Text
                    Rev-05
Author: Herbie Jones
Materials Processing


J-1175 SCHEMATIC ЩТЕРЕХ Materials Processing
J-1175 SCHEMATIC ЩТЕРЕХ Materials Processing HOT CLIMATE & STOCKPILER DRIVE
J-1175 HYDRAULICS ЩТЕРЕХ Materials Processing WATER PUMP OPTION
J-1175 HYDRAULICS - PRE-SCREEN ЩТЕРЕХ Materials Processing
POWER UNIT ORIENTATION-LHS FIXED DISPLACEMENT TANDEM PUMPS VARIABLE DISPLACEMENT TANDEM PUMPS 6 PORT DIVERTER’S (Upper valve out of sight) PRESSURE RELIEF VALVE T-BLOCK CEE-TOP 5 PRESSURE TRANSDUCER Charge/Crushing Pressure HYDRAULIC PULLROD OVERIDE BUTTON FLOW CONTROL/S PRE-SCREEN BLOCK JAW ADJUSTMENT CEE-TOP 3
POWER UNIT ORIENTATION-RHS ЩТЕРЕХ Materials Processing OIL COOLER HIGH PRESSURE INLINE FILTER (6 MICRON) NODE BLOCKS #1,2 & 3 HYDRAULIC OIL TEMPERATURE SENSOR RETURN MANIFOLD HYDRAULIC PULLROD ADJUSTMENT BLOCK
HYDRAULIC TANK ЩТЕРЕХ Materials Processing Sentry Breather 2 off Return filters 3 Off suction pipes for the tandem and single pumps Hydraulic oil level sensor Oil fill pipe > The sentry air breather replaces the standard breather cap on a tank. The air sentry breather uses a three stage filtration system to ensure optimum protection by removing water vapour and solid contaminants before they enter the oil tank. > The hydraulic oil level sensor is located next to the suction lines. If the oil level drops below minimum it will shut the engine down and will display ‘Low Hydraulic Oil’ on the main display screen. > The return filters have a blockage indicator, mounted on both filter housings. The filters should be changed every 500hrs, but if the indicator is in the red and showing a blockage then the filter elements should be changed. The filters have a rating of 10 MICRON.
RETURN FILTER & BREATHER ЩТЕРЕХ Materials Processing RETURN FILTER ASSEMBLY SENTRY AIR BREATHER
HYDROSTATIC SYSTEM ЩТЕРЕХ Materials Processing CRUSHER DRIVE
HYDROSTATIC SYSTEM Materials Processing TRACK DRIVE Inlet flow Case pressure Control pressure Charge pressure High pressure
VARIABLE DISPLACEMENT PUMP ЩТЕРЕХ Materials Processing SERVO PRESSURE PORT SERVO PISTON (SWASH ADJUSTMENT) SWASH PLATE & ARM NEUTRAL SWASH POSITION PUMP PISTONS > This is a sectioned view of the internal workings of variable displacement piston pump. > The pump is in a neutral position at the moment, this is noted by the way that the swash plate is at 90o to the axis of the pump pistons, as shown. > This means that the pistons are not being able to pump oil and generate pressure.
VARIABLE DISPLACEMENT PUMP ЩТЕРЕХ Materials Processing FULL SWASH POSITION DRIVEN HUB > You can now see how the servo piston has been shifted to the right hand side, thus shifting the linkage arm and put the swash plate to its full operating angle, shown. > The pistons are now being drawn ‘in & out’ as the driven hub rotates thus creating a sucking and pumping effect on the opposite ends of the pistons as they are being spun against the angled swash plate. > A sectioned view can be seen on the following slides.
HYDROSTATIC PUMP ЩТЕРЕХ WORKING VIDEO Materials Processing
HYDROSTATIC PUMP - WORKING ЩТЕРЕХ Materials Processing
PUMPS SCHEMATIC ЩТЕРЕХ Materials Processing > This is the schematic variable displacement pumps. Our charge oil enters at the ‘G’ ports, and the ‘MA & MB’ ports are the operational lines for the hydrostatic system. > If the pressure in the system exceeds the value of 395 BAR then ports ‘MA & MB’ will cross and allow oil to circulate within the system only for a given time frame.
