Operation and Maintenance Hydraulic System Troubleshooting Telsmith Model 5060 Jaw Crusher HYDRAULIC SYSTEM TROUBLESHOOTING CHART Refer to Table 10-2 for the hydraulic system troubleshooting, chart When indicated in the Corrective Action column, refer to the hydraulic system maintenance procedures in Chapter 9 Item numbers in brackets [ _ } correspond to the hydraulic, ‘components shown in Figures 10-4 and 10-5 Table 10-2: Hydraulic SystemTroubleshooting Chart ‘SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION 1. Time-delay relay (TR3) |A Hydraulic control panel door | Ciose and secure the control panel door Verify that opens - crusher stops open [door interlock switch works property B, Hydraulic control panel power | Reconnect power to the control panel disconnected C. Hydraulic system low pres= [Check the hydraulic pressure gauge with the selec-| sure switch open tor switch in CRUSH mode If less than 1800 PSIis S indicated, hydraulic pressure is too low Reefer to / | Step 3 of troubleshooting. D. Loose connections [Check for loose connections inside the hydraulic SN contro! panel ‘Check for loose connections at the hydraulic sys- tem low pressure switch [Check for loose connections at time-delay relay (TRA). Refer to Chapter 9 for hydraulic system wiring dia- ‘gram E Time-delay relay (TR3) defec- | Replace time-dolay relay (TR3). tive 2 High oil temperatures [A Low oil level Check oil level Hydraulic reservoir is full when oil level is about 2/4 inch from top of sight gauge foil level is low, add additional oil as required. Refer to a |Chapter 9 for hydraulic oil specifications, Before checking oil level, verify that hydraulic pump is off and that the hydraulic pressure gauge indi cates (0) PSI B Low water flow through oil | Check water flow through oll cooler [52] Approxi- cooler mately 4 GPM will provide adequate cooling under most operating conditions Water flow can be increased if needed to provide additional cooling However, the flow rate must not exceed 20 GPM C Oillcooler passages clogged | Flush the oil cooler [52] to clean out clogged pas- sages Refer to Chapter 9 for procedure 1100 ate 1ONES 10-9 p ANTI, S.A. 3908Hydraulic System Troubleshooting Operation and Maintenance Telsmith Model 5060 Jaw Cru: ‘Table 10-2: Hydraulic System Troubleshooting Chart ‘SYMPTOMS: POSSIBLE CAUSE CORRECTIVE ACTION 2 High al temperatures |D Oil erulating pump detective [1 Lockouttagout power tothe Hydraule control (Continued) panel 2 Verily thatthe pressure gauge indicates zero (0) Psi. 3 Place a hydraulic flowmeter in the outlet line of the oil circulating pump [10] The flowmeter must be capable of operating at pressures of at least 5000 PSI 4, Place the selector switch in the HOLD position Reconnect power and start the hydraulic pump 5 Observe the flowmeter reading The flow rate should be approximately 43 GPM E. Dirty or unchanged hydraulic Drain and flush the hydraulic reservoir Replace oll hydraulic filter element and suction strainer Refill hydraulic reservoir with new oll of the proper viscosity Refer to Chapter 9 for hydraulic oll speci fications and recommended oil change intervals 3 Low hydraulic pressure |A. Low oillevel Check oil level. Hydraulic reservoir is full when oil / level is about 3/4 inch from top of sight gauge If oi! level is low, add additional oil as required Refer to Chapter $ for hydraulic oll specifications Before checking oil level, verity that hydraulic pump is off and that the hydraulic pressure gauge ind- cates zero (0) PSI B Pump turning in wrong direc- | Check direction of pump motor fan. Fan must tion rotate in same direction as arrow on fan housing . Reverse electrical leads it necessary © Suction strainer clogged _| Drain the hydraulic reservoir. Remove and inspect ‘suction strainer [14] Replace if clogged or dam- aged Note: If suction strainer is clogged, cil may be dirty. Drain and flush reservoir Replace hydraulic fiter ‘element Refill reservoir with new hydraulic oil of the correct viscosity Refer to Chapter 9 for hydrau-| lie oil specifications 1D Pump suction line clogged or | Check for loose or cracked suction line fitings leaking ‘Tighten or replace fitings as requitod check suction line for obstructions, Remove i present. E System ralet valve std3k open | Check Betting of system relict valve [35] Readiust or set to0 low oF Yeplace as required 10-10 x 11100 oSOperation and Maintenance Telsmith Model 5060 Jaw Crusher Hydraulic System Troubleshooting Table 10-2: Hydraulic SystemTroubleshooting Chart ‘SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION 3 Low