QJ341 Hydraulic

QJ341 Hydraulic System
09 QJ341 Hydraulics issue 0 090812

1
It is the engineer responsibility to
ensure that all risk assessments and
method statements are in place before
any work is carried out.

2
HD022 QJ341 with lowering Conveyor.
3
Hydraulic System
Hydraulic Schematic
Main Pumps
Engine Radiator
Clamp Circuit
PVG Control Valves

Including all Functions

4
Hydraulic System
Pump 1
Pump Location
1. The pumps are being
driven at a \1 : 1 drive
ratio
2. Pump 1 is the closed Pump 2
loop pump supplying
oil to drive the Jaw
Crusher
3. Pump 2 is supplying oil
to the 6 station PVG
Pump 3
valve bank
4. Pump 3 is supplying
the Jaw toggle clamp
manifold.

5
Hydraulic System
Charge pressure relief

Close Loop Pump set at 24 Bar
Case drain (L1)
1. The closed loop pump
is a Series 90, 180cc
pump supplying up to
a maximum flow of 324
L/M (85.6 USG) to
drive the jaw motor.
Drive flow going to the

crusher drive motor Maximum displacement
limiter
Suction into the charge pump

from the hydraulic tank

6
Hydraulic System
Jaw Drive Motor

1. Driving the jaw is a
Series 51, 250cc Bent Main motor case
Axis Piston motor ,
speed is 1200 rpm drain returning back
which gives a jaw into “L1” port on the
speed of 320rpm.
main pump
Return/Reverse
Forward drive flow from pump
flow from pump

7
Hydraulic System
Closed Loop Hydraulic Circuit

8
Hydraulic System
Charge Circuit During normal operation the charge circuit is

continuously recharging the closed loop circuit
to replace with cool clean filtered oil.
10 micron filter
24 bar relief, This allows part of the cool

charge oil thought the pump to aid with
lubrication and cooling of the main pump

9
Hydraulic System
When the drive motor is being driven it
Crushing Circuit moves a hot shuttle over to allow the return
line to link to a 20 bar relief
20 Bar Pressure
A total of 55- Relief
60 L/M is
travelling
through the
case drain
The case drain from the drive motor

and 20 bar relief is sent through the
The return oil blows over the 20 bar relief to
Pump to aid with cooling &
allow the closed loop circuit to be topped up by
lubrication
the charge pump continuously

10
Hydraulic System
EDC Control
1. The Electronic
Displacement
Control is the
control for putting
the pump onto EDC not energised so there
swash is 0 bar sitting at the pump
which means minimum
displacement
When the drive pressure reaches

420 bar it blows over the relief this
sends a pilot signal to move the
other relief off its sit which in turn
allows a pilot pressure down to de-
When the EDC is operated
swash the pump
electrically it allows a 24 bar pilot
signal to swash the pump over to
give more displacement
11
Hydraulic System
Closed Loop Circuit

1. To play the closed
loop circuit
animation click on
the picture to the
right

12
Hydraulic System Load sensing
line
Case
drain
Pump 2
1. This is a series 45
pump supplying oil to
the 6 station PVG
Valve
2. The pump supplies oil
on demand via the
load sensing line
3. When a pressure is
seen on the load
sensing line the pump
goes onto swash and
supplies a greater flow
of oil.
Sauer Danfoss
Pump Speed 1800 RPM
Displacment 130cc ( 7.93 C/IN)
Max Flow 234 L/M (61.82 USG) 09 QJ341 Hydraulics issue 0 090812
13
Hydraulic System 20 Bar (Standby
Pressure Relief )
Pump Valves settings

1. Before adjusting the
relief on the pump Lock
please ensure the Screws
locking screws are
released (only adjust
when the engine is
switched off)
2. The stand by pressure
is required in the circuit
for operation of the
PVG valve bank.
3. The track are the only 310 Bar (Main
function on the
machine that will see
Locking Relief Pressure
the pump main relief Screws )

14
Hydraulic System
PVG Valve block
The Pressure and Return is

fed into the centre
slice.
6 Slice PVG Valve

15
Hydraulic System
PVG Valve block

1. NF (Side) Conveyor on
A Port, Auxiliary for
Hopper and Dirt
Conveyor on B Port.
2. Feeder on B Port.
3. L/H Tracks on A and B
Port.
1 2 3 4 5 6
4. R/H Tracks on A and B
Port.
5. Main Conveyor and
Overband Magnet on
B Port.
6. Hydraulic oil cooler on
A Port, Auxiliary for
Jacking Legs, Main
conveyor folding and
rear section, plus
toggle clamp on B
Port.

