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Where ever you are currently attending this webinar please ensure you are fully aware
of the nearest exit and are aware of any site specific regulation along with the relevant
muster point in case of emergency .

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• Hydraulic control block used to control jaw setting adjustment, trapping pressure
within the toggle retention system and clamping the adjustment system during
operation.

• Currently used on QJ241 & QJ341 units control block is slightly different to the
original Extec C10 and C12 control block.

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Toggle control block, known commonly as the “G Block” part number HV3032.
• Oil is Supplied into the block by a single 6cc fixed displacement pump.
• Electronically actuated solenoids control oil flow to connected hydraulic cylinder's
• Each solenoid is powered by a 24 Volt PLC output.

Functions controlled by the G block include;


• Hydraulic adjustment system controlling the jaw setting by using a wedge adjustment
cylinder
• 2 clamping cylinders which are used to clamp the wedge during crushing operation to
prevent setting movement under load.
• 2 toggle retention cylinder’s which are used to ensure constant load on the toggle
plate during crushing operation.
• Clamping cylinders and retention cylinders are all linked in one circuit.

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System Overview

• Entire system works against the crusher mainframe which is ridged.

• The Wedge adjustment cylinder is used to control the position the adjustment wedge
(Green) in and out of the frame.
• By moving the wedge inwards the cross beam is pushed forwards (or down in the
illustration) causing the moving jaw to move closer to the fixed jaw – Reducing the
jaw setting.
• By moving the wedge outwards the jaw setting is increased.

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• Clamping cylinders are used to lock the wedge and cross beam (Yellow) by locking
pressure within the cylinders.
• This clamps the wedge during operation and ensures that the jaw setting remains
constant.

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• Toggle cylinders are used to ensure constant load on the toggle plate (Light Blue), by
pressurizing the cylinders the moving jaw (Orange) is constantly pulled back towards
the cross beam creating this load onto the toggle plate (Dark Blue).
• If the pressure within the retention cylinders falls there will not be enough load

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against the toggle plate during operation, this will cause the plate to knock against the
toggle seats and damage each component reducing the expected component life.

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• The control valve provides an effective solution for controlling the oil flow to these
cylinders and therefore the operation.
• Using electrical signals generated by the machine PLC, valves listed are opened and
closed to control oil flow delivered from the valve block.

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• An activation valve is energized to trap the oil supplied for a pump within the valve,
this creates a pressure.

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• Two directional control valves mounted to the front face of the block are used to
control;
• Wedge adjustment used to open and close the moving jaw setting

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• Clamp system controlling the pressure within clamping and toggle retention
circuit

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• Finally a dump valve which is used to lock the pressure within the clamp and

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retention circuit during operation.

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Jaw Adjustment

• To adjust the jaw setting (minimum gap between the moving jaw and the fixed jaw)
• Oil is supplied into the wedge adjusting cylinder
• This forces the wedge (Green) into the frame against the internal profile of the front
beam (Pink)
• As a result the cross beam (Yellow) forces the clamping cylinders to retract forcing the
moving jaw towards the fixed jaw.
• Once adjustment is made the clamping cylinders are pressurized to lock the system.

• Activation valve and jaw close valve will both be activated during this operation.

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Jaw Pressure

• During operation oil is trapped within all cylinders to ensure the entire system is
locked
• Clamping cylinders are pressured to extend (full bore side) – generating force
between the fixed side frames and cross beam locking the wedge.
• Retention cylinders are pressured to retract (annulus side) – holding the moving jaw
against the toggle plate and cross beam and maintaining a constant force.

• Activation valve, system dump valve and toggle pressure charge will be activated
during this operation
• System dump valve will remain on for the entire time machine is in plant mode.

• Oil pressure within this system is constantly monitored using a pressure transducer.
• If pressure within this system falls oil will be automatically recharged.

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System Supply

• Oil supply into the clamping and retention system is fed from one valve on the G
block (Port C (Orange Line))

• All four cylinders will experience equal pressure during the crushing operation
clamping the adjustment and toggle system.

