Module 1

Hydraulic Systems
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 Foreword

The purpose of this manual is to provide maintenance and servicing personnel with a
clear understanding of the operation and safe servicing procedures associated with the
Rotary hydraulic system. Before attempting any in depth fault diagnosis or maintenance
procedure associated with the hydraulic system, ensure you have adequate experience and
product knowledge to prevent serious personal injury or equipment damage. If you are
unsure of any aspect, DO NOT proceed until you have received correct and current
advice from Sandvik Mining and Construction.

From time to time changes to procedures and / or equipment may occur to ensure the
continued reliability and efficiency of the equipment. Therefore, to ensure that this
publication remains a current and accurate source of reference, and amendment service is
provided for all users. As and when such changes occur, the amended page/s together
with an amendment summary will be provided by Sandvik Mining and Construction.

In order to assist in understanding the various components and circuits illustrated in this
manual, the colour code below has been adopted.

All rights reserved. No part of this manual may be reproduced in any form
or in any means without the express permission in writing from
SANDVIK MINING and CONSTRUCTION Rotary Drills.

© COPYRIGHT 2005

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 D25KS HYDRAULIC TRAINING

Propel Hot Oil Shuttle Valves

Hot oil shuttle valve part number 001088-039

Relief cartridge part number 001468-051
Shuttle check cartridge part number 016 468-051

In the D25KS propel application, hot oil shuttle valves are used to shuttle a fixed
amount of 4 GPM hot oil returning from the propel motors back to the the
hydraulic tank low pressure return in the closed loop propel circuit. These hot oil
shuttle valves are used in the propel mode only, as a rotation motor hot oil shuttle
valve and open loop feed circuit fulfill this function in the drill mode.

Propel hot oil shuttle valves remotely mounted

Hot oil shuttle valves activation

Hot oil shuttle valves are activated via pilot pressure from the pressurized side of
the circuit which pilots over the spring centered shuttle check cartidge, allowing
hot oil on the return side of the circuit to flow to the relief cartridge. Once the relief
cartridge is piloted open, hydraulic oil will return to the hydraulic tank low
pressure return at a flow of 4 gallons per minute.

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Fourth Edition (AUS): Oct 2009 Document Controller: Craig Bosch
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 D25KS HYDRAULIC TRAINING

Hot Oil Shuttle valve Positions

Reverse Propel Neutral Forward Propel

Tightening torque

When tightening Hot oil shuttle valve components, overtightening should be

avoided. Incorrect tightening torque may lead to o-ring seal fatigue, a cracked
housing bore, binding spool operation and a possible loss of system pressure.

Tighten components as follows:

• Relief valves 40-48Nm
• Check valves 61-68Nm
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 D25KS HYDRAULIC TRAINING

Propel Hot Oil Shuttle Valve Adjustments

Step1. Install an flowmeter inline with the LPR oulet hose.

Step2. Set the engine at high idle, mode switch in tram mode, with the relevant
pump stroked up.

Step3. Check the flow meter reading. A flow of 3.5 to 4 gallons (13-15 liters)
per minute is standard.

Step4. Adjustments can be made as follows:

• Clockwise adjustments increases pressure and decreases flow.
• Counter clockwise adjustments decreases pressure and increases
flow.

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Fourth Edition (AUS): Oct 2009 Document Controller: Craig Bosch
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 D25KS HYDRAULIC TRAINING

Feed & Rotation Pressure Control Valves

Part number 003500-001
Denison R1E02 series

Feed and rotation pressure control valves are used to adjust feed and rotation
pressure during drill mode to suite drilling conditions.

• According to adjustment value, pressure control valves may be hot to the

touch if open , allowing pressure from the system to return back to tank.

• Control valves may generate some noise when venting.

• If the cone cannot settle onto the valve seat properly, oil may leak past and
effect the overall system pressure.

• In D25KS applications, solenoid valves are connected in line with both

feed and rotation pressure control valves which serve to override the
pressure control valves. (Torque control & feed override solenoids) This is
neccessary to keep the pumps at full pressure when propelling.

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 D25KS HYDRAULIC TRAINING

P T

Hydraulic oil enters the inlet valve port P as shown in red and lifts the cone off the
seat once the hydraulic pressure overcomes the spring pressure adjustment.
Returning oil shown in blue is returned back to the hydraulic tank in the feed
application and back to rotation pump Kg port in the rotation application. A spring
loaded piston pushing on the bottom of the cone acts as a dampener.

