How To - Understanding Clutches REV3

How To – Understanding Clutches
This presentation deals with the PT Tech 12” Dry, 12” Wet and 14” Wet clutches, Desch clutch and has the
following appendices:
Appendix A: Troubleshooting using the PT Tech Display

Appendix B: SPN FMI codes
Appendix C: Machine Types Vs Controller types
Appendix C: Desch clutch
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Safety Alert Symbol
This is the safety alert symbol. It is used in this manual to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
Before you start

The information included in this document is intended for experienced personnel familiar with this type of
equipment.
Only trained and competent personnel should perform the work outlined in this document.
If there are any questions regarding the information provided or the application of the provided information,
please contact, techtraining@terex.com
Operation and maintenance of the machine must be done in accordance with the instructions in the operation
manual for the machine.
Review the safety, operation, and maintenance sections of the operation manual prior to performing this work.
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Lockout / Tagout
WHEN CARRYING OUT MAINTENANCE OR ADJUSTMENT THE FOLLOWING

LOCKOUT / TAGOUT PROCEDURE MUST BE FOLLOWED:
1.Ensure the machine is empty prior to shut down.

2.Disengage each machine component (e.g. conveyors, etc.) using the control levers.
Note:Turning off all machine components at once causes a pressure spike in the hydraulic circuit.
A slight pause between disengaging each component can prevent this spike from taking place.
3. Turn components off in the order:
A. Component one (e.g. Feeder)
B. Component two (e.g. Side Conveyor or Main Conveyor)
C. Component three (e.g. Crushing Chamber or Screenbox/Fines Conveyor)
D. Component four (e.g. Product Conveyor or RH/LH Side Conveyor)
4. Switch off engine and remove ignition key. Carry the key with you.
5. Engage emergency stop.
6. Use padlock to secure machine isolator at powerunit to prevent restart.
7. Place appropriate maintenance warning sign.
NEVER WORK ALONE
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Hydraulic System Safety

• Fluid escaping under pressure can penetrate skin and result in death or serious injury.
• Relieve pressure before disconnecting hydraulic lines.
• Stay clear of leaks and pin holes. Use a piece of cardboard or wood to search for leaks. Do not use you hands to check
for leaks.
• Fluid injected into skin must be surgically removed within a few hours by a doctor familiar with this type of injury, or
gangrene will result.
• High pressure fluid is present in operational hydraulic systems.
• Fluids under pressure are hazardous and can cause serious injury or death.
• Always consider gravity before carrying out any work on a hydraulic machine (stored energy risk).
• Any part of a hydraulic circuit that is supporting a load can remain pressurized (stored energy risk).
• Even after the system has been shut down, attempting to remove a hydraulic line or component that is supporting a load
can result in a sudden release of pressure and/or uncontrolled movement of the load, causing serious personal injury
and/or property damage.
• Modifications to hydraulic systems require written approval from Terex.
• Do not make repairs or adjustments to any hydraulic system unless you are competent or working under competent
supervision.
• If in doubt, consult the technical support department.
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Stay Safe
• ALWAYS use gloves or barrier cream.
• ALWAYS Lockout / Tagout machine prior to carrying out any work.
• ALWAYS immediately clean up any spilled hydraulic oil with correct absorbent material.
• NEVER work alone.
• NEVER use your hands to check for leaks (skin injection risk).
• REMEMBER: Hydraulic systems use fluids under high pressure which can cause major injury or death.
• REMEMBER: STAY SAFE, STAY ALIVE
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Personal Protective Equipment (PPE)
Your personal safety is the number one priority. Before performing any task or procedure you should wear the
following personal protective equipment as required:
•Safety glasses
•Steel toed safety boots
•Hearing defenders
•Hard hat
•Gloves (heat resistant gloves if performing hot work)
•Tight fitting overalls (fire retardant overalls if performing hot work)
•High visibility vest
•Full body harness (if working at height)
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PT Tech 12” Dry
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PT Tech 12” Dry - External Components
Display Unit Hydraulic Manifold

CMCDU-008 CHYMA-24V-001-DBC
Terex: 2451-9182 Terex: 65501467
Speed Pick-up
Clutch Controller Basic 2 CECSP-003-D
CMCMU-008-DBC59 Terex: 2451-9176
Terex: 2451-1608
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PT Tech 12” Dry – Speed Pick-up Sensor