16
Hydraulic System
The PVEA knows when to stop pushing

Control voltage of 18 volts
PVEA Cross Section the spool as there is an electronic sender
is sent to move the spool
unit communicating the position at all
1. The picture shows times
the 13 bar pilot
pressure sitting on
the two valves
internal to the
PVEA valve
2. This is the control
pressure for moving
the spool
electronically
The valve internal to the PVEA moves to

allow the 13 Bar pilot pressure onto the
spool which pushes it into position

17
Hydraulic System
PVG Port Identification

1. This identifies the
“A” and “B” ports of
the PVG valve
along with the flow
restrictors
origination and B A A
manual operation
level direction
B

18
Hydraulic System
PVG Flow restriction

1. The travel of the
spool can be
restricted by
altering the flow
restricting screws
on the side of the
PVG.
2. As you screw these
in they restrict the
travel of the internal
cam which in turn
inhibits the spool
travel thus reducing
the output flow from
“A” and “B” ports
12.5 +- 1

19
Hydraulic System
Spool Types
1. The spools used in
the PVG valves
look very similar Spool size is
and in there
diameter are the
determined by
same. the groove
2. But you should
never change
spools from
different functions
as it can result in
Cylinder Motor Spool
circuit holding Spool
pressure, running
too fast or slow.

20
Hydraulic System
PVG Relief
1. Each port of the
PVG with the
exception of the
tracks has an
impendent LS relief
valve
2. These are covered
by a plastic dust
cap and are
adjustable with an
Allen key
3. Screwing the relief
inwards will
increase the
pressure of the
relief.
Test Point
21
Hydraulic System
PVG Relief Settings

1. The tables shows 6 Station PVG
the relief valve set Pressure Spool Size Spool
point for each
Section Operation Port Bar Psi L/M USG Type
function of the PVG
A 310 4495
1 Tracks 130 34.3 Open
2. It also shows the B 310 4495
spool size for each A 200 2900
2 Feeder 50 13.2 Open
function B 200 2900
Side Conveyor A 200 2900
3 40 10.6 Open
Auxliary B 220 3190
A 240 3480
4 Main Conveyor 100 26.4 Open
B 240 3480
Cooler Fan A 180 2610
5 25 6.6 Open
Auxliary B 220 3190

22
Hydraulic System
PVG Solenoids
1. Select either the
PVEA or PVEO
solenoid to find out
more information.

23
Hydraulic System
Full flow to Port

PVEA Proportional
Solenoid 19 Volts B 75%
1. Signal Voltage, this
can vary depending
on what operation
is being controlled
but it will vary from
6-19 volts
Signal Voltage
2. Battery Voltage, 12 Volts 50
this varies from 24- %
28 volts Battery Neutral
Voltage
3. Earth,
Earth
4. Error Signal,
Error Signal
6 Volts 25%
Full flow to Port
A

24
Hydraulic System
PVEO ON/OFF
Solenoid
1. 24 volts on “Pin 1”
will allow full flow
out of “Port A” on
the section
2. 24 volts on “Pin 2”
will allow full flow
out of “Port B” on
the section
3. Pin 3 is not used
Pin 2 Signal Pin 1 Signal
voltage Port B voltage Port A
Earth

25
Hydraulic System
Clamp Pump Location

1. This pump is supplying
oil to the Jaw clamp
block
2. As soon and the
engine is running this
pump is supplying oil
to that circuit
Pump
Pump Speed 1800rpm
Max Flow 10.8 L/M (2.85 USG)
26
Hydraulic System
The Pump supplies the

Adjustable Jaw Control
Valve.
Which is used to Clamp
the Toggle Plate,
Increasing and
Decreasing the CSS of
the Jaw via the clamp
and wedge rams.

27
Hydraulic System
Jaw adjustment circuit
 



28
Adjustment
Hydraulic System Cylinder
Retention Cylinder Adjustment Wedge
Clamping Cylinder
Toggle Plate Guide Keys

25mm(1”)
Thick
Toggle Beam
29
Hydraulic System

30
Hydraulic System
Clamp Block solenoid identification

1. Operates the wedge ram
(Adjustment Wedge solenoid).
2. Clamp Cylinders solenoid.
3. System Pressure solenoid.
4. Dump Solenoid, reliefs pressure
from the Accumulator circuit
when the machine is switched
off.
 