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Fourth Edition (AUS): Oct 2009 Document Controller: Craig Bosch
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 D25KS HYDRAULIC TRAINING

Propel Shutdown Valve / Pump Vent Solenoid

Part Number 014878-003
Denison A4D01 series

Propel shutdown valve

The propel shutdown valve is used in conjunction with the tram foot switch
(Deadman switch). Activation of the tram foot switch energises the propel
shutdown valve, dead heading system pressure. The tram foot switch must be
kept depressed for tramming. The tram foot switch must not be used as a brake.

Tram foot switch

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Fourth Edition (AUS): Oct 2009 Document Controller: Craig Bosch
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 D25KS HYDRAULIC TRAINING

Propel shutdown valve, base plate not shown.

When ordering parts, ensure the correct model number is used.

The model numbers are the last digits of the denison number on the identification
plate.

Model 28 shown

Model options: 28, 328, L28.

Sandvik rotary drill parts manuals list the part numbers applicable to each model.
Copyright © Sandvik Mining and Construction Australia 2009
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 D25KS HYDRAULIC TRAINING

Back Pressure Valve

Part Number 001066-001

D25KS backpressure valve located on the hydraulic tank

Returning oil from the feed, fan and accessory circuits flow through the
backpressure valve. The valve keeps a 175psi back pressure on these circuits to
prevent cylinder drift. The backpressure valve is low maintenance. There are no
seals, one spring pushes the steel piston onto the seat. The seat is a brass disc
set into the cast land of the housing.

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Fourth Edition (AUS): Oct 2009 Document Controller: Craig Bosch
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 D25KS HYDRAULIC TRAINING

Back pressure valve adjustments

Step1. Connect a 400psi pressure guage to the high pressure return manifold

Step2. Take HPR pressure reading with engine at full rpm’s and all controls in the
neutral position. 175psi should be obtained

Step3. If adjustments need to be made:

3.1 Remove cap from top of back pressure valve.

3.2 Loosen locknut.
3.3 Turn adjustment clockwise to increase pressure, anticlockwise to
decrease pressure.
3.4 Adjust pressure to obtain 175psi pressure.
3.5 Tighten locknut and replace cap.
3.6 Remove guage.

Important Note:
HPR pressure should be lower than pump replenishing pressure. It is
recommended that the pump replenishment and HPR maintain a 30-50 psi
pressure differential. Pressure should be adjusted on the raise (If pressure is too
high, reduce pressure below spec and increase slowly up to spec.)

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 D25KS HYDRAULIC TRAINING

Feed Control Valve

The feed control valve is a cable operated 3 position 4 way directional control
valve. It’s function is to direct oil to either the feed cylinder retract or extend side
when the feed pump is placed on stroke. Feed control valves have a few
variations. The most notable difference being the mount position of the
mechanical linkages.

D25KS feed control valve (002769-006)

A new feed control valve was introduced in 2005, part numbers as follows.

Pre 2005:
• Feed control valve part number 002769-001‫٭‬
• Feed control valve part number 002769-004‫٭‬

Post 2005:
• Feed control valve part number 002769-005
• Feed control valve part number 002769-006

‫٭‬When replacing a pre 2005 feed control valve, part number 002769-100
should be ordered as a new valve field installation kit. the kit will include
mounting hardware and new linkage.

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 D25KS HYDRAULIC TRAINING

Replacement kit 002769-100 installation:

Upon installation, the new valve will require relocating the drain hose. Remove
the original drain hose and adapter from the feed manifold. Use the SAE plug to
close the original drain port. Place a 90 degree boss o-rin adapter into the new
valve external drain port. Connect the drain hose to the new valve drain port.

Note: Ensure ½” UNC 1” long mount bolts are used upon installation.
Mount bolts too long can bottom out and crack the feed manifold housing.

Feed control operation:

Incorrect operation of the feed control valve can cause excessive wear, and
greatly reduce valve service life.

Correct usage guidelines:

• The feed control valve should be used in the full detented positions only.
• Cylinder speed should be controlled by adjusting the feed pressure control
valve, not the feed control valve.
• Prior to shifting feed control valve position, derate the feed pressure first by
adjusting the feed pressure control valve.