When fitting the speed pick-up sensor ensure the tip is 1.5 turns away from drive ring face. Care must be taken
as it is possible to insert the sensor tip between drive ring splines. This will result in the drive ring damaging the
sensor as soon as the engine is started.
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PT Tech 12” Dry – Hydraulic Manifold

Pressure at the inlet port should be a minimum of 400Psi, with a flow of at least 7.5 L/min
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PWM Valve - CHYPV-002 (Labelled PBFB on the manifold) Powerscreen part number: - 2451-9179
Coil only - CECCL-002-D Powerscreen part number: - 2451-9178
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Pressure Transducer - CHYPT-003-D (Labelled PS on the manifold) Powerscreen part number: - 2542-
1611
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On/Off Valve - CHYSV-001 (Labelled DMDA on the manifold) Powerscreen part number: - 2451-9180
Coil only - CECCL-002-D Powerscreen part number: - 2451-9178
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Test Point (Labelled G on the manifold)
Tank Drain Line

5 PSI maximum
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Operation: Key On GP1 = 0 Psi
5 AMP
lt
o
24 V
24 Volts
+ 12 Volts
0.8 to 1.2 volt
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Engine Running GP1 = 225 Psi
5 AMP
24
Volt
24 Volts
400 PSI
+ 12 Volts
Minimum
225PSI
4 Volts
PWM Coil
0 PSI
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Clutch Engaging GP1 = 0-225 Psi
5 AMP
24
Volt
24 Volts
400 PSI
+ 12 Volts
Minimum
0 – 225 PSI
1 - 4 Volts
5 PSI
Maximum
ON/OFF PWM Coil
Coil
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Clutch Engaging
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Pro-Link Start Up
Pro-Link is the Diagnostic Software programme provided by PT Tech.
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Clutch Engaged GP1 = 225 Psi
5 AMP
24
Volt
24 Volts
400 PSI
+ 12 Volts
Minimum
225PSI
4 Volts
5 PSI
Maximum
ON/OFF PWM Coil
Coil
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Clutch Disengaged GP1 = 225 Psi
5 AMP
24
Volt
24 Volts
400 PSI
+ 12 Volts
Minimum
225PSI
4 Volts
PWM Coil
0 PSI
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Oil Travel
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PT Tech 12” Dry - Controller Light Functions
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PT Tech 12” Dry - Controller Operating Sequence

Key On:
•Power light ON
•Pressure transducer light ON
•J1939 CAN light ON (if connected)
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Engine Running, Clutch Disengaged:
•Power light ON
•Input speed light ON
•Pressure in “G” port of manifold is 220 psi
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Engine Running, Clutch Engaging:
•Power light ON
•Pressure in “G” port of manifold drops to 0 psi when engage button is pressed
•Clutch engaged light flashes after button is held for 3 seconds
•Controller “bumps” clutch until output and input speed are equal
•Pressure in “G” port fluctuates during clutch engagement process
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Engine Running, Clutch Engaged:
•Power light ON
•Pressure in “G” port of manifold is 220 psi
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Clutch Controller Basic 2 (CMCMU-008-

DBC 59) (SP1)
The SP1 denotation at the end of the part number shows that this clutch is for the 1300 Maxtrak.
This Controller disables the PT Tech display’s on/off button.
See “Appendix C” for machine details on controller types
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Grey Plug
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Black Plug
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Pro Link 2.1.1

Pro Link 2.1.1 displays the following data in real time:
•Clutch information;
– Clutch output speed
– Temperature switch
– Solenoid status
– Pressure sensor status
•Engine information;
– Coolant temperature
– Speed
– Percentage load
•Fault History For Diagnostics
•Data Viewing, Recording and

logging
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PT Tech 12” Dry - Maintenance

• Initial 10 hours
– Check clutch supply oil level
– Check hydraulic connections
– Check bolt tension
– All electrical connections
– Obtain oil base line
• Daily
– Check the oil level
• Every 500 hours

– Replace oil filter
– Oil sample (compare against base line for any treads)
• 5000 hours
– Internal inspection and service
• Contact PT Tech Representative
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Oil Information
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PT Tech 12” Wet
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PT Tech 12” Wet

Clutch 12” Wet VG Terex: 10.27.6007
Speed increase: 1:1.27 (on pump pad drive) HPTO12TY1-TCZA-3
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PT Tech 12” Wet - External Components
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Powerscreen parts (None PT Tech supplied)
Cooler Hydraulic Pump Oil Reservoir Filter Assembly
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Display Unit Torsional Coupling

