TEREX FINLAY C-1550

HYDRAULIC ORIENTATION

Rev-00

Author: Herbie Jones

Date: 17/05/2011
Subject to change without notice
OVERVIEW

Engine Power-unit

Hydraulic
Tank

Cone Lubrication
Tank & Pump
Power-unit Hydraulic
Controls

Cone Hydraulic Control

& Lube Oil
Components Track Controls
HYDRAULIC SCHEMATIC
HYDRAULIC SCHEMATIC

CONTROL BANK CIRCUIT

HYDRAULIC SCHEMATIC
CONE CONTROL CIRCUIT
 HYDRAULIC SCHEMATIC
CONE LUBRICATION CIRCUIT
 HYDRAULIC CABINET

Electric Oil Cooler Temperature

Sensor
Integrated Control Auxiliary Drive
Block (Optional – Block
Not Shown)

Danfoss PVG
Valve Bank Auxiliary Block

Transfer Conveyor
Pressure Switch
Geared Flow
Track Block Divider

Return Manifold
Variable Pump High
Pressure Filter
Ventable Relief
Side Conveyor & Pre Valve
Screen Solenoids
 ENGINE AND DRIVE
CAT C15 ENGINE & PT TECH CLUTCH

The C-1550 is powered by a CAT C15 407Kw engine. A

PT Tech HPTO14D clutch with auxiliary drive points is
used to drive the crusher and all the hydraulic functions.

AUX Drives

An arrangement of
internal cogs deliver
power to the auxiliary
drive points.

Crusher Drive
PT TECH CLUTCH
PT TECH CLUTCH OPERATION
Clutch Port

Clutch Pack

Engine Side

When the clutch is activated oil is

pumped into the clutch port and
compresses the clutch pack. When the
pack is locked together the engine side
outer drive is locked onto the clutch pack
starting the crusher.
When the oil supply is stopped the
pressure is removed from the clutch pack
Pressure Plate Pulley Side
and the drive is lost.
 ENGINE AND PUMPS
PUMP LOCATIONS

There are 7 hydraulic pumps fitted as

standard on the machine. 6 fixed
displacement pumps and 1 variable
displacement pump. An optional fixed
displacement pump can also be fitted to
the side of engine. The pumps are driven
from the auxiliary drive points on the PT
Tech clutch.
 VARIABLE DISPLACEMENT PUMP
PUMP & VALVE

The variable displacement

pump supplies oil to the PGV
valve bank which is used to
control 3 functions on the
machine.

PVG Valve Bank Variable Pump

 PRESSURE FILTER
PRESSURE FILTER LOCATION
The pressure line coming from the variable
displacement pump passes through a 10 micro
pressure filter before entering the PVG valve. The
filter is fitted with a bypass and a blockage
indicator.
 VARIABLE DISPLACEMENT PUMP
PUMP COMPONENTS AND LAYOUT

Pressure
Swash Plate Output
& Pump

Pressure
Bias Spring Control (PC)
Spool

Servo
Piston Load Sensing (LS)
Spool

Load Sensing line from

PVG valve
 VARIABLE DISPLACEMENT PUMP
PUMP COMPONENT DESCRIPTION
 PUMP OPERATION 1
PUMP OPERATION
Pump swash plate position with the engine switched off – As the engine is
switched off no hydraulic pressure is being generated and the bias spring sets
the pump to max swash.

Pump at Max Swash with

engine switched off
 PUMP OPERATION 2
PUMP OPERATION Pump swash plate position with the engine switched on but no functions selected -
The pump immediately starts to build hydraulic pressure because all outputs are closed.
When 30 BAR is reached the ‘Load Sensing Spool’ opens and allows oil into the servo
piston, overcoming the bias spring force and de-swashing the pump. 2cc per rev will now
be generated to maintain the 30BAR pressure. 15 BAR pilot oil is also being supplied to
the control valves through a pressure reducing valve to drive the valves into position when
required. 15 Bar
Pilot Oil

30 Bar
Pressure
 PUMP OPERATION 3
PUMP OPERATION Pump swash plate position with a function selected and LS feedback active – When
a function is selected, the LS spool detects a pressure drop on the 30 bar and allows the
bias spring to move the swash plate to pump more oil. The LS line feeds back the
operating pressure to the LS spool on the pump. The pump swash plate will keep adjusting
until it has generated 30BAR pressure difference again between the pump output and the
LS line.
Pump Output - 30 Bar
greater than LS line