Factors influencing feed control valve performance:

Undesired feed movement or reduced feed performance can be a result of any of
the following:
• Incorrect linkage and cable adjustments.
• Stretched or worn feed cable
• Loose or worn feed control
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 D25KS HYDRAULIC TRAINING

• Worn detent parts and springs

• Worn spool and landings
• Oil leaks
• Excessive dirt pile up around the feed control valve on earlier model feed
control valves, restricting spool movement and contaminating shaft seals.

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Fourth Edition (AUS): Oct 2009 Document Controller: Craig Bosch
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 D25KS HYDRAULIC TRAINING

SANDVIK D25KS

HYDRAULIC ADJUSTMENT PROCEDURES

• All safety Procedures and Precautions should be followed to avoid personal injury
and or machine damage.

• Follow all Mine site specific rules and regulations according to machine lockout
and commissioning (Live testing) when doing any adjustments on the machine.

• After any pump installation all pumps should be primed with oil in the pump
cases.

• After starting the machine for the first time after pump installation the machine
should be allowed to idle for 5 minutes to ensure all air is bled from the hydraulic
system.

• Slowly operate each function in turn to continue the bleeding process.

• Mast Raise and Jack cylinders should be bled carefully by operating short slow
duration then reversing the direction until these cylinders are fully bled.

• Pressure settings should be done when Hydraulic oil is warmed to working

temperatures.

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 D25KS HYDRAULIC TRAINING

Feed Pump Adjustments

Replenishing adjustment:

Step1. Connect a gauge to the replenishment port KG on the feed pump. Refer
to fig. 1 below for KG port location.

Step2. Start the engine and run the engine at high idle and check the
replenishment pressure. A reading of 200-300 psi should be obtained.

Step3. If the replenishment pressure is not within range, stop the engine and
remove the replenishment pressure regulator from the valve chest of
the feed pump. Manually adjust the replenishment regulator to give
the correct pressure. 1 Turn of the adjustment in is approximately 60
psi. The Replenishment Relief is fitted under the socket head cap as
shown in fig 2.

Step4. Refit the replenishment pressure regulator. Repeat steps 2 and 3 until
the pressure is set correctly.

FIG.1

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 D25KS HYDRAULIC TRAINING

Compensator Adjustment:

Step1. Connect a digital pressure gauge to V port to read pump main

pressure. Refer to fig 1 for V Port location.

Step2. Stall feed in the retract position.

Step3. Adjust Main compensator to 3500psi.

FIG.2

Servo Pressure:

Step1. Connect gauge to the servo port on the feed pump, see fig 1
for port location.

Step2. Start the engine and run at high idle. A servo reading of 300-500 psi should
be obtained in neatral, 400-580 psi when the pump is stalled out.

NOTE:
Servo pressure is not adjustable. A large deviation from the above pressure
indicates a problem in the pump or in the hydraulic system.

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 D25KS HYDRAULIC TRAINING

Rotation Pump Adjustments

Replenishing adjustment:

Step1. Connect gauge to the replenishment port KG on the Rotation pump,

refer to fig 3 for KG port location.

Step2. Start the engine and run the engine at high idle and check the
replenishment pressure. A reading of 200-300 psi should be obtained.

Step3. If the replenishment pressure is not within range, stop the engine and
remove the replenishment pressure regulator from the valve chest of
the Rotation pump. Manually adjust the replenishment regulator to
give the correct pressure. 1 Turn of the adjustment in is
approximately 60 psi. The replenishment relief is fitted under the
socket head cap as shown in fig 4.

Step4. Refit the replenishment pressure regulator. Repeat steps 2 and

3 until the pressure is set correctly.

FIG.3

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 D25KS HYDRAULIC TRAINING

Compensator Adjustment:

Step1. Connect a digital pressure gauge to V port to read pump main

pressure. Refer to fig 3 for V Port location.

Step2. Stall Rotation pump.

Step3. Adjust Main compensator to 3500psi.

FIG.4

Servo Pressure:

Step1. Connect gauge to the Servo Port on the Rotation pump, see fig 3.

Step2. Start the engine and run at high idle. A servo reading of 300-500 psi should
be obtained with the pump in neutral, 400-580 psi when the pump is stalled
out.

NOTE:
Servo pressure is not adjustable. A large deviation from the above pressure
indicates a problem in the pump or in the hydraulic system.

Copyright © Sandvik Mining and Construction Australia 2009

Fourth Edition (AUS): Oct 2009 Document Controller: Craig Bosch
Page 40 of 41
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