CMCDU-008 FCACT5-F5B-A113
Powerscreen: 2451- Powerscreen:
9182 65502594
ADV 4 Clutch Controller

CMCMU-008-12WA Speed Pickup
Powerscreen: 65502598 CECSP-003-D
Powerscreen:
2451-9176
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PT Tech 12” Wet – Hydraulic Manifolds

The HPTO 12 Wet clutch can come with one of two different types of hydraulic manifold; Hydraforce or SUNN.
Hydraforce Manifold SUNN Manifold

CHYMA-24V-004 CHYMA-24V-005
Terex: 65502584 Terex: 65502588
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PT Tech 12” Wet – Hydraforce Manifold

400Psi (27.6 Bar) Relief Valve - CHYRV-400-001
Powerscreen part number: - 10.27.6004
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260Psi (18 Bar) Priority Relieving Valve - CHYRV-260-002
Powerscreen part number: - 65502585
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4.5 GPM (17L/M) Priority Flow Control - CHYFV-005
Powerscreen part number: - 10.27.6003
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200⁰F (93⁰C) Temperature Switch - CHYTS-200-001-D
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On/Off Coil - CHYSV-004
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PWM Coil - CHYPV-003
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Pressure Transducer - CHYPT-003-D
Powerscreen part number - 2452-1611
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Operation: Key On 5 AMP

Volt
24
24 Volts + 12 Volts GP1 = 0 Psi GP2 = 0 Psi
Ref #: tdoc00061 0.8 to 1.2 volt

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Engine Running 5 AMP

24 Volt
260PSI
Ref #: tdoc00061 ≥ 4.5 volts

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Engaging 5 AMP
24 Volt
+ 12 Volts GP1 = 260 Psi GP2 = 0-225 Psi

24 Volts
ON/OFF Valve
PWM Valve
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Pro-Link Start Up - Hydraforce
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Engaged 5 AMP
24 Volt
ON/OFF Valve
PWM Valve
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4 volts
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Disengaged 5 AMP
24 Volt
+ 12 Volts GP1 = 260 Psi GP2 = 0-225 Psi

24 Volts
ON/OFF Valve
PWM Valve
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Oil Travel – Hydraforce Manifold
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PT Tech 12” Wet – SUNN Manifold

500 Psi Relief Valve - CHYRV-500-001 Powerscreen Part No: - 65502589
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260 Psi Sequence Valve - CHYSC-004 Powerscreen Part No: - 65502592
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4 GPM Flow Control Valve - CHYFV-002 Powerscreen Part No: - 65502608
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Temperature Switch - CHYTS-200-001-D Powerscreen Part No: - 60541014
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Pressure Transducer - CHYPT-003-D Powerscreen Part No: - 2452-1611
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Brake Valve - CHYPV-004 Powerscreen Part No: - 65502590
Brake Coil - CECCL-004-M Powerscreen Part No: - 65502591
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Proportional Valve - CHYPV-002 Powerscreen Part No: - 2451-9179
24 Volt Coil CECCL-002-D Powerscreen Part No: - 2451-9178
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Shuttle Valve - CHYSH-003 Powerscreen Part No: - 65502593
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Operation; Key On 5 AMP

24 Volt
24 Volts + 12 Volts
GP1 = 0 Psi GP2 = 0 Psi
PWM Valve
Brake Valve
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24 Volt
24 Volts + 12 Volts
GP1 = 260-500 Psi GP2 = ≥230 Psi
PWM Valve
Brake Valve
Operates
during a self
check
Ref #: tdoc00061 ≥4.07 volts

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Engaging 5 AMP
24 Volt
24 Volts + 12 Volts
GP1 = 260-500 Psi GP2 = 0-225 Psi
PWM Valve
Brake Valve
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Pro-Link Start Up - SUNN
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Engaged 5 AMP
24 Volt
24 Volts + 12 Volts
GP1 = 260-500 Psi GP2 = 225 Psi
PWM Valve
Brake Valve
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Disengaged 5 AMP
24 Volt
24 Volts + 12 Volts
GP1 = 260-500 Psi GP2 = 0-260 Psi
PWM Valve
Brake Valve
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PT Tech 12” Wet - Disengaging Holding Brake
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PT Tech 12” Wet – Controller Light Functions
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PT Tech 12” Wet – Controller Operating Sequence

Key On:
•Power light ON
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PT Tech 12” Wet - Controller Operating Sequence

