 2
Y325 2 Y327 2 Y324 2 calibrated values
- Both direction switches are not
activated at the same time
- Parking brake is released
- Door is closed
1 2 3 4
- Emergency stop is not active
RAISE BOOM LOWER BOOM BUCKET LOAD BUCKET DUMP - Engine is running
PUOMI YlöS PUOMI ALAS KAUHA YLöS KAUHA ALAS

Sandvik Mining and Construction

 Boom & bucket system 8
T9 rev1 03.07 MY
Electric diagram/boom up
RIGHT JOYSTICK
RJ3 BOOM UP / BOOM DOWN BUCKET UP / BUCKET DOWN BUCKET SHAKING
10/22 -Parking brake released.
DOWN UP DOWN UP -Engine running
R044 R043 -Door closed
SUPPLY FOR
SWITCHES

X1179 X1178 X1179 X1178 X1179 Interlock 137

RJ4 10 9 1 3 2 11 12 4 5 1 Output is active when:
10/22 - Emergency stop is not active
8 9 12 13 14
X53 X53 X53 X53 X53 -Manual /remote input XC1:23
10 11 15 2 1
+5V is not active (RC not selected)
X53 X53 X53 X53 X53
J600.1
18/13 Interlock 111
5 6 5 4 8 7 6 18 1 Output is active when:
- The boom joystick is turned from
XC2 XC2 XC3 XC3 XC2 XC2 XC3 XC1 XC2 the middle position
in in in GND in in in in +24V - The boom joystick’s direction
CHAIR MODULE switches are active in the same
direction as the controlling signal
CAN BUS
FRONT MODULE - The boom joystick’s analogy
voltage rating is inside the

FB-
FB-
137 111 112
25/11 24/11 24/11 calibrated values
XF2 XF1 XF1 XF1 XF1 XF1 XF1 - Both direction switches are not
activated at the same time
2 3 4 5 7 8 6
- Parking brake is released
GND.X221 - Door is closed
- Emergency stop is not active
1 5 4 1 5 4 1 5 4 1 5 4 1 5 4 1 5 4 - Engine is running

K2173 GND.X221 Interlock 112

2 3 K285 2 3 K286 2 3 2 3 K287 2 3 K288 2 3 K2174
Output is active when:
- The bucket joystick is turned from
the middle position
7 8 28 27 9 10 26 25 - The bucket joystick’s direction
switches are active in the same
JF109.1 X223 X223 X223 X223 X223 X223 direction as the controlling signal
7/25
1 1 1 1 - The bucket joystick’s analogy
voltage rating is inside the
Y328 2
Y325 2 Y327 2 Y324 2 calibrated values
- Both direction switches are not
activated at the same time
- Parking brake is released
- Door is closed
1 2 3 4
- Emergency stop is not active
RAISE BOOM LOWER BOOM BUCKET LOAD BUCKET DUMP - Engine is running
PUOMI YlöS PUOMI ALAS KAUHA YLöS KAUHA ALAS

Sandvik Mining and Construction

 Boom & bucket system 9
T9 rev1 03.07 MY
Functional description

Bucket main valve V204 (1.)

There are 2 spring centered proportional spools at the boom and bucket valve (V204). The spools are
controlled by external hydraulic pressure. Maximum hydraulic system operating pressure is controlled by
adjustment on the pump control valve. In case of malfunction the main pressure relief valve protects the system
by limiting the maximum valve inlet pressure to 310 bar (31,0MPa). Both spools have two circuit relief valves
(with two non-return valves) to limit the pressure at cylinders (bucket max 300 bar (30,0MPa),
boom max 340 bar (34,0 MPa) for lift and 300 bar (30,0 MPa) for lower) and the non-return valves to prevent
cavitation. Proportional spool (2) adjusts the position of the boom by adjusting the hydraulic flow going to the lift
cylinders and proportional spool (3) adjusts the position of the bucket by adjusting the hydraulic flow going to
the tilt cylinder. Main valve spools are pilot operated by individual electrically controlled servo valves (4).