LS line - 30 Bar less

than Pump Output
 PUMP OPERATION 3
PUMP OPERATION
Pump swash plate position when max operating pressure is reached – When the
pump output pressure reaches 250 BAR the ‘Pressure Control Spool’ opens and
allows high pressure oil to enter into the servo piston, overcoming the bias spring and
de-swashing the pump. 2cc per rev will still be generated, holding the pressure but
reducing the flow.
 PVG VALVE
PVG VALVE LAYOUT

PVEO – This spool is controlled electrically and is either on or off.

PVEP – This spool is controlled electrically and has a proportional function. Pulse Width Modulation
(PWM) is used to set the spool in the desired position.
Pump side module (PVP) – Oil enters the PVG valve through the P port. The main relief
and pilot relief are contained in this slice.
 PVG VALVE PIPING
PVG VALVE PIPING
Feed Conveyor
Control Banks
Tracks Fast Speed

Pressure
Tank

Load Sensing LS
 PVG FUNCTION 1 & 2
PVG VALVE FUNCTIONS 1 & 2

The variable flow output is used to drive the feeder and the control lever /
feeder slide function. The variable flow reduces the amount of unwanted oil
Feeder Slide Solenoid
being pumped around the machine helping to reduce heat generation.
 TRACKING AND PVG FUNCTION 3
PVG VALVE FUNCTION 3 & TRACKING
The 3rd PVG output is used for fast tracking. The system is set to
deliver maximum output and the oil is split equally through a geared
flow divider before entering the track control block.

Track Block

For slow speed tracking the tandem pump on the

50/50 Geared back of the PT Tech clutch supplies oil to the

Flow Divider track control block separately.
 TRACK BLOCK
TRACK BLOCK LAYOUT
Ventable relief
N/O valve set at
210 Bar
Relief valve set at
210 Bar

Tank Line
Tank line

P1 oil inlet P2 oil inlet

Oil outlet to side conveyor Oil outlet main conveyor

pre screen & transfer Track solenoid coils & Hydraulic driven water
conveyor. pump (Option)

Track hose connections

 TRACK BLOCK
TRACK BLOCK OPERATION
Oil passing into P1 port is held at 6 BAR pressure by the Sequence valve shown. This pilot oil is delivered to each
of the 4 track solenoids and is used to engage the main spools when the tracks are selected to move. Each of the
track solenoids have a pressure reducing line which limit the pressure going to the main spools when P1 & P2
pressure increases past 6 BAR.

6 BAR Sequence Valve

 TRACK MOTION CONTROL VALVE

• Forward/Reverse valve • Brake release line

• Forward/Reverse valve • Pressure/Return line
• Brake release PRV • Pressure/Return line
• Case drain line
 ENGINE COOLING FAN
COOLING FAN OPERATION
The engine radiator has two cores, one for the engine coolant and the
other for the charge air (intercooler). The cooling fan is a puller type
and is driven by a hydraulic motor @1000RPM and has a normal
operating pressure of 100BAR. The solenoid for starting the fan has a
210BAR relief valve fitted and is designed with a failsafe to allow the
fan to run even if there is an electrical fault with the solenoid.

N/C Ventable Relief

Fan Hydraulic Drive
 MAIN CRUSHING FUNCTIONS
HYDRAULIC SCHEMATIC LAYOUT FOR ALL CRUSHING FUNCTIONS EXCEPT THE CONE
 MAIN CONVEYOR & WATER PUMP
MAIN CONVEYOR, WATER PUMP & OIL COOLER
A normally open ventable relief is used to start the main conveyor and optional
hydraulically driven water pump. There is a 210BAR relief for protection.
The return oil passes through an electric oil cooler which has a 4.5BAR bypass to
protect the core from over pressurising.

Oil Cooler & 4.5

BAR Check Valve
N/O Ventable Relief
 PRE SCREEN & SIDE CONV. (OPT)
PRE SCREEN & SIDE CONVEYOR OPERATION
 Two Normally Open solenoids start and stop the side conveyor and pre screen functions. A 210 BAR relief
protects the system.
 A pressure switch set at 200BAR is fitted to the start of the pre-screen circuit. If any of the functions stalls or are
running under excessive load the feeder will stop. The feeder will restart again when the pressure drops below
200 BAR for 10 seconds.