•Power light ON
•Pressure in ‘GP2’ port of manifold is at least 260 psi (17.9 bar) (+/- 10%)
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•Power light ON
•Output Speed light ON
•Clutch engaged light ON
•Pressure in “GP2” port of manifold is 225 psi (15.5 bar)
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Engine Running, Clutch Braking:
•Power light ON
•Output Speed light ON until shaft speed drops below 100 RPM
•Pressure in “GP2” port fluctuates until shaft is stopped then pressure returns to at least 260 psi (17.9 bar) (+/-
10%)
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Oil Filter
• Filter Fault
– The Clutch Controller (Master Unit) will ignore the filter switch for the first 30 minutes once the engine has
been started. This is to allow for cold start up when the filter will be in by-pass
– Once this 30 minutes has elapsed and there is a filter fault while operational the Clutch Controller will
start a 15 minute count down. It will also flash a beacon (if fitted) and flash the “Filter Clogged” LED.
– If after this time the clutch has not been stopped then the Clutch Controller will disengage the clutch
Filter Head Pressure sensor
Element
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ADV 4 Clutch Controller (CMCMU-008-12WA)

Beginning May 2012, controller types are distinguished by label colour. Ensure the correct master unit is being
used by using the below table.
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ADV 4 Clutch Controller (CMCMU-008-12WA)

Below is a table of SPN FMI codes related to the clutch this can be seen in grater detail in “Appendix B” at the
end of this document
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Grey Plug
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Black Plug
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PT Tech 12” Wet - Maintenance

• Initial 10 hours
– Check clutch supply oil level
– All electrical connections
– Obtain oil base line
• Daily
– Check breather for clogs or obstructions
– Check ventilation holes in bell housing for clogs and obstructions
• Every 500 hours

– Replace oil filter (don’t overfill)
– Replace tank breather
– Replace clutch breather
• Every 1000 hours

– Inspect pump drive gears
• 5000 hours
• Contact PT Tech Representative
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PT Tech 12” Wet – Oil Information
Temperature Range
Below -4⁰F (-20⁰C) -4⁰F to 32⁰F (-20⁰C to 0⁰C) Above 32⁰F (0⁰C)
Caterpillar Arctic (Cold
Mobilfluid LT Mobilfluid 424
weather TDTO)
Shell Spirax S3 TLV Caterpillar TDTO (10W only)
p es
y ESSO Hydraul50 Shell Spirax S4 TXM
lT
Oi
ESSO Hydraul 56
Vermeer VMF Ultra Gold
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Some signs which show that the wrong type of oil has been used:
Excessive wear on clutch

gears and friction plates
due to wrong oil type.
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PT Tech 14” Wet
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PT Tech 14” Wet
Clutch 14 Wet FX
Speed increase 1:1.27 (at the pump pad)
HPTO 14TW3-TCTCWBWB-3
Terex - 15.37.0018 (1500 Maxtrak)
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PT Tech 14” Wet – External Components
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Powerscreen parts (None PT Tech supplied)
Cooler Hydraulic Pump Oil Reservoir Filter Assembly
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Torsional Coupling
FCAC65A-F5N-A113-14 2 x Speed Pickups
Powerscreen: 15.37.0011 CECSP-003-D
Powerscreen: 2451-9176
Hydraulic Manifold
ADV 3 Clutch Controller
CHYMA-24V-001-DA
CMCMU-008-DA
Powerscreen: 65502599
Powerscreen: 15.37.0016
Display Unit
CMCDU-008
Powerscreen: 2451-9182
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PT Tech 14” Wet – Internal Components
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Pump Pad Mount
Pump Drive Gear

Breather
Idler Gear
Speed Pick-up
Bell Housing
Clutch Body (Cup)
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Cylindrical Bearing
Clutch Pack
Holding Brake Pad
End Seal
End Stock
Oversized Spherical Bearing
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PT Tech 14” Wet – Hydraulic Manifold

On/Off Valve - CHYSV-001 (Labelled DMDA on the manifold ) Powerscreen Part No: - 2451-9180
Coil only - CECCL-002-D Powerscreen Part No: - 2451-9178
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PWM Valve - CHYPV-002 (Labelled PBFB on the manifold ) Powerscreen Part No: - 2451-9179
Coil only - CECCL-002-D Powerscreen Part No: - 2451-9178
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Pressure Transducer - CHYPT-003-D (Labelled PS on the manifold) Powerscreen Part No: - 2452-1611
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Temperature Switch (200°F) Powerscreen Part No: - 60541014
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4 GPM (15L/M) Flow Control Valve - CHYFV-002 Powerscreen Part No: - 65502608
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260Psi (18Bar) Pressure Relief Valve Powerscreen Part No: - 65502600
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Operation: Key On 5 AMP

