03 P21 Hydraulic Components - Without-Logo

PC21 Hydraulic Components
1
03 P21 Hydraulic components issue 0 110712
Safety first Protective
Equipment
Safety is our top priority
Emergency Emergency
Number Exit
Assembly
Point
Alarm
2
Hydraulic Tank
Hydraulic Drawing Number HD0026
The hydraulic tank holds
approximately 1400 litres of 46 grade
hydraulic oil as standard.
Air breather
The oil condition should be checked filter (EN1523)
every 250 hours
It is far more economical to have the
oil sampled every than change the
hydraulic oil
There is also a hydraulic breather that
when turning green requires changing.
Ambient Temperature Range Grade of Oil Six 90µ suction

≤ 5C ISO VG 32 strainers HF1017
≤ 30C ISO VG 46
≥ 30C ISO VG 68
3
Hydraulic Tank
On the out side of the tank are two 25µ Return
strainers that have a service indicator when this pops
up red the filter requires changing.
In cold temperatures these filters can pop up and
give a false reading.
These filters should be changed regardless @ 250
hours initially and then every 1000 hours.
The filter is easily removed by unscrewing the six
Allen bolts and then removing the filter element
Service indicator on
RED when requiring
changing
25µ Return Filter
4
Element EN1402 03 P21 Hydraulic components issue 0 110712
Flushing Procedure
The hydraulic oil should be flushed every 250 hours to do this

1. Run the machine normally for 2 hours
2. Then remove the 25µ return filter and replace with 3µ micron
flushing
3. Start the machine on Idle only 1200rpm and run the machine for a
minimum of 2-4 hours, do not feed material into the machine
during this period
4. Then stop the machine and remove the flushing filters and replace
with New 25µ Suction filters
5
Hydraulic Tank
All the return oil enters the
return manifold and
through the two 25µ filters 25µ Filters
then some of the oil enters
back into the tank over
2x1.5bar checks but the
rest goes back through the
Kawasaki pumps (HP1054).
Therefore the Kawasaki 1.5 bar check
valves
pump is basically a part
closed loop circuit which is
topped up by all of the
other pumps to ensure
there is enough oil for the
flow demand .
6
Return Manifold
Place a pressure gauge on the return manifold test point and
when the machine is running the pressure should be no greater
that 4 bar (58Psi) but in cold condition 6 bar (87Psi) can be seen
Test point
7
Hydraulic Pumps
The Kawasaki pump is a
tandem mounted pump
directly driven off the
engine,
It supplies the tracks and
crusher with oil via the
D-40 valves.
Kawasaki Tandem Pump (HP1054)

Pump Speed 1900 rpm
Displacement 148 X 2 = 296cc
Flow @ 1900 rpm 563 l/min
8
Bosch Pump Drain back
to tank
Suction pressure test

point should be between
1 – 1.5 bar
Suction
Pump flow control valves to set the
Pressure from the
from tank speed of the cone. Adjust equal as
pump to the D-40
this effects the tracking speeds
valves
9
Pump Flow Control
De-stroking
Valve (HM8512)
Flow Control
Signal
40 bar pressure from the Ce-top valve travels
into the de-stroking valve.
We send 0 bar into the pump to keep the pump
on full flow
When required we move the proportional valves
to increase the pressure entering the pump
De-stroking Valve (HM8512) This will decrease the flow of the pump
Proportion Control Valve
10
Normal Operating Condition De-stroking
During normal operating condition Valve (HM8512)
the solenoid is energised so that
there is zero bar sitting on the
pump flow control
This will give you full flow at the
pump
35 Bar pressure
reducing valve
40 Bar Variable setting

pressure reducing valve
11
Over Pressure Condition De-stroking
Valve (HM8512)
When the pressure in the
cone drive circuit reaches
220 Bar
The control module will
switch the flow control
solenoid off
This will allow pressure on to
the pump flow control
This will cause the pumps to
de-swash down to minimum
flow of approximately 10L/M
12
De-stroking
Tracking Valve (HM8512)
When tracking both solenoid are

powered
This sends a pressure through
the variable pressure reducing
valve normally around 25 Bar
This causes the pump to reduce
the flow
This has to be done as full flow
is too much for the track motors
to take
13
D-40 valves D-40 Valve (HV1056)
The D-40 Valves diverts the oil from

the Kawasaki tandem pump either
to the tank, Tracks or crusher.
the D-40s are controlled by pilot
pressure from the CETOP valve
Pilot operated block To Crusher Tank
2 way valves
To Track
Pilot Control Relief valves