PUMP SCHEMATIC ЩТЕРЕХ Materials Processing
PUMP CONTROL Materials Processing Pump Displacement Fwd direction 0 - 100% Servo control pressure Rev direction Servo control pressure Fwd direction Pump Displacement Rev direction 0 - 100% > Shown in the above graph is how the pump displacement is controlled via the pilot pressure (Charge oil) being sent to the servo in either a forward or reverse direction, > With only the engine running no oil is being pumped, when the PLC starts to increase the mA value the servo oil pressure increases accordingly, at 6 BAR Servo pressure the pump displacement starts to change slightly and the pump and just starts to deliver oil to the crusher motor once the servo pressure reaches its maximum of 18 BAR the pump will have reached its maximum displacement.
CRUSHER FIXED DISPLACEMENT MOTOR Materials Processing 0.35 BAR 261kW @ 1900 RPM CATERPILLAR C9 T3 Internal PORV's 395 Bar (not shown) MAIN CONV'R TAIL RAISE/LOWER PILOT OPERATED DIRECTIONAL VALVE (6 PORT DIVERTER) SIDE CON 495cc/rev 10.25.5210 J VIBRATING • FEEDER • 450-850 rpr -21-40 LPM I 85CC/REV 60 LPM 981 MOTOR RPM 350 BAR-192KW 80 Lrr MANIFOLD DRAIN HOSE вЕТиеч H*Ktrtl_D Aside conveyor 1 33cc/rev BOSCH A4VG110 Set TiANttM PUMP - 10.24.3692 46cc/rev PRIORITY BYPl 175 BAR FEEDER 80 LPb MAIN CONVEYOR 80 l_P "OLDING RAMS (SEE SHEET 2) PURGE VALVE SET AT 16 BAR RIGHT TRACK MOTOR The Crusher Motor is fixed @ 355CC/REV RETURN MANIFOLD
PURGE VALVE BREAKDOWN Materials Processing housing. > When the crusher is running the crusher motor purge valve uses the high pressure oil (On one side of the motor) to shift the spool & allow low pressure oil (From low pressure side of motor) to pass over the 16 BAR relief this an average of 16 LPM (approximately)this purged oil is also used to flush the motor before leaving with the case drain oil to be cooled by the Hydraulic cooler. NOTE: THE PURGE RELIEF IS FACTORY SET AND SHOULD NOT BE ADJUSTED!!!
6 PORT DIVERTER SIDE CONVEYOR PRIORITY 175 BAR -■I LOT OPERATED located inside the LHS of the main drive motor. IONAL VALVE T DIVERTER) 761RW @ 1900 RPM CATERPILLAR Г.9 ТЯ -CEDING :see s Webtec 10.16.6115 flow to either the tracks or crusher shown. SIDE GDIS 495cc/rev L0.£5.521C 395cc/rev ^ILOT OPERATED LI IL _:т г nN AL V AL . (6 PORT DIVERTER Materials Processing hydraulic cabinet. The purpose of the diverters is to change the oil The diverters are pilot operated as
T-BLOCK/PRESSURE TRANSDUCER ЩТЕРЕХ HYDRAULIC CABINET LHS Materials Processing !175 BAR FEEDER 80 LPM MAIN CONVEYOR 80 LPM PILOT OPERATED -.DIRECTIONAL VALVE 1(6 PORT DIVERTER) The crusher pressure transducer located in the ‘T’ block measures the hydrostatic charge pressure with only the engine is running, Once the crusher is started the transducer will then be reading the actual crushing pressure and will be displayed on the PDM screen. The T-Block is located on the LHS wall of the Hydraulic cabinet (Just below the 6 port diverters.) Its purpose is to combine the oil flows from both Hydrostatic pumps (46 & 47) for the main crusher drive system. CRUSHER MOTDR (BOSCH A2FM> HOTDRi 355 cc/rev - 1025.4044
FIXED DISPLACEMENT PUMPS ЩТЕРЕХ Materials Processing SIDE CONVEYOR PRIORITY BYPASS not ^nnwn) MAIN CONVEYOR 80 LPt“ < 1DI№ rBQi 4 F4 -OLDING RAMS :SEE SHEET 2) ZDNV'R TAIL RA IS /I wh R Э1ЕПТ OPERATED DIRECTIONAL VALV =TLOT OPERATED DIRECTIONAL VALVE C6 PORT DIVERTER) SIDE CON 495cc/rev L0.£5.521C i VIBRATING 28cc Single pump Side conveyor, Magnet, Pullrod & Main Conveyor tail (Raise/Lower) FEEDER CATERPILLAR C9 T3 [ 450-850 rpr -21-40 LPM 85CC/REV 46/46cc Tandem pump Pump nearest engine driving the Feeder & the pump on the outside driving Main conveyor & supplying Charge oil (For Hydrostatic system).