• Any internal leakage within the system will cause low pressure fault.

• Low pressure within the system will cause damage to cylinders, mounting points,
toggle plate and seats. A toggle pressure low fault will be triggered and the feeder will
be stopped.

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Within the Valve Block

• Pressure is trapped within the system by the control block, firstly on the supply line by
using a pilot operated check valve and secondly by activating the lock (dump) valve,
forcing the valve over and using the internal check valve to trap oil.

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• Once pressure is trapped, it is monitored by a 0-250 bar pressure transducer mounted


to the PSW1 port of the G block.

• As rock is introduced to the crushing chamber the pressure will begin to spike, to
control these spike an accumulator is fitted to act as a shock absorber.

• In the event that oil pressure reaches a high pressure a relief valve is used to allow oil
out of the system. This relief is set to 190 Bars (item 13).

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• Oil pressure within the clamping and toggle retention system is monitored continually
during operation using a pressure transducer.

• 0-250 Bar pressure transducer fitted to the G block transmits oil pressure within the
system.

• 0-5000 Millivolt signal is generated

• 500 mV = 0 Bar
• 4500 mV = 250 Bar (This give a linear pressure graph over a 4 volt scale)

• 0-500 mV (Low voltage) would indicate a potential broken circuit and will trigger an
out of scale fault
• 4500-5000 mV (High voltage) would indicate a potential short circuit and will trigger
an out of scale fault

• Pressure transducer and input signal can be easily tested on site easily using an
electrical multi meter.

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Possible Faults

Machine Fault - Jaw setting will not adjust


• This means when operating the jaw open or close activation via the display screen
the jaw will not adjust.

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Possible causes
• Mechanical lock of adjusting wedge, cross beam or moving jaw.

• No movement of wedge adjusting cylinder when oil is supplied. (Internal or External


oil leakage)

• No oil supply from G block

• Wedge activation spool valve is stuck – not moving

• Supply voltage outputs are not being received by the solenoids.

• Oil pressure within the G block is low due to no activation valve function or
a low relief valve setting

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• Testing – Oil flow into G block

• Oil is drawn into the gear pump whenever the pump is driven due to a suction in the
tank connection.
• Any restriction to this suction line will cause pump cavitation.
• Oil delivery produced from the pump is then passed through a filter and through the
G block until operation is required.

• Check oil flow produced by the pump using a flow meter fitted in the supply line
between the oil filter and G block, “P” port.

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• Testing – Oil pressure within G block

• 24 volt supply from the machine PLC is used to energize activation valve and generate
pressure within the G block
• By closing the activation valve and stopping oil flow through the G block oil is forced
against the main relief valve set to 180 bar

• Once oil pressure inside the G block reaches 180 bars the relief valve will open
allowing oil to exit
• Oil pressure should hold constantly at 180 bar when ever the activation valve is
closed
• If below this pressure check the relief valve setting

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• Testing – Oil pressure within Wedge adjusting system

• 24 volt supply from the machine PLC is used to activate wedge adjusting valve
supplying oil from the G block and extending the wedge cylinder
• With the activation valve still closed 180 bar system pressure will be enough to force
the mechanical wedge within the jaw mainframe
• To retract the cylinder the opposite side of the control valve is energised
• Once desired setting is achieved the 24 volt supply is removed and pressure is
trapped within both sides if the cylinder using in line pilot operated check valves

• If no movement is produced by activating either of the valves and with pressure being
developed in the G block
• This would indicate a mechanical lock preventing movement or that the spool valve is
not moving – check 24 volt supply and free movement of spool.

• If pressure within the valve is lost during activation of either valve


• This would indicate either external leakage form the connecting hoses or the cylinder
rod seal
• Or the cylinder may be leaking internally and passing oil across the internal seal

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Low toggle pressure
• During the crushing operating, oil pressure within the clamp and toggle retention
system is below 115 bars.