hydraulic pressure (Continued) F. Pressure compensating valve stuck open or set too low Check setting of both pressure compensating valves [9A] and [56] Readjust or replace valves as required Pressure compensating valve [9A] controls the RETRACT pressure setting Pressure compensating valve [56] controls the CRUSH pressure setting |G. Detective pressure gauge Install a second pressure gauge to verify that pres- ‘sure gauge [31] is providing accurate readings. Replace pressure gauge if defective. H. Hydraulic pump defective Repair or replace the hydraulic pump [9] 4. Low hydraulic flow [A Low oiv level (Check oll evel Hydraulic reservoir is full when oi level is about 2/4 inch from the top of the sight [gauge If cil evel is law, add additional oil as Tequired. Refer to Chapter 9 for hydraulic oil speci- fications Before checking oil level, verity that hydraulic pump is off and that the hydraulic pressure gauge indi- [cates zero (0) PSI Drain the hydraulic reservoir. Remove and inspect. suction strainer [14] Replace if clogged or dam- aged. Note: If suction strainer is clogged, oll may be dirty Drain and flush reservoir Replace hydraulic filter Jolement Refill reservoir with new hydraulic oil of the correct viscosity. Refer to Chapter 9 for hydrau- lic oll specifications. 'C, Pump suction line clogged or leaking ‘Check for loose or cracked suction line fittings Tighten or replace fitings as required [Check suction line for obstructions Remove if [present D Hydraulic pump defective Repair or replace the hydraulic pump [9] ‘5 CRUSH or RETRACT [functions do not operate [A Obstruction preventing move- ment of toggle beam and swing jaw ‘Check that the crushing chamber is free of tramp iron or jammed material. Clear the crushing cham- ber if necessary Verify that the toggle beam openings on both sides, of the crusher frame are unobstructed by dirt or [quarry material Remove obstructions if present 11/00 CT BEN S.A, Ri us 10-41Hydraulic System Troubleshooting Operation and Maintenance Telsmith Model 5080 Jaw Crusher ‘Table 10-2: Hydraulic System Troubleshooting Chart SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION {functions do not operate (Continued) 5 GRUSH or RETRACT|B No power to solenoid colls, [The pilot stage of control valve [37] contains two solenoid coils One coil activates the hydraulic RETRACT function The other activates the hydraulic CRUSH function ‘Check that voltage is present at the appropriate solenoid coll terminals when the function selector switch is in the CRUSH and RETRACT positions Refer to Chapter 9 for hydraulic system wiring dia- ‘gram. C. Solenoid coil is defective ‘Jog the selector switch several times between HOLD and RETRACT and between HOLD and CRUSH. Listen for the piot stage valve spool to shift, If the spool does not shift when the CRUSH or RETRACT functions are activated, one or both solenoid coils may be detective, To verity a defective solenoid coil, manually shift the spool in both directions by depressing the push-button at each end of the valve When either button is depressed, the spoo! will shift about 1/8 inch. Pressure should build immedi- ately, and the cylinder rods should begin to move. D. Directional control valve is Ifthe pilot stage valve spool is stuck and cannot be lor sat too low defective (pilot stage) ‘manually shifted, repair or replace the pilot stage of control valve [371 E System relief valve stuck open | Check setting of system relief valve [35] Readjust lor replace as required stuck open or set too low F. Pressure compensating valve | Check setting of the pressure compensating valves [9A] and [56] Readjust or replace the valves as required. Pressure compensating valve [9A] controls the RETRACT pressure setting Pressure compensating valve [56] controls the | CRUSH pressure setting 10-42 11/00Operation and Maintenance Telsmith Model 5060 Jaw Crusher Hydraulic System Troubleshooting Table 10-4 Hydraulic SystemTroubleshooting Chart ‘SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION 5 CRUSH or RETRACT functions do not operate (Continued) suction strainer H Low pump output or clogged |1 Lockout/tagout power to the hydraulic control panel 2 Verity that the pressure gauge indicates zero (0) Psi. 3 Place a hydraulic flowmeter in the pump outlet line The flowmeter must be capable of operating at pressures of at least 5000 PSI 4 Place the selector switch in the CRUSH or RETRACT position Reconnect power and start the hydraulic pump. IMPORTANT: The cylinder rods must be moving (extending or retracting) while the flowmeter| reading is checked in the