HYDRAULIC OIL COOLER/S ЩТЕРЕХ Materials Processing 5 Bar Check Valve > The hydraulic oil cooler is located in the RHS of the main control cabinet. The return line from the feeder, main conveyor and Cee-top5 is combined to form the inlet line to the oil cooler. > This line also has a check valve set at 5 BAR, meaning that if the pressure of oil is too high then the in the cooler, a certain amount will bypass the cooler and go straight to tank until the pressure is less than 5 BAR. > The thermostat switch will start the fan once the oil temperature has reached approximately 47 degrees. Oil return to tank By-Pass Oil from check valve Oil inlets to cooler (Optional) Additional Electric Hot Climate Cooler (Fitted above magnet area).
CEE-TOP 5 MAIN HYDRAULIC VALVE BLOCK gTEREX Materials Processing
CEE-TOP 5 MAIN HYDRAULIC VALVE BLOCK gTEREX Materials Processing DIRT CONVEYOR SOLENOID T MAGNET CONVEYOR SOLENOID TAIL SECTION (Raise/Lower) FEEDER CONTROL SOLENOID MAIN CONVEYOR SOLENOID
RELIEF VALVES (C-Top5) ЩТЕРЕХ Materials Processing FEEDER RELEIF VALVE FEEDER PRESSURE COMPENSATOR VALVE CHARGE PRESSURE RELIEF VALVE MAIN CONVEYOR RELIEF VALVE MAIN RELIEF FOR DIRT & MAGNET CONVEYORS, TAIL SECTION RAISE/LOWER & MANUAL VALVE BLOCKS
ADJUSTMENT OF RELIEF VALVES VALVE COVER NUT ALLEN-KEY VALVE ADJUSTMENT, 4.5mm 1) 2) Materials Processing RELIEF VALVES Main Conveyor Charge Pressure VALVE ADJUSTMENT LOCKING NUT REMEMBER!! Do not exceed 210Bar, or Finlay recommended setting, for the main conveyor. If you need to adjust the setting of the relief valves, once you have consulted Finlay, you can proceed as follows: > Remove the valve cover nut. > Then loosen the locking nut in an anti-clockwise direction, taking care not to let the valve adjuster move with the locking nut and thus disrupt the original setting. > By using a 4.5mm align-key you can increase the setting by turning the valve adjuster in a clockwise direction.
MAIN CONVEYOR SPEED ADJUSTMENT gfEREX Materials Processing location flow > The Webtec flow control is located inside the main hydraulic cabinet behind the middle support member of the power unit and connected to the Cee-Top 5 via a 90 degree fitting. > To alter the speed of the main conveyor simply turn the gauge, the Priority flow goes to the main conveyor motor while the bypass is returned back into the charge line for the Hydrostatic system.
MAGNET SPEED ADJUSTMENT Materials Processing Adjusting Dial Webtec flow control location > The Webtec flow control is located inside the main hydraulic cabinet and connected to the Cee-Top 5 via a 90 degree fitting. > To alter the speed of the Magnet conveyor simply turn the gauge, the Priority flow goes to the magnet motor and the bypass is connected into the return side of the magnet motor.
ORIFICE PLUGS FOR FEEDER CONTROL gTEREX Materials Processing > The 2 orifice plugs shown, both have a 0.5mm hole drilled in them to vent oil > The plugged port, next to the feeder pressure port ‘G’, must be removed, and then the 2 orifice plugs can be removed if necessary using a 3mm align key. 32 over the pressure compensator valve. > They are located under the plug port, next to the feeder pressure port labelled ‘G’.