 09 QJ341 Hydraulics issue 0 090812
31
Hydraulic System
Clamp Block solenoid

operation
The first function is to

open the full bore side of
the clamping cylinders to
tank.
The adjustment Wedge

is driven in on the full
bore side into the
crusher thus reducing
the C.S.S.
Once the correct C.S.S

is achieved all of the
cylinders are then
charged on the
respective sides to clamp
everything into place.

32
Hydraulic System
Clamp Block solenoid

operation
When jaw out is pressed

the clamping cylinder
annulus side is open to
tank.
The adjustment wedge is
then pressurised on the
annulus side which pulls
the wedge out thus
increasing the C.S.S.
Once the correct C.S.C.

is achieved all of the
cylinders are then
charged on the
respective side to clamp
everything into place.

33
Hydraulic System
Clamp Pressure Transducer

1. The pressure
Transducer has 3 set
points programmed
Test Point G1 Test Point G2 Cylinder
into the electrical
Supply Pressure clamp pressure
panel.
2. 180Bar is the pressure
set point the system
stops charging at
3. Below 150 Bar is the
pressure set point
when the system starts
to charge.
4. Below 100 Bar is the
fail safe where the
feed and crusher will
stop.
This pressure can be
view on the display
screen, or by fitting a
test gauge to test point
G2. The supply
pressure to the system
(block) can be seen by
fitting a test gauge to
G1.

34
Hydraulic System Test Point G2 = Clamp
pressure (Pressure switch,
Accumulator)
Clamp Block Hoses 180 Bar Pressure relief,

system pressure (Port 14)
1. The accumulator is in
the circuit to act like a
spring when the jaw is
moving. Accumulator 135 Bar
(ACC Port)
2. The movement and
weight of the jaw stock
will try and compress Toggle Clamping
and retract the toggle Rams (Port C)
cylinders during
operation.
3. So the accumulator will
compensate for this Toggle Clamping
movement and keep Rams (Port D)
the cylinders up to
pressure.
Wedge adjust ram
(Port A)
Wedge adjust ram

(Port B)

35
Hydraulic System
Clamp Check Valves

The clamp block has 3
pilot operated check
valves located in the
side of the block these
are used to hold
pressure ion the circuit Pilot operated check for the toggle
cylinders
Cross line checks for the wedge

cylinder

36
Hydraulic System
Clamp Reliefs 190 Bar

This relief is set @ 180 Relief
bar and is there in the
circuit to protect the
cylinders from over
pressurizing when
operated.
This relief is set @190
bar and is in the circuit 180 Bar
to stop the clamping
circuit over Relief
pressurizing during
operation

37
Hydraulic System
Clamp Block Gain Orifices

All of the orifices are in
the clamping block to
reduce the flow going
to certain functions

38
Hydraulic System
5 Way Manual Valve
The 5 way manual valve station is used for

1. Wear Plate (Jaw Plate) ejection Ram.
2. Toggle plate clamping rams (full bore
side which is vented to tank) (the lever
only works one way and this locked in
position). it is a Detent valve and only
operated to remove toggle plate.
3. Rear hydraulic support legs.
4. Front hydraulic support legs
5. Product conveyer head drum folding
sections.
1 2 3 4 5

39
1
Hydraulic System
5 Way Manual Valve
Fixed jaw plate removing ram
1 2 3 4 5
Toggle retaining cylinders
5
3
4
Main product conveyor raise cylinders

40
Hydraulic System
Product Conveyor Tail

Section Raise and
Lower
1. The tail conveyor will
lower automatically
when you select “Plant
Mode” and then raise
when you select “Track
Mode”

41
1 2 3 4
Hydraulic System
 The Aux levers at the rear of the
machine under the feeder are used for
setting up the Hopper Doors and
Natural fines conveyor, Fold up the
hopper sides doors first.
1. L/H Hopper Side
2. Rear Hopper Side
3. R/H Hopper Side
4. Natural Fines Conveyor Fold.

42
Hydraulic System
Engine Cooling Fan

1. This pump is supplying
oil to the engine
radiator
2. The pump is being
driven an a 1 to1 ratio
off of the PTO (Power
Take Off) on the
Caterpillar engine
Suction from
hydraulic tank
Sauer Danfoss
Pump Speed 1800 RPM
Flow to proportional
control valve
Max Flow 135 L/M (35.66 USG) 09 QJ341 Hydraulics issue 0 090812
43
Hydraulic System
Proportional Control
1. The engine radiator
fan speed is controlled
via a proportional
solenoid
2. The direct is controlled
via the On/Off solenoid
3. When Auto Stop is On/Off
pressed the fan will Solenoid Pilot Operated Directional
ramp down, select
reverse, ramp up to full Control Valves
speed in reverse over
a 60 second period.
Note. If the Proportional

solenoid is unplugged,
then the fan will run at
full speed.
190 Bar
Shock Valves
Proportional Solenoid
with 155 Bar relief
44
Hydraulic System
Engine Cooling Fan