next step 5, Of serve the flowmeter reading. The flow rate [should be approximately 1 5 to 2.5 GPM. Go to step ST of troubleshooting ifthe flow rate is within _oaeceptable limits, 6 I the flow rate is below acceptable limits: Drain the hydraulic reservoir and inspect the suc- tion strainer [14] Replace the suction strainer if itis [clogged or damaged Check the pump suction line for obstructions or leaks Refill the hydraulic reservoir with now oll Check the flow rate again as described in steps 4 and 5 of this procedure. Repair or replace the hydraulic pump [9] if the flow rate is stil below acceptable Tits {. Directional control valve is [defective (main stage) ‘Troubleshoot the main stage of control valve [37]. \Verity proper operation. Repair or replace the main stage as required }J_ Hydraulic cylinders leaking defective: or | Repair or replace the hydraulic cylinders as required 11100 Eve 10-13Hydraulic System Troubleshooting Operation and Maintenance Telsmith Model 5060 Jaw Crus Table 10-2: Hydraulle System Troubleshooting Chart ‘SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION 6 Low hydraulic system oil | A. Oi {temperature il heater not working” (Check that the oil heater is properly connected to a [power source of the correct voltage Check that thermostat is set to between 70°F (21°C) and 90°F (82°C) Check for carbon build-up on heating element Clean as required |Check for defective thermostat or burned-out heat- ing element Make repairs as required. low" B. Oil heater thermostat sot too Raise the temperature of the oil heater thermostat, ‘as required The oll heater thermostat is normally set at 70° to 90°F (21° to 32°C) depending on outside ambient temperature It can be set up to 100°F (38°C) for especially cold climates. Refer to Chapter 9 for additional information C Oil cooler providing excessive amount of cooling Reduce water flow through the oil cooler [52]. '7. Oil cooler does not pro- [A Cooling water temperature’ vide enough cooling too high [To provide adequate cooling, the water tempera- ture at the cooler inlet should be 20 to 40°F colder than the hydraulic oll B, Water flow too loW Increase water flow through the oil cooler (52) Approximately 4 GPM will provide adequate cool- Ing under most operating conditions, Water flow can be increased as needed to provide additional cooling However, the flow rate must not exceed 20 GPM [C. Oil cooler passages clogged Flush the oil cooler [52] to clean out clogged pas- /sages. Refer to Chapter 9 for procedure. D Oil circulating pump detective 1 Lockoutvtagout power to the hydraulic control panel 2 Verity that the pressure gauge indicates zero (0) Psi. 3 Place alhydraulic flowmeter in the outlet ine of the oil circulating pump [10] The flowmeter must be capable of operating at pressures of at least 5000 PSI }4 Place the selector switch in the HOLD position Reconnect power and start the hydraulic pump 5 Observe the flowmeter reading The flow rate should be approximately 43 GPM. *Units equipped with oil heater only (optional equipment) 10-14 11100Operation and Maintenance Hydraulic System Troubleshooting Telsmith Model 5060 Jaw Crusher Table 10-2: Hydraulic SystemTroubleshooting Chart ‘SYMPTOMS: POSSIBLE CAUSE CORRECTIVE ACTION 8 Oil heater failure A. Carbon build-up on heating —_| Periodically clean and inspect the heating element element” to prevent premature failures B, Heating element not ‘Aiways disconnect power to cil heater before drai irmmorsed in ot” ing oil |Always disconnect power to oil heater during sea- sonal storage © Heating element touching res-| When performing maintenance, be careful not to ervoir* bend the heating element The element must not touch the inside of the reservotr. [9 Hydraulic system loses |A Hydraulic reservoir leaking | Inspect the hydraulic reservoir for leaks. Make oil repairs as required B Leaking hydraulic hoses and/_} etréck all hydraulic hoses and fittings for leaks. or loose fittings Tighten fittings or replace hoses as required. C. Leaking hydraulic ¢orhipo- \\° | Check hysdratilic components for visible leakage pO 2c rents Repair or replace leaking hydraulic components as required. “Units equipped with oil heater only (optional equipment) EMPRES 1ONES BENV S.A. Ru ' us O28 a EMO 11700 1045Hydraulic System Troubleshooting Operation and Maintenance Telsmith Model 060 Jaw Cros Table 10-2: Hydraulic System Troubleshooting Chart SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION 10 Pump not pumping A No power Check power source B Incorrect wiring ‘Check wiring diagram Reler to Chapter 9 | Pump