210 BAR
Relief

Pressure Switch N/O Solenoids

 TRANSFER CONV. BYPASS VALVE
BYPASS VALVE

 If the Pre Screen and Transfer conveyor become overloaded

the High Pressure Ball Valve can be opened allowing the Pre
Screen to be started independently.
 When the screen deck is cleared the valve can be closed
allowing the material on the transfer conveyor to pass over the
screen. High Pressure Ball
Valve
 PRE SCREEN SPEED CONTROL
PRE SCREEN SPEED CONTROL

 The speed of the Pre Screen is set using a valve which is bolted on
the screen subframe. CT1 regulates the oil flow to 67LPM driving the
screen at 1200RPM.
 CT2 acts as an anti-cavitation valve should the screen overrun or
the oil supply is blocked when the screen is running.

Flow Regulator
 PT TECH CLUTCH CONTROL
CLUTCH CONTROL

Control
Block
Oil Cooler

Tank
Pressure Filter
 CLUTCH CONTROL PIPING
CLUTCH CONTROL PIPING
CLUTCH CTRL SOLENOIDS & SENSORS
CLUTCH CONTROL BLOCK

Proportional Solenoid

On / Off Solenoid

Temperature
Switch

Relief Valve 16Bar

Clutch Engage Pressure Transducer

 CLUTCH STARTING SEQUENCE
STARTING SEQUENCE

 With the engine running oil is pumped continuously into the clutch
control block from the single 20cc fixed displacement pump. This
steady supply of oil is being used to lubricate the clutch.

 The 16Bar relief holds a pre-charge

pressure which is used to activate the 16Bar
clutch.

 For the crusher to start the on/off

solenoid must activate, then the
proportional solenoid slowly engages. The
output speed of the clutch is monitored in
relation to the engine speed, once the
speeds are equal and the clutch is fully
engaged the engine RPM ramps up.
 AUXILIARY HYDRAULICS
AUXILIARY DRIVE CONNECTION
 1 x auxiliary connection is standard on all C-1550 machines. A max
output of 65LPM and a max operating pressure of 200BAR is
available. A loop pipe can be removed and a pressure, return & drain
line fitted.
 A further auxiliary drive is available but must be ordered at time of
purchase. The specification can be designed to suit the specific
application.

Drain Connection

Pressure Connection

Return Connection
Loop Pipe
 AUXILIARY HYDRAULICS
AUXILIARY BLOCK LAYOUT

Tank

210 BAR Relief

Flow Control &

Pressure
Solenoid
Regulated
Output
 CONE CONTROL & LUBE BLOCK
CONE CONTROL AND LUBE PUMP SUPPLY BLOCK
 The 14cc pump supplies oil to the Solenoid Block for controlling the Cone Control and Lube pump.
 When entering manual or automatic mode the lube pump will be activated.
 The Cone Control block only gets oil when required.
 CONE CONTROL & LUBE BLOCK
INTEGRATED VALVES

• Main Relief Valve: CT1 (210 Bar)

• Primary Flow Control Valve: CT2
• Secondary Flow Control Valve: CT3
• Lube Pump Solenoid Valve: CT6
• Secondary Relief Valve: CT4 (175 Bar)
• Cone Setting Control Supply Solenoid Valve: CT5
 CONE CONTROL & LUBE BLOCK
INTEGRATED PIPE PORTS

• Oil Supply Line: Port P

• Tank Line: Port T
• Cone Setting Control Supply Line: Port P1
• Lube Pump Supply Line: Port M
 HYDRAULIC TANK
HYDRAULIC TANK TOP LAYOUT

Oil Level Sensor Cone Clamping

Return-Line Filters
Ram Suction Line

Suction Lines:
Gear Pumps

Suction Line:
Tank Breather Drain Lines Variable Pump
AIR FILTER AND RETURN INDICATOR

Hydraulic return filters are to

be changed every 500 Hrs
Hyd oil sample to be taken at
1000 Hrs and replaced if
necessary.
 CONE CLAMPING CYLINDERS
Solenoid Dump Crushing Pressure Solenoid Dump Valve:
Valve: NO Gauge De-energized