1. The Fan speed is set
by the m-amp from the
PLC.
Engine Coolant Fan Motor

Displacement 75cc (4.58C/In)
Working RPM 1500 rpm
MAX RPM 1800 rpm
45
Hydraulic System Oil Cooler Motor
Motor Speed 2650rpm
Relief 180 Bar (2610 Psi)
Hydraulic Oil Cooler
1. The hydraulic
cooler will only be
on when the
hydraulic oil tank
temperature
exceeds 40°C
(104°F)
2. The fan will turn off
when the tank
temperature drops
below 35°C (95°F)
3. Oil from the Return
Manifolds is cooled
by this cooler
Air flow

46
Hydraulic System
Pressure in and
Tracks Brake out ports
1. The tracks receive Release
oil from the PVG
valve
2. These are
proportionally
controlled so
having more control
when loading and
manoeuvring the
machine.
3. The tracks use the
pumps main relief
which is set at 310 Motion control
Bar (4640 Psi) Case Drain Valves
Track Motor
Displacement 90cc (5.49C/In)
Rpm 1444 rpm
Gear Box Ratio R 142:1
Rpm After 10 rpm
Running Pressure Empty 40Bar ( 580 PSI)
Spool Size 130L/M (34.34 USG/M)
Relief 310Bar (4495Psi)
47
Hydraulic System
X-line
Checks
Tracks
1. We send pressure
down the brake line
to release the
tracks
2. The flow used to
drive the tracks
sends a pilot signal
down the X-line
check to allow the
return oil to flow
back to tank.
Brake release Pressure = Pressure

reducing @ 35 bar (508PSI)
= Return Flow
= Case Drain
= Brake Pressure

48

QJ341 Hydraulic

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QJ341 Hydraulic

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QJ341 Hydraulic System

09 QJ341 Hydraulics issue 0 090812

09 QJ341 Hydraulics issue 0 090812

PVG Control Valves

09 QJ341 Hydraulics issue 0 090812

09 QJ341 Hydraulics issue 0 090812

Charge pressure relief

Drive flow going to the

Suction into the charge pump

09 QJ341 Hydraulics issue 0 090812

Jaw Drive Motor

09 QJ341 Hydraulics issue 0 090812

Closed Loop Hydraulic Circuit

09 QJ341 Hydraulics issue 0 090812

Charge Circuit During normal operation the charge circuit is

24 bar relief, This allows part of the cool

09 QJ341 Hydraulics issue 0 090812

The case drain from the drive motor

09 QJ341 Hydraulics issue 0 090812

When the drive pressure reaches

Closed Loop Circuit

09 QJ341 Hydraulics issue 0 090812

Pump Valves settings

09 QJ341 Hydraulics issue 0 090812

PVG Valve block

The Pressure and Return is

6 Slice PVG Valve

09 QJ341 Hydraulics issue 0 090812

PVG Valve block

09 QJ341 Hydraulics issue 0 090812

The PVEA knows when to stop pushing

The valve internal to the PVEA moves to

09 QJ341 Hydraulics issue 0 090812

PVG Port Identification

09 QJ341 Hydraulics issue 0 090812

PVG Flow restriction

09 QJ341 Hydraulics issue 0 090812

09 QJ341 Hydraulics issue 0 090812

PVG Relief Settings

09 QJ341 Hydraulics issue 0 090812

09 QJ341 Hydraulics issue 0 090812

Full flow to Port

09 QJ341 Hydraulics issue 0 090812

09 QJ341 Hydraulics issue 0 090812

Clamp Pump Location

The Pump supplies the

09 QJ341 Hydraulics issue 0 090812

Jaw adjustment circuit

09 QJ341 Hydraulics issue 0 090812

Retention Cylinder Adjustment Wedge

Toggle Plate Guide Keys

09 QJ341 Hydraulics issue 0 090812

Clamp Block solenoid identification

Clamp Block solenoid

The first function is to

The adjustment Wedge

Once the correct C.S.S

09 QJ341 Hydraulics issue 0 090812

Clamp Block solenoid

When jaw out is pressed

Once the correct C.S.C.

09 QJ341 Hydraulics issue 0 090812

Clamp Pressure Transducer