24 Volt
24 Volts + 12 Volts
GP1 = 0 Psi GP2 = 0 Psi 0.8 to 1.2 volt

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24 Volt
24 Volts + 12 Volts
225PSI
PWM Valve
GP1 = 400 Psi GP2 = 225 Psi 4 volts

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Engaging 5 AMP
24 Volt
24 Volts + 12 Volts
0 - 225PSI
PWM Valve
ON/OFF Valve
GP1 = 400 Psi GP2 = 0-225 Psi 4 volts

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Engaging
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Pro-Link Start Up
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Engaged 5 AMP
24 Volt
24 Volts + 12 Volts
225PSI
PWM Valve
ON/OFF Valve

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Disengaged 5 AMP
Volt
24
24 Volts + 12 Volts
225PSI
PWM Valve

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Oil Travel
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PT Tech 14” Wet – Controller Light Functions
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PT Tech 14” Wet – Controller Operating Sequence

Key On:
•Power light ON
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•Power light ON
•Pressure in ‘GP2’ port of manifold is at least 225 psi (15.5 bar)
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•Power light ON
•Output Speed light ON
•Clutch engaged light ON
•Pressure in “GP2” port of manifold is 225 psi (15.5 bar)
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Clutch Controller (CMCMU-008-DA) ADV 3

Beginning May 2012, controller types are distinguished by label colour (therefore this one will be Sky Blue).
Ensure the correct master unit is being used by using the below table.
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Grey Plug
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Black Plug
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Clutch Disengagement or Lock Outs

• Key on
– Pressure transducer return voltage is out of range 0.8 to 1.2 volts
• Engine running not engaged

– Clutch oil pressure 10% below 225Psi for a set period continually
– Temperature fault
• During engagement
– If the battery voltage to the clutch controller drops below 20Volts
– Too great a difference between the input and output speed (if you attempt an engagement and the mass is still
spinning)
– Engine speed dropped to zero or lost during engagement.
• While engaged
– Clutch oil pressure 10% below 225Psi for a set period continually
– Temperature fault after being present for 15minutes.
– Filter clogged after 15 minutes of being engaged.
– Engine speed dropped below 500 rpm.
– Too great a difference between the input and output speed
• Lockout
– In a lock out situation you will need to run the engine for five minutes continuously to clear the lock out fault.
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PT Tech 14” Wet - Maintenance

• 10 hours
– Check oil level
– Check electrical connections
– Base line oil sample
• Daily
– Check breather for clogs or obstructions
– Check ventilation holes in bell housing for clogs and obstructions
• Every 500 hours

– Replace oil (don’t over fill)
– Replace tank breather
– Replace clutch breather
• Every 1000 hours

– Inspect pump drive gears. Contact PT Tech for inspection procedure and additional information
• 5000 hours
– Contact a PT Tech representative
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Temperature Range
Below -4⁰F (-20⁰C) -4⁰F to 32⁰F (-20⁰C to 0⁰C) Above 32⁰F (0⁰C)
Caterpillar Arctic (Cold
Mobilfluid LT Mobilfluid 424
weather TDTO)
Shell Spirax S3 TLV Caterpillar TDTO (10W only)
p es
y ESSO Hydraul50 Shell Spirax S4 TXM
lT
Oi
ESSO Hydraul 56
Vermeer VMF Ultra Gold
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Some signs which show that the wrong type of oil has been used:
Excessive wear on clutch

gears and friction plates
due to wrong oil type.
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Appendix A
Troubleshooting using the PT Tech Display
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Troubleshooting Using Controller Display
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Appendix B
SPN FMI codes
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PT Tech Clutch Fault Codes

SPN FMI PARAMETERS FMI DESCRIPTION PARAMETER DESCRIPTION Adv4 Adv3 Adv2R Basic 2 Basic R
Machine battery voltage is below