Figure 1 Figure 2
When the cone is crushing at normal operating pressures, the control system is pressurized as shown in Figure 1.
If an un-crushable falls into the chamber and sends the pressure up to the pre-set Tramp Relief Pressure, 158
BAR, (shown in Figure 2) or you press the Tramp Test button, the solenoid valve will close and dump all
pressurized oil in the top side of the cylinders. But the cavity below the piston on each of the main chamber
cylinders requires extra oil to fill up, thus the suction pressure induced by the rams being ‘pulled’ up, opens the
check valve sucks oil in directly from the tank.
CONE CLAMP CYLINDERS CHECK VALVE

CHECK VALVE LOCATION

Cone Clamping
Cylinder Suction Check
Valve

Cone Control
Block Tank
Return
CONE HYDRAULIC CONTROL CIRCUIT
1) Crushing Pressure Gauge
CONE CONTROL BLOCK
2) Raise / Lower Solenoid
3) Crushing Pressure Transducer
4) Tramp Relieve Solenoid
1 2 3 4 5 6 7 8
5) Dumpy Jack Pressure Transducer
6) Normally Open (N/O) Needle Valve
7) Incoming Oil Pressure Gauge
8) Dumpy Jack Pressure Gauge
9) Normally Closed (N/C) Needle
Valve
C-1550 Main Control
Cabinet 10) Filter - Tramp Relief Cylinder
Return
11) Dumpy Jack Relief
12) Incoming Relief (not shown)
13) Filter – Incoming Oil
14) Pressure Reducing Valve – Raise
/ Lower
14 15 9 10 11 12 13 15) Pressure Reducing Valve –
Dumpy Jack
CONE HYDRAULIC CONTROL CIRCUIT
STICKER LOCATION AND MEANING CHARGE PRESSURE

CRUSHING PRESSURE

DUMPY JACK PRESSURE

NORMALLY CLOSED NORMALLY OPEN

HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT
CONE HYDRAULIC CONTROL CIRCUIT
1) Crushing Pressure Gauge
10 2) Raise / Lower Solenoid
19
1 3) Crushing Pressure Transducer
4) Tramp Relieve Solenoid
3
5) Dumpy Jack Pressure Transducer
6) Normally Open (N/O) Needle Valve
7) Incoming Oil Pressure Gauge
8) Dumpy Jack Pressure Gauge
16
2 145 9) Normally Closed (N/C) Needle Valve
Bar

4 5 10) Filter - Tramp Relief Cylinder Return

14
11) Dumpy Jack Relief 171 BAR
6 12) Incoming Relief 186 BAR
186 17
12 Bar

13) Filter – Incoming Oil

7 8
14) Pressure Reducing Valve Raise /
165 Lower 145 BAR
Bar
9
175
Bar
15) Pressure Reducing Valve Dumpy
Jack 166 BAR
13 15 16) Dumpy Jack Cylinders
11
17) Clamping Cylinders
18 18) Clamping Cylinder Cross-Port
Reliefs 186 BAR
Incoming Oil Supply 6-8 LPM when required 19) Tramp Suction Check Valve 0.35Bar
CONE HYDRAULIC CONTROL CIRCUIT
The pressure to hold the cone upper frame in place,
crushing pressure, is being constantly displayed on
this gauge and pressure transducer. The dump
solenoid valve is controlled by the PLC and will be
opened when the crushing pressure reaches 158
BAR. This is known as the Tramp Release Pressure.

The pressure gauge is displaying

the supply system’s oil pressure.

This filter is the in-line This filter is the in-line

pressure filter for the pressure filter the supply oil
clamping side of the main passes through before it
chamber cylinders. enters the control manifold.
It needs to be changed after It needs to be changed after
the first 100Hrs & there after the first 100Hrs & there after
every 500Hrs. every 500Hrs.
CONE HYDRAULIC CONTROL CIRCUIT

Dumpy
Jacks
Supply

166 Bar

171
Bar

• Normally Open, NO, Needle Valve for the Dumpy Jacks’ Circuit
• Pressure Transducer, for the Dumpy Jack Circuit. This pressure signal is being constantly fed to the
PLC – If the pressure drops to 120 BAR, then the circuit will automatically be recharged & if the
pressure drops to 82 BAR, for 30 secs, then the crusher will be shut down due to ‘Low Dumpy Jack
Pressure’.
• Normally Closed, NC, Needle Valve for the Dumpy Jacks’ Circuit – used to manually dump all
pressure out of the circuit i.e. When removing the upper frame for maintenance etc.
• Dumpy Jacks’ Circuit Pressure Gauge
CONE HYDRAULIC CONTROL CIRCUIT