PIPING CONFIGURATIONS Materials Processing BOTTOM VIEW OF MANIFOLD “A” Pressure Line to Dirt Conveyor “F” Lower Tail Section (J-1175 ONLY) “B” Return Line from Dirt Conveyor “G” Pressure Line to Feeder “C” Pressure Line to Magnet “H” Pressure Line to Main Conveyor “D” Tank Line “J” Charge Line “E” Raise Tail Section (J-1175 ONLY)
PIPING CONFIGURATIONS - CONT’D j^TEREX Materials Processing LHS VIEW OF MANIFOLD RHS VIEW OF MANIFOLD P1 - PRESSURE LINE TO DIRT CONVEYOR, MAGNET, TAIL SECTION RAISE/LOWER & MANUAL VALVES. P2 - PRESSURE LINE TO FEEDER P3 - PRESSURE LINE TO MAIN CONVEYOR T - TANK LINE GUAGE - CHARGE PRESSURE TEST POINT (Before Filter)
CHARGE PRESSURE ЩТЕРЕХ Materials Processing > The relief valve labelled #14 is the Main Conveyor primary relief valve, set at 210 Bar (maximum). If the Main conveyor stalled under load you can see how the relieved oil will still be held at 40 BAR via the 40 BAR relief labelled #8. > This relief valve is the charge oil main relief and is set in factory around 38-40 Bar. The charge pressure can be checked from the gauge port shown opposite. This arrangement is such to ensure that if there is blockage or seizure on the Main Conveyor and the oil is forced to dump over the primary relief we will still have charge oil going to the hydrostatic pumps. > When the Main Conveyor is not being run the oil passes through the valve, labelled 2B and sent out port ‘J’ to the Charge Oil High Pressure in Line Filter then on to the Hydrostatic Pumps. > When the Main Conveyor is engaged the pressurised oil will be supplied to the Main Conveyor motor through port ‘H’ and its return oil will then be linked back into the charge line leaving port ‘J’.
CHARGE PRESSURE CONT’D Materials Processing TEST POINT CHARGE PRESSURE RELIEF VALVE > Charge pressure is very important to the workings of this hydraulic system, it is very important to adhere to the proper service intervals. > Track brake release, Track diverters & Purge operation rely solely on good Charge Pressure. > There are other relief valves located in the variable displacement pumps, crusher motor and track drive motors that control the charge oil pressure. > The charge oil is used to adjust the servo piston on the main pumps, it also pumps in cool oil into the hydrostatic system, it is used as the pilot pressure to divert the 6 Port Diverters and to release the track brakes.
CEE-TOP 3 HYDRAULIC BLOCK ЩТЕРЕХ Materials Processing ^ILOT OPERATED DIRECTIONAL VALV C6 PORT DIVERTER) control of the brakes when in whether the machine will be in The Cee-top 3 diverts oil for the tracking mode and controls the pilot operated directional valves (6 port diverter valves) to determine tracking or crushing mode.
TRACK CONTROL VALVE ЩТЕРЕХ Materials Processing •Drive line •Drive line • Drain line to tank • Case drain line • Brake release line from Cee-top3 • Main relief valve • Purge valve relief valve
FLOW REGULATOR VALVE & PRV Materials Processing Pressure Relief Valve Priority/By-pass Control setting which can be adjusted using an Allen key Standard Flow Control J By-pass line to Cee-top 5 Priority line to Hydraulic Pullrod An extra flow control valve is also fitted if any one of the following options are required, > Hydraulic Stockpiler drive > Hydraulically driven water pump In this example the pressure line from the single pump firstly goes through a PRV, then to the flow control valve. By-pass pressure line is transferred to the Cee-top 5, which in turn is operating the dirt conveyor. The Priority pressure line goes to the hydraulic pull rod. Note that if any of the other options are required then 2 Flow Controls valves are required.