Low Voltage at Clutch Voltage Below Normal, or
521500 4 20 volts while attempting to X X X X X
Controller Shorted to Low Source
engage clutch.
Machine Ignition Input speed detected but no
Current Below Normal or
521501 5 Voltage Missing at voltage received from ignition X X X X X
Open Circuit
Clutch Controller switch.
Input speed missing while
521502 11 Input Speed Missing Root Cause Not Known X X X X X
attempting to engage the clutch.
Pressure transducer offset is
Pressure Transducer Voltage Below Normal, or
521503 4 returning a voltage below 0.9 X X X
Fault Shorted to Low Source
volts.
Pressure transducer offset is
Pressure Transducer Voltage Above Normal, or
521503 3 returning a voltage above 1.2 X X X
Fault Shorted to High Source
volts.
Clutch Oil Pressure Data Valid but Below
521504 18 Clutch oil pressure is low. X X X X X
Fault Normal Operating Range
Clutch disengaged due to a
Clutch Oil Pressure Data Valid but Below
521505 18 pressure fault while it was X X X X X
Fault while Engaged Normal Operating Range
engaged.
Clutch Oil Data Valid but Above
521506 16 Clutch oil temperature is too high. X X X
Temperature Fault Normal Operating Range
Clutch Oil Clutch disengaged after 15
Data Valid but Above
521507 16 Temperature Fault minutes of a temperature fault X X X
Normal Operating Range
while Engaged being reported
Data Valid but Above Filter is clogged and must be

521508 16 Clutch Oil Filter Clog X X X
Normal Operating Range replaced.
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SPN FMI PARAMETERS FMI DESCRIPTION PARAMETER DESCRIPTION Adv4 Adv3 Adv2R Basic 2 Basic R
Clutch disengaged after 15

Clutch Oil Filter Clog Data Valid but Above
521509 16 minutes of a filter clog being X X X
while Engaged Normal Operating Range
reported.
PWM Coil may be defective with
521510 5 PWM Coil Fault too high of a resistance or a wire X X X
Open Circuit
may be cut
PWM Coil may be defective with
Current Above Normal or
521510 6 PWM Coil Fault too low of a resistance or a wire X X X
Grounded Circuit
may be grounded.
ON/OFF Coil may be defective
521511 5 ON/OFF Coil Fault with too high of a resistance or a X X X X X
Open Circuit
wire may be cut
ON/OFF Coil may be defective
Current Above Normal or
521511 6 ON/OFF Coil Fault with too low of a resistance or a X X X X X
Grounded Circuit
wire may be grounded.
Equipment Safety Switch not returning voltage to
521512 5 Fault while the controller. Clutch can not be X X X X
Open Circuit
Disengaged engaged.
Switch not returning voltage to
Equipment Safety Current Below Normal or the controller. Clutch will not
521513 5 X X X X
Fault while Engaged Open Circuit automatically disengage due to
this fault.
Clutch will not engage if the
Engagement Safety Data Valid but above
521514 16 engine speed is above 1100 X X X X X
Fault while Engaged Normal Operating Range
RPM.
Clutch Oil Engine speed went to zero or
Data Valid but below
521515 18 Temperature Fault was lost while attempting to X X X X X
Normal Operating Range
while Engaged engage the clutch.
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FMI
SPN FMI PARAMETERS PARAMETER DESCRIPTION Adv4 Adv3 Adv2R Basic 2 Basic R
DESCRIPTION
Data Valid but
Disengagement
Above Normal Clutch will not disengage if the engine speed is
521516 16 Prevented because of X X X X X
Operating above 1200 RPM.
Engine Speed
Range
Data Valid but While clutch was engaged the engine speed
Clutch Shock load with Below Normal dropped below 500 RPM most likely due to a
521517 1 X X X X X
Lockout Operating shock load at the mill. Clutch automatically
Range disengaged.
Data Valid but
Above Normal While attempting to engage, the clutch overload
521518 0 Clutch Overload X X X
Operating had not completely dissipated.
Range
While attempting to engage the clutch or while the
Data Valid but
clutch was already engaged too great a difference
Clutch Overload with Below Normal
521519 0 between clutch input speed and output speed was X X X
Lockout Operating
detected (slippage). Clutch automatically
Range
disengaged.
Clutch may go into lockout after 3 consecutive
attempts at any of the following: while attempting
engagement the engine speed goes to zero, the
Clutch in Lockout – Due Root Cause Not
521520 11 operator attempts to increase engine speed while X X X X X
to other Reason Known
the clutch is engaging, the operator pushed the
engage/disengage button while the clutch is in the
process of engaging.
Output speed signal present and then NOT
Lost Output Speed Root Cause Not
521521 11 present while engaged or Never present upon X
Signal Known
engagement attempt.
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Appendix C
Machine Types Vs Controller types
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Appendix D
Desch Revox clutch
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Desch Revox
The Desch Revox wet clutch is specifically developed for the drive line for jaw and impact crushers
It features a soft start up, 3 connections for hydraulic pumps and a reverse drive option
For the reverse drive option the clutch is equipped with a connection to assemble an attachment on the gearbox side
The drive pulley mounted on the output shaft is connected to the crushing chamber by vee belts
Technical details are listed below
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Component parts
The unit is equipped with a wet operating clutch inside the cast housing
The oil to actuate the clutch is located centrally via the rotor unit through the output shaft
Clutch engagement is hydraulically actuated via the machine hydraulic system
The clutch and gearbox oil are two totally independent systems
Engine side Output shaft side
Speed sensor
Wet clutch
Start up motor Clutch oil supply
Output shaft
Oil filter
Flexible coupling
Oil circuit pump
Pump connections
Gear oil drain plug Temperature sensor
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Start up overview
Prior to clutch engagement an auxiliary start up hydraulic motor is used for a soft start with the engine at idle speed producing
adequate flow to the motor
The auxiliary motor is located on the engine side of the gearbox housing and accelerates the chamber rotor from start to the idle
speed of the engine
Start up motor Rotational movement of flywheel