SHUTOFF VALVES
 Three shutoff valves are fitted to the
outputs of the cone control block.
 During testing these valves are closed to
set the pressures of the cone block.
 If problems occur during operation they can
be closed to do troubleshooting to determine
if the problem is with the block or the
cylinders on the cone.
 CONE LUBE OIL COMPONENTS

Kobold Flow Meter

In-Line Filters:
Kobold Flow Meter: With Clog Indicator & By-
Pass Valve
The flow of the cone lubrication oil is constantly being
read by the PLC and if the flow is below 4 Lt/min when
the oil is below 30oC, or below 8 Lt/min when the oil is
above 31oC, you will not be able to operate the cone.
In-Line Filters:
With Clog Indicator & By-Pass Valve
When the filters are registering a large enough
restriction, pressure drop across the filters, the cone
will be stopped by the PLC.
 CONE LUBE SCHEMATIC
LUBE COMPONENTS

1) Twin In-line Filters with By-Pass

9 & Clog Indicator
1 5
2) Oil Cooler with Electric Motor &
2 6 By-Pass
3) Lube Oil Pressure Gauge
4) Lube Oil Tank Assembly
5) Cone Lube Oil Feed Line
6) Cone Assembly
7) Cone Lube Oil Return Line
3
(gravity return)
8) Lube Oil Pump Drive Motor
4
7 1200rpm
9) Kobold Lube Oil Flow Meter
8
 CONE LUBE OIL TANK ASSEMBLY
 The cone lube oil tank holds approximately 265 Litres which is 1) Lube Oil Pump Drive Motor

recommended be changed at 1000Hr intervals. 2) Lube Oil Pump

 Lube oil suction filter #(15) changed at 1st 500Hrs then every 1000Hrs. 3) Lube Oil Supply Line
4) Lube Oil Tank
 Lube oil pressure filters x2 changed at 1st 100Hrs and then every 500 Hrs.
5) Tank Level Indicator
1 9 10 11 12
6) Lube Pump Low Pressure Relief

2 Valve 5 BAR
7) Lube Pump High Pressure Relief
3 Valve 25 BAR
8) Drain Port
4 9) Level Indicator
10) Breathable Filler Cap
5
11) Bulls Eye Level Gauge
13
12) Lube Oil Return Line (gravity
6
14 return)
13) Lube Oil Temperature Transducer
7
15 14) Tank Sediment Tray
8 15) Lube Oil Suction Strainer
TANK ASSEMBLY - EXTERNAL

Lube Oil Level Breathable Filler

Sensor Cap

Lube Oil Drive Motor

& Pump Assembly

Lube Oil Relief Valve

& Suction Filter
(Not Visible)

• Lube Oil Level Gauge

• Lube Oil temperature Transducer
• Tank Drain Port & Stop Cock
 TANK ASSEMBLY - INTERNAL
 In cold conditions the solenoid contained in the tank can be activated to force oil over the high pressure relief.
This will generate heat and help increase the lube oil flow rate.

Lube Oil Outlet

Solenoid

5 BAR Low Pressure

Relief 25 BAR

Tank
Sediment 25 BAR High Pressure
Tray Relief
 TANK ASSEMBLY - INTERNAL
LUBE TANK SUCTION STRAINER

The lube oil suction strainer is 90 micro and should be 1st changed at 500 Hrs then every 1000 Hrs.

5 BAR
LUBE OIL COOLER & PRESSURE GUAGE

• Oil Cooler Out-Let Line

• Oil Cooler In-Let Line
• Oil Cooler By-Pass Valve,
2 Bar.

Lube Oil Pressure Gauge

 HOT CLIMATE COOLER
OPTIONAL HOT CLIMATE COOLER
 An optional electrically driven hydraulic oil cooler is available. It cools the side conveyor & pre screen return oil.
 As with all oil coolers there is a bypass (4.5 BAR) to protect the core of the cooler from over pressurizing.

4.5 BAR Bypass Check

Valve