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Possible causes
• Excessive movement within the clamp or retention cylinders. (Over stressing of the
machine causing toggle plate to flex during operation) normally caused by operating
below minimum jaw CSS setting.

• Internal oil leakage within cylinders or control (G) block. (Oil passing the cylinder
internal seal and escaping to tank)

• No oil supply to recharge the circuit from G block.

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• Testing – Oil pressure within G block (As before)

• 24 volt supply from the machine PLC is used to energize activation valve and generate
pressure within the G block
• By closing the activation valve and stopping oil flow through the G block oil is forced
against the main relief valve set to 180 bar
• Once oil pressure inside the G block reaches 180 bars the relief valve will open
allowing oil to exit
• Oil pressure should hold constantly at 180 bar when ever the activation valve is
closed
• If below this pressure check the relief valve setting

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• Testing – Oil supply within Clamp and toggle retention system

• 24 volt supply from the machine PLC is used to activate clamp/toggle pressure valve,
supplying oil from the G block extending the clamp cylinders and retracting the
retention cylinders
• With the activation valve still closed 180 bar system pressure will be enough to
charge the system above 155 bars (Recharge cut out pressure)

• If no pressure is produced by activating the charge valve


• This would indicate hydraulic leakage (either internal or external)

• Oil could be lost internally within any of the hydraulic cylinders – this can be checked
by fitting a ball valve within the return line of each cylinder, testing one at a time.
• Oil may be being lost across the 190 bar relief valve - Check setting
• Oil may be being lost across the Lock valve – Check solenoid supply and oil flow out of
the tank line.

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• Testing – Activation of the Lock valve

• 24 volt supply from the machine PLC is used to activate the lock (Dump) valve and
trap pressure within the clamping system
• By closing the activation valve and stopping oil flow through the G block oil is forced
against the clamp system relief valve set to 190 bar
• Oil pressure should be charged and hold constantly at 155 bar when ever the
activation valve is closed and charge has been performed
• If below this pressure check the relief valve setting and internal cylinder leakage

• Pressure within the system is constantly monitored using a pressure transducer fitted
at PSW1
• At 135 bar the system will be automatically recharged
• If the pressure falls below 115 bar a toggle pressure low fault will be reported.

• During the crushing operation an accumulator charged to 135 bar, fitted to the ACC
port of the G block is used to dampen pressure spikes caused by the crushing of feed
rock inside the chamber.
• If the accumulator pressure is low, spikes in the system pressure will be forced over
the 190 bar relief valve causing the system to be constantly recharged.

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• Normal valve condition during crushing operation

• 24 volt supply from the machine PLC is used to activate the lock (Dump) valve and
trap pressure within the clamping system
• Activation valve is de-energized allowing oil flow through the valve and back to tank.

• This pressure is expected to remain fairly constant with the occasional recharge to
compensate for natural pressure loss.
• Lock valve will remain energized at all times during machine crushing operation.

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In Summary

• Adjusting the Jaw setting is achieved using one single cylinder.

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• Oil supply and flow direction is controlled using a 3 position directional control
valve.

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• Mechanical wedge inside the jaw frame changes the moving jaw position.

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• Once the setting is adjusted to the desired size the system is automatically locked.

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• Clamping and toggle retention pressure is generated within one single circuit.

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• Oil pressure is continuously monitored during operation to ensure any low pressure
condition is addressed.

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• Oil is trapped within the circuit using a Lock valve (Dump valve).

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• An accumulator is used to protect the retention system against pressure spikes


during crushing.

• Overstressing the jaw chamber due to exceeding minimum setting can cause
damage to the retention system.

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5 key take away points

• Controls setting adjustment and clamping system during operation.

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• Automatically controlled by machine PLC.

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• Pressure is monitored by a pressure transducer.

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• Pressure loss within cylinders will trigger a low pressure fault.

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• Easy fault diagnosis using basic tooling.

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