Pressure Lines set @ 340 Bar
Flow from the Pumps

14
Tracks
The tracks are controlled from a pilot pressure from the ce-top valve block
The pilot pressure moves the D-40 valves across and sends pump flow to
the track motors
The Ce-top valve also sends a pilot to remove the brake from the track
Brake Pressure in
Release and out ports
Track Motor
Displacement 90cc (5.49C/In)
Rpm 4729rpm
Gear Box Ratio R 142:1
Rpm After 33.3rpm
Running Pressure Empty 50-60Bar ( 725-870 PSI)
Motion control
Case
Valves
Drain
15
Tracks
X-line
We send a pressure down Checks
the brake line to release it.
We also send a pressure
into the track and this in
turn send a pilot signal
down the X-line check to
allow the return oil to flow
back to tank.
= Pressure
= Return Flow Brake release
= Case Drain Pressure @ 35
bar (508PSI)
16
Torque Arm of the Crusher
Return pressure
test point Drive pressure
Pressure Switch
set @ 320 Bar
(HV5009)
When the Cone is selected the
Kawasaki pump sends full flow
to the Cone motor to drive the Case drain
Crusher Cone Hydraulic Motor (HN1021)
Displacement 533cc (32.5 C/In)
We monitor the pressure going Rpm 1056rpm
Running Pressure Empty 50-60Bar ( 725-870 PSI)
to the cone so if the pressure
becomes too high
17
Crusher Manifold Block
The relief are in the circuit to prevent over pressurisation of the cone drive motor.
But they also control the slow down speed of the cone when switched off, the
higher you set the relief pressure the sooner the cone will come to a stop.
Forward Relief
set at 350 Bar
Anti cavitations control

valve (HV3029)
18
Start Pressure
Attached the pressure gauge where
indicated
350 Bar
Relief Now start the Cone on speed 2 until
running and then press stop
The pressure gauge should read 350
Bar if not follow the next procedure
Adjust the relief valve as indicated
(clockwise increases pressure anti-
Test Point clockwise reduces pressure)
repeat the same as procedure as
above until 350 bar is achieved
19
Brake Pressure
Attach a pressure gauge to the
point shown
100 Bar Relief
Now start the cone on speed 2
allow to run up to speed and
then press stop
The pressure should read 100
Bar if not adjust the relief shown
Test Point as required
(Anti-clockwise reduces pressure
Clockwise increase the pressure)
20
Pump PTO
The Triple pump is using the PTO off the side of the Bosch
pump and this is being driven at a 1:1 ratio.
It is supplying the Feed conveyor, Product Conveyor, the supply
to 6 lever manual control and clamp blocks.
Pressure lines
Sauer Danfoss Triple Pump

Pump Speed 1900 rpm
1 44cc (2.69C/in)
Displacement 2 44cc (2.69C/in)
3 19cc (1.16C/In)
1 80 l/m (21.13 USG/Min)
1 Flow @ 1900 rpm
2 2 81 l/m (21.13 USG/Min)
3 3 34 l/m (8.98 USG/Min)
21
Feed Conveyor Pump
TP P M The Feed Conveyor is being driven by a hydraulic
pump mounted onto the Tandem Bosch Pump which
in turn is being drive directly by the engine
Pressure
T out
Relief set @ 200 1

Solenoid Valve
Bar (2900 Psi)
Suction In
Sauer Danfoss Pump

Pump Speed 1900 rpm
Displacement 44cc (2.69C/in)
Flow @ 1900 rpm 80 l/min (US 21.13 G/Min)
Feed into the
block P5
22
Feed Conveyor Motor
The feed Conveyor is controlled via the control panel
It uses a proportional control valve to regulate the feeder speed
Pressure Pressure to Return to tank

Port B feeder Motor
Tank Port A
Case Drain
Feed Conveyor Motor Pressure

Displacemnet 49.1cc(3C/In) from Pump
Rpm 1618rpm
Running Pressure Empty 50Bar (725Psi)
Gear Box Ratio 31.1:1
Out Put Rpm 52 rpm
23
Product Conveyor Pump
TP P M
The Product Conveyor is being driven by a hydraulic
pump mounted onto the Tandem Bosch Pump which
in turn is being drive directly by the engine
Pressure
T
out
Solenoid Valve Relief set @ 240