allowing rotor to pick up to
engine idle speed
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Start up overview
The auxiliary start up motor is directly connected to the output shaft
When the engine and output shaft are running at 800 rpm and 560 rpm respectively the clutch will engage allowing the engine
speed to be increased to working speed
The start-up time varies depending on oil flow and resistance from the crushing chamber unit
If there is a chamber blockage, start-up may not be possible and the PLC will stop oil flow to the start-up motor after 30 seconds
and flag an alarm on the PDM
Due to the hydraulic start-up function a dedicated electronic controller is not necessary
The PLC continuously monitors the engine, output shaft, crusher RPM and the E Stop circuit and can drop the oil flow to the start
up motor or clutch actuation at any time
Working speed
Idle speed
Start up motor
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Start up procedure
The machine is keyed on, the engine start request input is received by the PLC and the ECU allows the engine to crank
Oil is then supplied to the PVG banks
Port 2a on the LHS PVG and port 3b on the RHS PVG valve switch on
The start up motor is now engaged and allows the rotor speed to pick up
The PLC monitors the start up motor
and rotor
Shaft speed sensor
Rotor speed sensor
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Start up procedure
During start up port 2a on the LHS PVG is turned on to raise pressures to the PVG slices and clutch switch ON circuit to 41 bar
The start up motor becomes the pump and re circulates oil around the circuit taking from the distribution manifold as necessary
At synchronising speed port 3a on the RHS PVG is turned off and stops the oil supply to the start up motor
Pressure reducing
valve 50 bar
Distribution manifold
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Start up procedure
The clutch solenoid will be turned on allowing oil flow to the clutch actuation
This pressure will be continuously monitored
The engine will then ramp up to working speed
Clutch actuation
Clutch pressure sensor
3 way 2 position valve
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Start up summary
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PLC connections
There are 2 main outputs connected from the PLC to the clutch functions
Clutch on/ off
Clutch start proportional signal
The on/ off status will be displayed using green icons
Clutch status
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PLC connections
The clutch start signal allows the oil flow to the start up motor to take the rotor from idle to clutch engagement speed
The output power is sent from Node 1
The PWM signal is sent from the PLC
These are sent via the hydraulic cabinet harness to the solenoid of slice 3 on the PVG
The ramp up time can be adjusted by the user ( top level password required)
The desired clutch output speed is calculated using a 0.7 ratio ( engine to clutch speed)
The on/ off solenoid switches on to allow oil to be diverted to engage the clutch once ramp up/ synchronisation success
Hydraulic Clutch on/off Clutch start signal

cabinet solenoid RHS valve bank
harness
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Node 1 connections
Other remaining inputs and output connections are operated through the CANBUS and Node 1
Clutch Pre-Start( X21 Pin 1) turns on PVG LHS Slice 2b to supply the required 41bar + 3bar for the clutch to start
This connection runs from the Node 1 through the hydraulic cabinet harness and connects to the solenoid via SKT 69
Clutch pressure
Clutch gear oil
temperature
Clutch pre
start
Clutch speed
Crusher speed
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Node 1 connections
The clutch pressure sensor ( X11 Pin 14) monitors the clutch pressure
Alarm – Clutch pressure fault – Less than 37 bar, more than 41 bar – Clutch will not engage
Alarm – Clutch low pressure fault – Less than 33 bar for 5 seconds – Clutch will shut down under control
Alarm – Clutch high pressure fault – More than 46 bar for 5 seconds - Clutch will shut down under control
The clutch gear oil temperature sensor ( X11 Pin 12) monitors gear oil temperature
Alarm – Clutch temperature warning fault – More than or equal to 100 degrees for 30 seconds – Warning displayed on PDM
Alarm – Clutch temperature shutdown – More than or equal to 105 degrees for 60 seconds – Controlled shutdown and warning
displayed on PDM
Clutch Clutch gear oil

