The Hydraulic System is designed to use ISO 32 hydraulic
oil. At higher ambient temperature (in excess of 105°F (41°C) it may be necessary to switch to ISO 46 hydraulic oil.
A detailed specification for the hydraulic oil can be found later in this Instruction Manual. Refer to Section 5 Hydraulic Oil Change Interval
The hydraulic oil should be changed once a year at a minimum, or sooner if conditions dictate. A frequently plugged hydraulic oil filter is a good indication that it is time to change the hydraulic oil. The inside of the oil reservoir should also be thoroughly cleaned, as well as the magnetic suction strainer.
The following signs are typical indications of the need to change the hydraulic oil and clean the hydraulic system:
1. Plugged filter indication on the hydraulic oil filter.
2. Irregular operation of the hydraulic circuits that may include high oil temperatures.
3. Existence of emulsions.
4. Hydraulic oil that shows indications of any or all of the following: Dark (burnt) color; cloudy or milky appearance; rancid or burnt smell; incorrect oil viscosity.
Cleaning the Hydraulic System
To clean the hydraulic system, do the following:
1. Following proper lockout procedures, turn off and lock out the electrical power to the hydraulic power.
Do not rely on the Push/Pull power button on the manual control panel.
2. Open both the tramp release and clamping system dump valves so both system pressures are at zero Close both valves once both systems have been completely depressurized.
3. Drain all the oil from the power unit reservoir. Unless there is a serious issue with oil contaminations, the oil in the release and clamping systems and their lines can be left in place when the reservoir is drained and cleaned.
4. Remove the round “clean-out” reservoir cover and filler pipe strainer.
5. The inside of the reservoir should be cleaned with a solvent and dried with lint free rags or wipes.
6. Reinstall the filler pipe strainer, suction strainer, and
“clean-out” cover.
7. Fill the reservoir with the hydraulic oil. Refer to Hydraulic Oil Specifications in Section 5 Changing the Oil Filter
Depending upon the manufacturer of the Hydraulic Power Unit, the oil filter is located either inside or outside of the cabinet. A visual indicator located on the top of the filter will signal when replacement of the cartridge is required.
This signal will automatically reset when the cartridge has been changed.
ACCEPTABLE HIGH
COPPER (Cu) Below 100 PPM Above 210 PPM
ALUMINUM (Al) Below 5 PPM Above 10 PPM
IRON (Fe) Below 20 PPM Above 50 PPM
SILICA (Si) Below 25 PPM Above 65 PPM
CHROMIUM (Cr) Below 0.5 PPM Above 1.5 PPM
LEAD (Pb) Below 70 PPM Above 190 PPM
CONTAMINATION LEVEL
(TOTAL SOLIDS) Below 0.1% Above 0.2%
WATER Below 0.1% Above 1.0%
Table 3-1
Oil Contamination Guidelines
To change the filter cartridge, do the following:
1. Use proper lockout procedures to electrically isolate the Hydraulic Power Unit. Do not rely on the Push/Pull power button on the remote/manual control panel.
2. As a matter of safety, dump the pressures in both the clamping and tramp release systems, using the dump valves as described above.
3. Remove the filter canister cover.
4. Remove the filter element from the housing and clean the housing with a mild solvent.
5. Place the new, clean element in the housing, centering it on the element locator.
6. Inspect the cover o-ring and replace if necessary.
7. Install the canister cover.
Hydraulic Drive Assembly Service
The lubricating oil in the planetary gear reducer should be changed out every 12 months of operation. There is one grease fitting at the labyrinth seal at the top of the planetary gear reducer. This seal should be greased every 6 months.
Due to the complicated and precise design of the Hydraulic Drive Assembly, any disassembly or work on internal parts should be left to trained service technicians.
Removing the Tramp Release Cylinders
A leaking Tramp Release Cylinder should be replaced or removed and rebuilt as soon as possible. Tramp Release Cylinder leaks normally occur at the seal in the cylinder head, and this is indicated by oil at the top of the cylinder.
It is also possible to have oil leaking past the piston, which will manifest itself as oil leaking from the breather at the bottom of the cylinder. A leaking condition can result in excessive repressurization of the hydraulic Tramp Release Circuit by the Automated Control System (ACS). If the repressurization cycles exceed a prescribed limit, the ACS will take action to shut feed off to the Crusher and shut down the Hydraulic Power Unit.
The procedure for removing a Tramp Release Cylinder from the Crusher is as follows:
1. Do a clearing cycle to displace as much oil as possible from the Tramp Release Cylinders. Do not re-pressurize the Tramp Release Cylinders.
2. Open the dump valve for the Tramp Release Circuit to ensure there is no residual pressure. Leave the dump valve open throughout the maintenance procedure.
Warning
Do not, UNDER ANY CIRCUMSTANCES, disconnect any of the hoses from any of the components in the Release System without making sure that there is zero pressure in the system. A hose being disconnected under high pressure is very dangerous and can cause serious harm from the escaping high velocity oil and the possibility of being hit by a whipping hose.
3. Disconnect the cable that tethers the Tramp Release Cylinder to the Main Frame, and allow the weight of the Tramp Release Cylinders to displace any oil that may remain in the cylinders.
4. Disconnect the hydraulic hoses. Note: There will still be some hydraulic oil displaced, so be prepared to catch this oil in a container.
5. There is a tapped hole at the end of the piston rod to install 20mm ring bolt. From an overhead lifting device, attach suitable cable or nylon sling to the piston rod and take a light strain on the Tramp Release Assembly to free up the 80mm spherical nut.
6. Remove the 80mm nut from the piston rod and slowly lower the Tramp Release Cylinder through the hole in the Adjustment Ring and the corresponding hole in the Main Frame. Pay particular attention to not damaging the piston rod or the piston rod thread.
7. Once the cylinder assembly is lowered to the deck at foundation level, the cable or sling will have to be reattached to lift it away, or the cylinder assembly placed on a conveyance to carry to the location of repair.
8. The Tramp Release Cylinder has rebuild kits referenced in the Parts Books under the Tramp Release Cylinder Assembly. FLSmidth Excel highly
recommends that a customer have a spare Tramp Release Cylinder Assembly on hand to change out as needed. The Tramp Release Cylinders operate under high pressure, so only persons fully trained in such repairs should work on these components.