motor detective Ret or replace pump motor [6] as required D Low oil lavel Check oil evel Hydraulic reservoir is full when oil level is about 3/4 inch from the top of the sight gauge. If ol level is low, add additional oil as Tequired Refer to Chapter 9 for hydraulic oll speci- fications Before checking oil level, verity that hydraulic pump is off and that the hydraulic pressure gauge indi- ‘cates zero (0) PSI | Pump turing in wrong direc tion, (Check direction of pump motorfan Fan must rotate in same direction as arrow on fan housing Reverse electrical leads if necessary. F. Suction strainer clogged Drain the hydraulic reservoir Remove and inspect suction strainer [14] Replace if clogged or dam- aged Note: if suction strainer is clogged, oil may be dirty Drain and flush reservoir, Replace hydraulic iter jelement Refill reservoir with new hydraulic oil of thé correct viscosity Refer to Chapter 9 for hydrau- fic oil specifications [G Pump suction line clogged or leaking ‘Check for loose or cracked suction line ftings.. Tighten or replace fitings as required [Check suction line for obstructions Remove if present H. Oilis wrong vcosity Drain hydraulic oil from reservoir Refill reservoir with new hydraulic ol of the correct specifications Refer to Chapter 9 for oil specifications | Hydraulic pump defective Repair or replace the hydraulic pump [9] 10-16 1100Operation and Maintenance Telsmith Model 5060 Jaw Crusher Hydraulic System Troubleshooting Table 10-2: Hydraulic System Troubleshooting Chart ‘SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION 11 Noisy pump A Oilis cold Pump may be noisy when oil is cold, but should become quieter as oll warms up B. Low oil level Check oil level Hydraulic reservoir is full when oil cates zero (0) PSI level is about 3/4 inch from top of sight gauge |f oil levol is low, add additional oil as required Refer to Chapter 9 for hydraulic oil specifications Before checking oil level, verify that hydraulic pump is off and that the hydraulic pressure gauge indi [C Pump turning in wrong direc- | Check direction of pump motor fan Fan must tion rotate in same direction as arrow on fan housing Reverse electrical leads if necessary D Incorrect hydraulic fiter ele- | Install a new filter element of correct micron size ment (10-microns) E Suction strainer clogged” | Drain the hydraulic reservoir Remove and inspect Von aged" lic oil specifications [suction strainer [14] Replace if clogged or dam- Note: If suction strainer is clogged, oil may be dirty Drain and flush reservoir Replace hydraulic fil element. Refill reservoir with new hydraulic oil of the correct viscosity Refer to Chapter 9 for hydrau- r E Pump suction line clogged or | Check for loose or cracked suction line fittings. leaking Tighten or replace fitings as required |Check suction line for obstructions Remove if present G Pump damaged Repair or replace the hydraulic pump [9] 11700 ENtr' s BENW 1, S.A. he ieauacun FIMO 10-17Hydraulic System Troubleshooting Operation and Maintenance Telsmith Model 5060 Jaw Crustivr Table 10- \ydraulic System Troubleshooting Chart SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION 12 Filter element needs frequent replacement Sludge at bottom of hydraulic reservoir [A Oil poured from an unclean ‘container Be sure that oll container is clean to prevent dirt and other harmful contaminants from entering the hydraulic system. B Unchanged oil [Change oil at the proper time interval Refer to [Chapter 9 for hydraulic system maintenance schedule C. Pump suction line clogged or leaking ‘Check for loose or cracked suction line fitings Tighten or replace fittings as required. ‘Check suction line for obstructions Remove it present 13. Cylinders extend or retract when selector tion, switch is in the HOLD posi- [A Incorrect wiring or damaged electrical components Check electrical wiring Refer to Chapter 9 for hydraulic system wiring diagram. Repair or replace electrical components as required. B. Directional control valve is| defective (pilot stage) Manually shift the pilot stage spool of control valve [371 in both directions by depressing the push-but- ion at each end of the valve \When either push-button is released, the spool should return to the center position and the cyiin- [ders should not move {tthe valve spool is stuck in the CRUSH or RETRACT positions and cannot be manually shifted, repair or replace the pilot stage of control valve [37]. Directional control valve is defective (main stage) Repair or replace the main stage of control valve (371, D Hydraulic cylinders leaking or defective Repair or replace the hydraulic cylinders as required. 