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Rev: 3 sensor sensor
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Node 1 connections
The clutch output speed sensor ( X10 Pin 4) monitors the clutch output speed
Alarm – No output speed detected – No output speed detected at Start up – Clutch will not engage
Alarm – Clutch speed fault – If equal to or minus 50 rpm of desired output speed at Start up – Clutch will not engage
Alarm – Clutch slow speed fault – minus 2.5% of desired clutch output speed – Clutch will not engage
The crusher output speed sensor ( X10 pin 2) is located at the driven pulley and monitors the crusher output speed, it is a
proximity sensor and counts 6 pulses for each revolution of the chamber rotor
Clutch output Crusher output

speed sensor speed sensor
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Node 1 functions
Node 1 is located in the DC Panel and Inputs and Output Signals are transmitted via the CANBUS system which operates
between other PDM, PLC other nodes
Inputs and outputs can be monitored from the PDM
Crusher speed
Clutch speed
Clutch pre start
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Aut: N McClelland

How To - Understanding Clutches REV3

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How To – Understanding Clutches

How To – Understanding Clutches

Appendix A: Troubleshooting using the PT Tech Display

Safety Alert Symbol

Before you start

WHEN CARRYING OUT MAINTENANCE OR ADJUSTMENT THE FOLLOWING

1.Ensure the machine is empty prior to shut down.

Hydraulic System Safety

• ALWAYS use gloves or barrier cream.

• ALWAYS Lockout / Tagout machine prior to carrying out any work.

• NEVER work alone.

• REMEMBER: STAY SAFE, STAY ALIVE

Personal Protective Equipment (PPE)

PT Tech 12” Dry

PT Tech 12” Dry - External Components

Display Unit Hydraulic Manifold

PT Tech 12” Dry – Speed Pick-up Sensor

PT Tech 12” Dry – Hydraulic Manifold

PT Tech 12” Dry – Hydraulic Manifold

PT Tech 12” Dry – Hydraulic Manifold

PT Tech 12” Dry – Hydraulic Manifold

PT Tech 12” Dry – Hydraulic Manifold

Tank Drain Line

Operation: Key On GP1 = 0 Psi

0.8 to 1.2 volt

Engine Running GP1 = 225 Psi

Clutch Engaging GP1 = 0-225 Psi

Clutch Engaged GP1 = 225 Psi

Clutch Disengaged GP1 = 225 Psi

PT Tech 12” Dry - Controller Light Functions

PT Tech 12” Dry - Controller Operating Sequence

PT Tech 12” Dry - Controller Operating Sequence

PT Tech 12” Dry - Controller Operating Sequence

PT Tech 12” Dry - Controller Operating Sequence

Clutch Controller Basic 2 (CMCMU-008-

See “Appendix C” for machine details on controller types

Pro Link 2.1.1

•Fault History For Diagnostics

•Data Viewing, Recording and

PT Tech 12” Dry - Maintenance

• Every 500 hours

PT Tech 12” Wet

PT Tech 12” Wet

PT Tech 12” Wet - External Components

PT Tech 12” Wet - External Components

Cooler Hydraulic Pump Oil Reservoir Filter Assembly

PT Tech 12” Wet - External Components

Display Unit Torsional Coupling

ADV 4 Clutch Controller

PT Tech 12” Wet – Hydraulic Manifolds

Hydraforce Manifold SUNN Manifold

PT Tech 12” Wet – Hydraforce Manifold

PT Tech 12” Wet – Hydraforce Manifold

PT Tech 12” Wet – Hydraforce Manifold

PT Tech 12” Wet – Hydraforce Manifold

PT Tech 12” Wet – Hydraforce Manifold

PT Tech 12” Wet – Hydraforce Manifold

PT Tech 12” Wet – Hydraforce Manifold

Operation: Key On 5 AMP

24 Volts + 12 Volts GP1 = 0 Psi GP2 = 0 Psi

Ref #: tdoc00061 0.8 to 1.2 volt

Engine Running 5 AMP