Sandvik Mining and Construction

 Boom & bucket system 10
T9 rev1 03.07 MY
Functional description
Boom / Bucket proportional servo valves V203 (4.)
There are four valves at pilot control valve V203. Each valve is
connected to boom and bucket valve V204 pilot control ports. Moving
the bucket control lever causes the corresponding proportional valve
to open and let the pilot pressure to enter themain valvespool.
Solenoid valve Y224
When lowering the bucket, solenoid valveY224 connects pilot
pressure line to the proportional valve pilot control line. When lifting
the bucket, solenoid valve Y224 connects pilot control line from
proportional valve to the tank line.
Solenoid valve Y225
When lowering the boom, solenoid valve Y225 connects pilot
pressure line to the proportional valve pilot control line. When
lifting the boom, solenoid valve Y225 connects pilot control line from
proportional valve to the tank line.
Solenoid valve Y227
When lifting the bucket, solenoid valve Y227 connects pilot pressure
line to the proportional valve pilot control line. When lowering the
bucket, solenoid valve Y227 connects pilot control line from
proportional valve to the tank line.
Solenoid valve Y228
When lifting the boom, solenoid valve Y228 connects pilot pressure
line to theproportional valve pilot control line. When lowering the
boom, solenoid valve Y228 connects pilot control line from
proportional valve to the tank line.

Sandvik Mining and Construction

 Boom & bucket system 11
T9 rev1 03.07 MY
Functional description

Priority block V315

The function of this component is to prioritise oil flow from forward section of pump P301 to steering. Priority
block directs all extra flow to boom / bucket hydraulics. Full function of priority block is presented in chapter
General Hydraulics.

Pump P303
The function of this component is to supply oil flow to boom / bucket hydraulics. Function of pump P301 is
presented in chapter General Hydraulics.

Double pump P301

The function of this component is to primarily supply oil flow to steering, extra flow directed via priority block
V315 to boom / bucket hydraulics. Full function of double pump P301 is presented in chapter General
Hydraulics.

Return filter Z308

The function of this component is to filter all tank return oil flow from steering and boom / bucket hydraulics.
Complete component function in chapter General Hydraulics.

Sandvik Mining and Construction

 Boom & bucket system 12
T9 rev1 03.07 MY
Functional description

Boom limit switch S236

When the boom is lowered, there is an inductive sensor
S236 near the boom’s lower extreme position for end
position
cushioning. The end position cushioning will not be activated
if the boom enters the end position cushioning zone and the
movement is just beginning or its direction changes.

Ride control limit switch S234

Ride control will not be activate unless boom is lowered and
S234 is active. See also other ride control function
conditions.

Bucket limit switch S257

When the bucket is raised, there is an inductive sensor S257
near the bucket’s upper extreme position for end position
cushioning. The end position cushioning will not be activated
if the boom is in the end position cushioning zone and the
movement is just beginning or its direction changes.

Sandvik Mining and Construction

 Boom & bucket system 13
T9 rev1 03.07 MY
System description, Bucket shaking

Bucket shaking moves the bucket back and forth according to joystick movements in sharp, fast movements.

The bucket shaking is activated by pressing and holding the shaking button and moving the bucket control
joystick back and forth. During shaking, the control valve is fully open regardless of how far have moved the
control joystick away from the middle position.

Safety interlocks
The system prevents bucket controlling in the following situations that do not occur in normal usage:

• The control joystick’s direction switches are not active in the same direction as the
controlling signal
• The control joystick’s analog voltage rating is too high or low compared to the
calibrated parameters
• Both direction switches are activated at the same time
• Parking brake is on
• Door is open
• Emergency stop is activated
• The engine is not running

Sandvik Mining and Construction

 Boom & bucket system 14
T9 rev1 03.07 MY
System description, Ride control
(option)

The purpose of ride control is to improve the machine’s driving comfort when the boom is suspended on the
pressure accumulators during driving. Ride control also reduces stress on the machine frame components.

Automatic ride control function is activated by pressing the ride control button on the control panel. After this,
the bucket must be hauling, the boom lowered down, joystick at center position and the machine’s tramming
speed increased (2. gear, speed over 5 km/h). Ride control will not be activated until all parameters are met.
When ride control is activated, the boom is lifted until the lower limit of the boom’s lower limit sensor is
exceeded. Boom cylinder pressure is measured and the correct pressure accumulator is selected according to
bucket load. If the boom cylinder pressure exceeds the adjusted parameter value (the bucket is fully loaded),
pressure accumulator 2 is opened, otherwise pressure accumulator 1 is opened. If the boom has descended
below the lower limit during the opening of the pressure accumulator, the boom is again lifted until the boom is
above the ride control limit switch S234.

Ride control can be deactivated by pressing the ride control button again. If the bucket is controlled during ride
control, ride control will be deactivated for the time period when the bucket is used. When the boom is
controlled, ride control will be deactivated but the selection will remain active ( the operational parameters
must be fulfilled again, before ride control will be reactivated).

Sandvik Mining and Construction

 Boom & bucket system 15
T9 rev1 03.07 MY
System description, Ride control
(option)

The symbol to the left on the main window tells the status of
ride control. The symbol is grey when ride control is not
activated.
When you press the ride control button, the symbol becomes
darker. Ride control is activated only when all its operational
conditions are fulfilled.