Bar (3480 Psi)
Suction In
Sauer Danfoss Pump
Pump Speed 1900 rpm
Feed into the Displacement
Flow @ 1900 rpm
44cc (2.69C/in)
80 l/min (US 21.13 G/Min)
block P5
24
Product Conveyor Motor
The product conveyor motor is directly driven through a
high torque motor
Pressure line
Return Line
OPC Motor
Displacement 490cc (30 C/In)
Rpm 163rpm
Belt Speed 144 M/Min (472 F/Min)
Running Pressure Empty 55-60 Bar (797.7-870 PSI)
25
Third Slice of the Pump
The third slice of the

pump is supplying oil
to the
6 lever manual
control levers, Clamp 3
blocks, Ce-top valve
and the Anti spin
Sauer Danfoss Pump
Pump Speed 1900 rpm
Displacement 19cc (1.16C/in)
26
6 Lever Manual Control Valve
27
Clamp Block
There are two clamp blocks Right-hand

mounted to the machine Clamp block
The right one is used for

operating the 6 large
cylinder around the cone
and adjusting the Gap
setting
The left one is used for
clamping the concave lock Left-hand
and rotating the feed Clamp block
conveyor
28
Left-hand Clamp Block Solenoids
1= Accumulator pressure solenoid
2= Hydraulic pressure release

3&4 = Concave clamping cylinder adjustment
5&6 = Feed conveyor slew
7 = locking solenoid

29
Left-hand Clamp Block Reliefs
= Main relief for clamp blocks
stop the pressure going
though reaching 190 bar
= Relief to protect the concave
clamping cylinders over
pressurising set at 220 Bar
30
Right-hand Clamp Block
1= Accumulator pressure solenoid
2= Locking solenoid
3= Manual Tramp

4= Clamp Main Cylinders
5&6 = Cone gap setting adjustment

31
Right-hand Clamp Block Reliefs
= 220 bar relief for protecting

the main cone cylinders from
over pressurising
32
Clamp Block Charging the System
R/H Clamp
Block
L/H Clamp
Block
33
Running Condition/Overload
R/H Clamp
Block
L/H Clamp
Block
34
Opening the gap setting
R/H Clamp
Block
L/H Clamp
Block
35
Closing the gap setting
R/H Clamp
Block
L/H Clamp
Block
36
Clamp Block Pressure Gauge
The L/H pressure The R/H pressure
gauge will show the gauge will show the
pressure on the full pressure on the
bore side of the annulus side of the
clamping cylinders main cylinders
Pressure Switch for

Pressure Switch for
the clamping
the main cylinders
cylinders set @
set @ 150Bar
150Bar
37
Ce-Top Valve
Pressure In
Pressure to
Anti Spin 40Bar relief set on
the Ce-Top valve
The Ce-top valve is used to

pilot the following functions

1 = Not Used
2 = L/H Track Drive
3 = R/H Track Drive
4 = Cone Crusher Drive
38
Hydraulic Water Trap
The water trap is there to remove
water from the hydraulic system
when the machine is running,
It is a 10µ filter which has a
blocked filter gauge.
When this is in the Red the filter
must be changed.
It should be changed at 250
hours and then every 1000 hours
regardless of condition
39
Anti Spin
The anti-spin manifold is mounted on the side of the Tele-Smith cone crusher
Its job is to prevent the cone head turning clockwise thus reducing
manganese wear & keeping a film of oil over the bearings
Pressure reducing
valve set @3.5 Bar
M2
G2 P
T
M1
Kick down relief

set @ 138Bar
40
Normal Crushing Conditions
Cone Shaft
Planetary
Gear Box
Anti Rotation
Motor
41
Anti Spin & Kick Down Circuit
Cone Shaft
Planetary
Gear Box
Anti Rotation
Motor
@ 138 Bar the Kick

Down Relief Works
42
Anti Spin
It is possible for air to

become trapped in the
anti spin circuit to
remove this place a
hose onto the test
point and into a bucket
Run the engine until
the oil runs clear with
no air bubbles
43
PTO Triple Pump
The triple pump mounted on the engine PTO is being driven
at a ratio 1.14:1
This is driving the cooling fans, screen, fines conveyor &
the return conveyor

Pump Speed 1900x1.14 = 2166 rpm
1 31.8cc (1.94C/in)
Displacement 2 22.5cc (1.37C/In)
3 9.5cc (0.58C/In)
1 2 3 1 65.4 l/m (17.28 USG/Min)
Flow @ 1900 rpm 2 46.3 l/m (12.23 USG/Min)
3 19.6 l/m (5.18 USG/Min)
44
Fines, Cross & Over Size Conveyor
Flow Control
Fines Conveyor Motor

Fines motor Displacement 394cc (24.04C/In)
Rpm 166 rpm
Belt Speed 124M/Min (407 F/Min)
Cross Conveyor
Displacement 245cc (14.95 C/In)
Rpm 267rpm
X-Motor Belt Speed (MAX) 215M/Min ( 705 F/Min)
1 Over Size
motor Displacement
Over Size Conveyor
394cc (24.04 C/In)
Rpm 166 rpm
Belt Speed (MAX) 124 M/Min (407 F/Min)
45
Screen Box
The screen is being driven directly from one half of the Tandem pump
There is a flow diverter in line to reduce the speed of the screen box
down to 1120rpm
2
Screen Box Motor
Displacement 32.9cc (2 C/In)
Rpm 1407rpm (MAX)
46
Cooling Fan Supply
3