1) Outlet Pressure Port (To flow) 2) Pressure Port 1 (From Pump 3) Gauge Point Port 4) Relief Port to tank 5) Mounting Holes 6) Relief Setting Adjustment
FLOW REGULATOR VALVE 1) 2) 3) 4) 5) Pressure port Regulated Port Bypass Port Flow Adjustment Mounting Holes > Once you have correctly fitted the flow regulator valve, you need to ensure that the valve has been set correctly as the flow going to the pull Mounting Position of Flow Regulator Valve. rod is the REGULATED flow. Materials Processing > You must not divert the full flow of the pump to the pull rod system. Flow Adjusting Screw Locking Nut > Firstly loosen the locking nut, then make sure that the adjustment screw is completely turned in, clockwise. > Then turn it back, anti-clockwise, 1/4 turn. > This setting will suit initially and will stand as protection for the pull rod hydraulic system, as the bulk of the oil is being diverted to the bypass line.
MAIN PRV & FLOW REGULATOR ЩТЕРЕХ Materials Processing BYPASS CONVEYOR HOPPE? LEFT WALL HOPPER RACK WALL HOPPER &SGHT WALL LP EXTENDED BYPASS CONVEYOR ELESCDPIC #P MAIN-CEN HEAD ХЕСПИГч EXTENDED BYPASS CDNVEYQR TELESCOPIC Flow regulator valve, mounted after PRV and before main Cee-Top 5 hydraulic manifold. 1/5 JsAk Main pressure relief valve, set @175 Bar, direct from pump.
J-1175 HYDRAULIC PULL ROD ЩТЕРЕХ Materials Processing Hydraulic Pull Rod Controls Hydraulic Pull Rod Control Bank & Pressure Release Valve Over-ride Button & Adjustment Directional Valve > The manual restricting valve #2 must be in the open position, screwed fully out. > If the manual restrictor valve is left in the closed position when the dump solenoid is energised the pressure in the Pullrod system will not be able to drop to zero, & adjustment of the jaw may not be possible. > Possible damage may be incurred on the adjusting wedges’ contact faces.
HYDRAULIC PULL ROD ADJUSTMENT ЩТЕРЕХ CSS ADJUSTMENT Materials Processing STEP 1: Stop the jaw in its fully open position. STEP 2: Press & hold the over-ride button. STEP 3: Adjust jaw setting with directional valve. STEP 4: Release over-ride button & begin crushing.
J-1175 FULLY HYDRAULIC PULL ROD ЩТЕРЕХ Materials Processing COMPONENTS: 1) Manual Dump Valve 2) High Pressure Relief Valve 3) Pressure Gauge 4) Solenoid Dump Valve 5) Low Pressure Relief Valve (Behind Pressure Transducer) 6) Pressure Transducer 7) Main Solenoid Directional Valve
SETTING CORRECT SPRING TENSION ^TEREX Materials Processing MAX PRESSURE > To set the spring tension set your engine rpm to 1900 rpm. (Two people required to complete this task.) > Firstly remove the ram stopper plate at the rear of the support tube (figurel) Manual dump Valve Ram Stopper Plate > Then open the manual dump valve so as to allow the spring to extend to its full length, then mark where the rear guide runner is in the tube section, shown in figure 1. > Then close the manual dump valve and allow the ram to charge up. > When the guide runner has stopped moving, measure how far it moved when compressing the spring, This should be 80mm (This gives the spring a compressed length of 300mm
SETTING CORRECT SPRING TENSION |^|TEREX Materials Processing MAX PRESSURE > You can adjust the settings on the screen accordingly to give you the correct measurement, i.e. if under 80mm, increase the value slightly and then press the oil dump button and allow the pressure to drop in the ram, then release the button and allow the ram to recharge then repeat the measurement. > Repeat this step until the correct measurement is achieved. Adjust this value to get the correct spring compression. IE Increase this value if the pullrod spring compresses less than 80mm and decrease this value if the spring compresses more than 80mm
SETTING CORRECT PULL ROD RECHARGE LENGTH (MIN PRESSURE) STEREX Materials Processing Once the correct high pressure setting has been achieved, the low pressure setting must now be set. > The low pressure setting needs to be set such that the rear guide runner moves back a max of 10-12mm before the system re-charges. > To set this, 1 person must open the manual dump valve SLIGHTLY. (This releases the pressure on the pullrod ram and allows it to creep releasing the spring tension.) > The other must sit with a tape measure on the rear runner and measure the distance the rear runner travels back before the ram recharges. > If the measurement is bigger than 10-12mm, then the tension Min value on the screen needs to be increased slightly. and the measurement repeated. > If the measurement is smaller than 10-12mm, then the tension Min value on the screen needs to be decreased slightly and the measurement repeated. > It is important that the movement of the spring between the high and the low pressure set points is a Min and Max of 10mm & 12mm respectively).