Safety interlocks
The system prevents ride control in the following situations:
• Controlling the bucket with control joystick
• Controlling the boom with control joystick
• General lockings of boom control

Sandvik Mining and Construction

 Boom & bucket system 16
T9 rev1 03.07 MY
System description, Ride control
(option)

One ride control valve (V222) package is

located on the front frame, next to the
bucket main valve. On both sides of the
front frame is one 7,0 liters piston type
hydraulic pressure accumulator. Left
accumulator (Z204) precharge pressure is
20 bar (2,0 MPa) and right (Z205) is 80 bar
(8,0MPa). The smaller precharge
accumulator is used when hauling with
empty bucket. Higher precharge
accumulator is used when hauling with
loaded bucket.

There is a pressure sensor in the piston side pressure line of the lift cylinder formeasuring if the bucket empty or
loaded. Flows inside the block are controlled by 3 cartridge valves, which all are piloted by on/off solenoid
valves.Pilot valveY259 controls the cartridge valve which connects rod side of the cylinder to tank
line.Correspondingly pilot valves Y236 and Y237 control cartridge valves, which connect hydraulic accumulators to
the piston side of the cylinder. The operator can select ride control via a switch in corner instrument panel.

Sandvik Mining and Construction

 Boom & bucket system 17
T9 rev1 03.07 MY
System description, Boom floating
(option)

The purpose of this function is to let the bucket trail the ground,
for examplewhen you want to clear fallen stones off a road.
Boom float is taken into use by pressing the float button on the
corner instrument panel. The boom’s lower limit sensor S236
must be activate.When float is engaged, boom must be lowered
against the stoppers. Boom floating can also be activated with
the display
module’s forced functions window. Boom float is deactivated by
pressing the float button again. Controlling the boom or bucket
will also deactivate float. The symbol to the left on the main
window tells the status of boom floating. The symbol is grey
when floating is not activated, and becomes darker when you
activate floating.

When boom floating is activated, following situations occurred:

• Control valve Y225 activated
• Tank line valve Y259 activated

Safety interlocks
The system prevents boom floating in the following situations:
• The boom’s lower limit sensor is not activated.
• Controlling the bucket with control joystick
• Controlling the boom with control joystick
• General lockings of boom control

Sandvik Mining and Construction

 Boom & bucket system 18
T9 rev1 03.07 MY
Checking and adjusting

General
The hydraulic oil temperature should be 60...80 C.
Connect and disconnect pressure gauge(s) only when the circuit is not pressurized. Use only appropriate
couplings for pressure testing. Do not overtighten couplings. When special couplings are used, finger tight is
adequate. Over tightening can damage couplings and cause harmful leakage.
Use hose(s) long enough to read the gauge(s) while sitting in the cabin.
1. Ensure that the machine is on an even surface, the parking brake is applied and movement is prevented by,
for example, wheel chocks.
2. Install the frame locking pin.

Before adjusting bucket valve pressures, following

measures must be done:
• Remove steering pump LS--line
from the steering pump controller.
• Plug open end from of the LS-line.
Do not plug controller. This prevents unnecessary
load on the engine when adjusting bucket valve and
bucket pump pressures.

Never adjust pump pressures when engine is running. The rotating cardan shaft can
cause serious injury.

Sandvik Mining and Construction

 Boom & bucket system 19
T9 rev1 03.07 MY
Checking and adjusting
Note! The “boom up” shock-load valves open at 340 bar. The integrated main relief valve in the bucket main
valve is set to 310 bar and must be adjusted to 350 bar. when testing the “boom up” shock-load valve
opening pressure.

Adjusting main relief valve to 350 bar

3. Connect a 400 bar pressure gauge to the bucket pump

pressure line.

4. Screw the bucket pump maximum pressure adjusting

screw to almost closed position. Never screw down the
adjustment screw to fully closed position.

The hydraulic pressure can rise to a

dangerous level. Always remember to reset
the pump pressures to correct pressure
adjustment.

Sandvik Mining and Construction

 Boom & bucket system 20
T9 rev1 03.07 MY
Checking and adjusting

5. Start the engine and operate it at 1200 rpm.

6. Disconnect the electric connector from the bucket pump
controller.
7. Record the gauge reading. The pressure should be 350
bar. (35,0 Mpa).
8. If the readings do not match the specification:
• Adjust themain relief valve opening pressure by turning
the adjustment screw.
• If correct pressure settiing can not be set by adjusting the
main relief valve. Screw the pump maximum pressure
adjusting screw to more closed position.
Note! Never screw down the adjustment screw to fully
closed position.