Pump Speed 1900x1.14 = 2166 rpm
Displacement 3 9.5cc (0.58C/In)
Flow @ 1900 rpm 3 19.6 l/m (5.18 USG/Min)
Drain to 5
Flow
block manifold
from the
pump
125 Bar relief

set point
Flow to the oil
coolers
47
Pump Supplying Lube System
The Pump supplying the

lube solenoids is driven
from the PTO (Power Take
Off) on the side of the
engine
This is driving the pump
and a 1.41:1 ratio so the
Lube Pump
pump is turning at 2679rpm Pump Speed 2679rpm (1900 x 1.41)
(1900rpm x 1.41) Displacement 17cc (1.04C/in)
48
Lube Control Manifold
1 = Hydraulic drive for the Cone
lubrication oil
2 = Pre-heat cone lube oil motor
3 = Hydraulic Drive for the cone
lube oil cooling fan

200 Bar Relief

49
Cone Lubrication Circuit
40.6cc Lube
Motor
130cc Lube
Pump
The main lube oil pump is being

driven from a 40.6 cc motor
spinning at approximately
1050rpm
This deliverers a maximum flow
of 130L/M through the cone
50
Cone Lubrication
Pressure
Temperature switch Oil
switch LT1 filter
Flow Meter
Thermo By-
pass valve
Temperature
switch LT2
51
Flow Meter
The flow meter is monitoring

the flow of lubrication oil
entering into the cone
When the cone is running
normally you will have a flow
of approximately 65 l/m
If the lube flow is below 45 l/m
then the cone will not start
52
Pressure Switch
The normal running

pressure for the
lubrication oil is
approximately 4-5 bar @
65 l/m
If the pressure drop
below 1.5 bar or above
13.5 bar for longer that
10 seconds then the cone
crusher will shut down
53
Temperature Switches
LT1 = If the temperature is below 25°C or above LT1
51.5°C (57°C with high ambient package
and 220 gear oil) then the cone will shut
down/not start.
When the temperature monitored here is
below 25°C the lube oil heat exchanger is
working. There for heating the oil ready to
start the cone
LT2
LT2 = The temperature monitored here
operates the lube oil cooler when the
temperature is above 35°C then the cooler
is switched on thus cooling the lube oil.
When the temperature drops below 32°C
then the cooler is switched off
54
Lube Filter and Thermo Switch
Thermo By-pass
2 X 25µ (micron) filters
When the temperature of the
lube oil reaches 35°C the by-pass
starts to close diverting oil
through the oil cooler
When the temperature of the
lube oil reaches 44°C the by pass
is fully closed sending full lube
flow through the cooler.
On the side of the filter
housing there is a blocked
filter gauge
55
Lube Oil Heat Exchanger
The oil from the lubrication tank is passed through a heat exchange until
the return oil from the cone reaches 25°C
At which point it stops the motor pumping oil through the heat exchanger
Heat Exchanger
Engine Coolant
66cc Motor
Lube Oil
124cc
56
Pump
Lube Oil Radiator Cooler
The oil cooler for the lubrication
tank is off unit the cone return Oil flow to cone
oil reaches 35°C crusher
The fan is then driven normally
until the cone is stopped Fan drive
motor
25.2 cc
The temperature
drop across the
cooler is
approximately 6-8°C
57
58
59

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PC21 Hydraulic Components

Ambient Temperature Range Grade of Oil Six 90µ suction

The hydraulic oil should be flushed every 250 hours to do this

Kawasaki Tandem Pump (HP1054)

Suction pressure test

40 Bar Variable setting

When tracking both solenoid are

The D-40 Valves diverts the oil from

Pilot Control Relief valves

Flow from the Pumps

Anti cavitations control

Sauer Danfoss Triple Pump

Relief set @ 200 1

Sauer Danfoss Pump

Pressure Pressure to Return to tank

Feed Conveyor Motor Pressure

Solenoid Valve Relief set @ 240

The third slice of the

There are two clamp blocks Right-hand

The right one is used for

= 220 bar relief for protecting

Pressure Switch for

The Ce-top valve is used to

Kick down relief

@ 138 Bar the Kick

It is possible for air to

Sauer Danfoss Triple Pump

Fines Conveyor Motor

Sauer Danfoss Triple Pump

125 Bar relief

The Pump supplying the

200 Bar Relief

The main lube oil pump is being

The flow meter is monitoring

The normal running

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