SETTING CORRECT PULL ROD RECHARGE LENGTH (MIN PRESSURE) S TEREX Adjust this value to get the correct spring compression. Increase this value if the pullrod creeps back more than 10mm before the system recharges. Decrease the value if the pullrod creeps back less than 10mm before the system recharges. Materials Processing IF THE DIFFERENCE IS TOO GREAT THE TENSION ON THE TOGGLE PLATE WILL NOT BE SUFFICIENT ENOUGH AND IT COULD FALL OUT DURING OPERATION! PLEASE NOTE THE TENSION MAX PRESSURE SETTING MUST BE GREATER THAN THE TENSION MIN PRESSURE SETTING.
CHECKING SPEED OF RAM MOVEMENT gТЕREX Materials Processing > When the ram has stopped moving, make note of what pressure is being displayed on the pressure gauge. The nominal pressure in the pull rod system should be approximately 60 - 65 bar. — PULL ROD PRESSURE GAUGE > Once complete, keeping the manual valve shut, press the red button on the control box, hold down for a few seconds then release it. > At this moment watch the speed at which the ram closes in on the spring, it should take no more than 3 or 4 seconds to compress at an engine speed of 1900rpm. > If it takes over 4 seconds for the ram to compress the spring you need to turn the adjusting screw on the flow regulator fractionally anti-clockwise until the correct speed is reached. > If it goes too quickly, fractionally turn the flow regulator screw clockwise until the correct speed is reached.
HYDRAULIC STOCKPILER ЩТЕРЕХ Materials Processing 3 1 2 Stockpiler Drive with bridge hose REG p[pW Regulator PRV 175 Bar 4 BYP 1 2 Stockpiler Relief Valve Bridging Hose Main PRV 175 Bar Cee-Top 5 Hy drawl c Manifold Approximate oil flow available at stockpiler supply 36Lt/min. 3 4 Timing Gear Hydraulic Pump CAT C9 ACERT Engine Stockpiler Drive Location
HYDRAULICALLY DRIVEN WATER PUMP gTEREX Materials Processing 1 2 4 v 7 G) (2 (3 ® Flow Diverter Valve Motor Flow Control Valve Hydraulic Drive Motor Motor to Pump Coupling Water Pump Approximate oil flow available to hydraulic motor: 36Lt/min, delivering 1200rpm to water pump. At given rpm the water pump will be capable to deliver up to 54Lt/min @ 6.9 Bar. Water Main Relief Valve Water Pump Location Running dry stack
PRE-SCREEN - OPTION ЩТЕРЕХ By-pass to Vibrating feeder Flow Regulator Valve 1 Materials Processing Anti-Cavitation loop PRV Priority (Regulated, to Pre screen) Pre-screen solenoid Tank line Pre-screen Buffers
PRE-SCREEN - OPTION ЩТЕРЕХ CONFIGURATION MODE I CRUSHER SETPOINTS ENGINE INFORMATION TRACK SWASH VALUES CRUSHER SWASH VALUES AUTO START/SHUTDOWN TIMES MANUAL START TIMES TEST START TIMES HYDRAULIC OIL TEMPERATURE HYDRAULIC PULLROD OPTIONS - ж Materials Processing > If options such as a Pre-screen or Hot Climate Pack have been fitted to the machine, they can be switched ON or OFF from the OPTIONS page. > Once on this page use the Scroll button & move the curser alongside the channel then press down on it to enter. (A passcode will be needed to change). > It is possible to scroll through the options selected and if they are ON or OFF.
HAMMER - OPTION Pressure Relief Valve Priority (Regulated, to Hammer) Materials Processing