44, Crusher will not main- tain discharge setting A. Low hydraulic pressure Refer to Step 3 for additional information B. Dirt on mating surfaces Remove all dust and dirt from the mating surfaces of the toggle beam and the toggle beam wedges. "To ensure good contact, be sure that both surfaces are smooth and free of rust or corrosion C Toggle beam liner plates loose or worn Replaceable liner plates are located above and below the toggle beam on both sides of the crusher frame ‘The liner plates must be tightly installed and in good condition to prevent the toggle beam from moving during crushing ‘Tighten the liner platas if loose Replace any worn or damaged liner plates 10-18 41700Operation and Maintenance Telsmith Model 5060 Jaw Crusher Hydraulic System Troubleshooting Table 10-2 Hydraulic System Troubleshooting Chart ‘SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION 5 CRUSH or RETRACT functions do not operate (Continued) 1H Low pump output or clogged suction strainer 1 Lockoutitagout power to the hydraulic control panel 2 Verity that the pressure gauge indicates zero (0) Psi. 3 Place a hydraulic flowmeter in the pump outlet line The flowmeter must be capable of operating at pressures of at least 5000 PSI 4 Place the selector switch in the CRUSH or RETRACT position Reconnect power and start the hydraulic pump. IMPORTANT: The cylinder rods must be moving (extending’or retracting) while the flowmeter reading is checked in the next step 5, Qb3erve the flowmeter reading. The flow rate should be approximately 1 5 to 25 GPM. Goto step 5T of troubleshooting ifthe flow rate is within Facceptable limits. 6 If the flow rate is below acceptable limits: Drain the hydraulic reservoir and inspect the suc- tion strainer [14] Replace the suction strainor if itis [clogged or damaged Check the pump suction line Hor obstructions or leaks Refill the hydraulic reservoir with new oil Check the flow rate again as described in steps 4 and 5 of {this procedure. Repair or replace the hydraulic pump [9] ifthe flow rate is stil below acceptable Fimits . Directional control valve is defective (main stage) Troubleshoot the main stage of control valve [37]. Verify proper operation. Repair or replace the main stage as required }J Hydraulic cylinders leaking or defective Repair or replace the hydraulic cylinders as required 11700 Ere: BE? wes S.A. Mo 10-13Hydraulic System Troubleshooting Operation and Maintenance Telsmith Model 5060 Jaw Crusisor ‘Table 10-2: Hydraulic System Troubleshooting Chart SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION 6 Low hydraulic system oil | A. Oil heater not working* temperature Check that the oil heater is properly connected to a power source of the correct voltage [Check that thermostat is set to between 70°F (21°C) and 90°F (32°C) ‘Check for carbon build-up on heating element Clean as required Check for defective thermostat or burned-out heat- ing element Make repairs as required. B. Oil heater thermostat sot too low’ Raise the temperature of the oil heater thermostat as required ‘The oil heater thermostat is normally set at 70° to |90°F (21° to 32°C) depending on outside ambient {temperature It can be set up to 100°F (38°C) for especially cold climates. Refer to Chapter 9 for [additional information ‘© Oil cooler providing excessive ‘amount of cooling Reduce water flow through the oil cooler (52). 7. Oil cooler does not pro- |A Cooling water temperature vide enough cooting too high 7 provide adequate cooling, the water tempera- ure atthe cooler inlet should be 20 to 40°F colder than the hydraulic oi B. Water flow too low Increase water flow through the oil cooler (52) /Approximatoly 4 GPM will provide adequate coot- ing under most operating conditions, Water flow can be increased as needed to provide [additional cooling However, the flow rate must not lexceed 20 GPM C. Oil cooler passages clogged Flush the oil cooler (52] to clean out clogged pas- /sages. Refer to Chapter 9 for procedure. D Oil circulating pump defective e s as 1 Lockout/tagout power to the hydraulic control panel 2 Verify that the pressure gauge indicates zero (0) Psi. /3. Place a hydraulic flowmeter in the outlet line of the oil circulating pump [10] The flowmeter must be capable of operating at pressures of atleast '5000 PSI 4 Place the selector switch in the HOLD position Reconnect power and start the hydraulic pump 5 Observe the flowmeter reading The flow rate should be approximately 43 GPM “Units equipped with oil heater only (optional equipment) 10-14 11/00