Note! If the engine must be started several times during

adjustment, connect the electric
connector to bucket pump controller during cranking. In this
manner the cranking motor is
less loaded.

Sandvik Mining and Construction

 Boom & bucket system 21
T9 rev1 03.07 MY
Checking and adjusting

Boom / bucket shock-load valves (boom up)

9. Connect a 400 bar pressure gauge to the lift cylinder

piston side quick disconnect fitting on the bucket main
valve.

10. Move the bucket control joystick to the “boom up”-

position and keep it there against the stoppers, record
the gauge reading.

11. The pressure should be 340 bar (34,0 Mpa).

12. If the readings do not match the specifications:

• The shock--load valve needs to be adjusted by turning
the adjustment screw (A).
• The shock--load valve is malfunctioning and it must be
replaced.

To check / adjust following pressures:

Boom / bucket shock-load valves (boom down)
Boom / bucket shock--load valves (bucket up)
Boom / bucket shock--load valves (bucket up)
See details from Workshop manual

Sandvik Mining and Construction

 Boom & bucket system 22
T9 rev1 03.07 MY
Checking and adjusting

Reseting the main relief valve to correct

pressure adjustment
1.Reset the main relief valve back to correct
pressure adjustment.
2. Connect a 400 bar pressure gauge to the quick
disconnect fitting on the bucket pressure line.

Sandvik Mining and Construction

 Boom & bucket system 23
T9 rev1 03.07 MY
Checking and adjusting
3.Record the gauge reading. The pressure should be 310
bar. (31,0 Mpa).
• Adjust themain relief valve opening pressure by turning
the adjustment screw.

Shut down the engine.

4. Connect the electric connector to the bucket pump

controller.

5. Reset the bucket pump maximum pressure to correct

pressure adjustment. See section “Checking of the bucket
pump pressures”.

The hydraulic pressure can rise to a

dangerous level. Always remember to
reset the pump pressures to correct
pressure adjustment.

Sandvik Mining and Construction

 Boom & bucket system 24
T9 rev1 03.07 MY
Checking and adjusting

General
The hydraulic oil temperature should be 60...80 C.
Connect and disconnect pressure gauge(s) only when the circuit is not pressurized. Use only appropriate
couplings for pressure testing. Do not overtighten couplings. When special couplings are used, finger tight is
adequate. Over tightening can damage couplings and cause harmful leakage.
Use hose(s) long enough to read the gauge(s) while sitting in the cabin.
1. Ensure that the machine is on an even surface, the parking brake is applied and movement is prevented by,
for example, wheel chocks.
2. Install the frame locking pin.

Before adjusting bucket valve pressures, following

measures must be done:
• Remove steering pump LS--line
from the steering pump controller.
• Plug open end from of the LS-line.
Do not plug controller. This prevents unnecessary
load on the engine when adjusting bucket valve and
bucket pump pressures.

Never adjust pump pressures when engine is running. The rotating cardan shaft can
cause serious injury.

Sandvik Mining and Construction

 Boom & bucket system 25
T9 rev1 03.07 MY
Checking and adjusting

Stand-by pressure
3. Connect a 400 bar pressure gauge to the bucket pump pressure
line test point (A).
4. Start the engine and operate it at 1200 rpm. Record the gauge
reading.
5. The pressure should be 35 bar. (3,5 Mpa).
6. Turn off the engine.

7. If the readings do not match the specification:

• Adjust the stand--by pressure by turning the adjustment
screw.

Sandvik Mining and Construction

 Boom & bucket system 26
T9 rev1 03.07 MY
Checking and adjusting

Maximum pressure
8. Connect a 400 bar pressure gauge to the bucket pump
test point.

9. Start the engine and operate it at 1200 rpm. Record the

gauge reading.

10. Disconnect the electric connector (B) from the bucket

pump controller.

11. The pressure should be 285 bar. (28,5 Mpa).

12. Turn off the engine.

Never adjust pump pressures when engine is

running. The rotating cardan shaft can cause serious
injury.

Sandvik Mining and Construction

 Boom & bucket system 27
T9 rev1 03.07 MY
Checking and adjusting

13. If the readings do not match the specification:

• Shut down the engine and adjust the maximum pressure
by turning the adjustment screw.
14. Connect the electric connector to the bucket pump
controller.
15. Check the bucket pump stand-by pressure.
Note! When adjusting the pump maximum pressure it will
also affect to the pump stand--by pressure and vice versa.

When bucket pump pressures are set, following measures

must be done:
• Connect the steering pump LS-line to the steering pump
controller.

Sandvik Mining and Construction