Sentinel Advanced Hydraulic System

Operator’s Manual

May 2013
EFM-SO#106134
Installation & Maintenance Instructions
Part# EFM00101-5002 INST
Part# EFM00301-5000 INST Hydraulic Power Unit Overview
Sentinel Advanced Hydraulic System
Operator’s Manual
Installation & Maintenance Instructions
Hydraulic Power Unit Overview

May 2013 EFM-SO#106134

Introduction
This Sentinel Advanced Hydraulic System replaces the compression
springs found on the Symons® Crusher with hydraulic cylinders. If an un-
crushable object stalls the crusher, the operator then relieves hydraulic
pressure by turning a switch and pressing a button to energize clearing
cylinders which lift the adjustment ring and bowl assembly off the main
frame seat. This allows material and/or tramp iron to fall through and
clear the cavity. Once the cavity is clear, the operator again flips a switch
and the crusher is ready for operation.

Symons® and Gyradisc® are trademarks of Metso® Minerals. Excel Foundry & Machine is not an authorized repair facility of
nor does it have an affiliation with Metso® Minerals. All manufacturer names, numbers, symbols, and descriptions are used
for identification purposes only. All parts are manufactured by, for, and warranted by Excel Foundry & Machine and are not
manufactured by, purchased from, or warranted by the original equipment manufacturer.

May 2013 EFM-SO#106134

Safety
It is STRONGLY SUGGESTED to study this manual and
follow the instructions carefully.

This SAFETY ALERT SYMBOL indicates important safety

messages in the manual. When you see this symbol,
be alert to the possibility of PERSONAL INJURY and
carefully read the message that follows. For example:

NEVER OPERATE WITHOUT ALL COVERS,

SHIELDS AND GUARDS IN PLACE. KEEP
HANDS, FEET AND CLOTHING AWAY FROM
MOVING PARTS.

Indicates an immediate hazardous situation that, if not

avoided, will result in serious injury or even death.

Read all of the safety signs on the machine and in this

Indicates a potentially hazardous situation that, if not manual. Replace any lost or damaged signs.
avoided, could result in serious injury or death. This
includes hazards that are exposed when guards are
removed.

HIGH PRESSURE GAS CHARGED CYLINDER

DISCHARGE GAS AND HYDRAULIC PRESSURE
BEFORE SERVICING.
Indicates a potentially hazardous situation that, if not
avoided, may result in minor to moderate injury.

NOTE: Some covers and guards have been removed for

illustrative/photographic purposes.
Used to address practices not related to personal injury.
For ordering repair parts, refer to repair parts section.

The serial number is located on the inside of the electrical

panel door.

May 2013 EFM-SO#106134

XHD Tramp System
7 Ft. Symons Crusher
®

Fabricated Frame
External Pins

Part# EFM00101-5002 INST

May 2013
Bill of Materials Part# EFM00101-5002 INST

Item # Qty. Description Part #

1 4 Accumulator Mounting Ring EFM00101-0004
2 20 Accumulator Clamp EFM00101-0005
3 4 Clearing Cylinder EFM00101-0008
4 16 Breather EFM00101-0009
5 4 Adapter, JIC Swivel,Tee Bbranch EFM00101-0030
6 4 Adapter, 24 ORB X 20 JIC EFM00101-0031
7 32 Adapter, 45° 16 JIC - 16 ORB EFM00101-0032
8 12 Hose Assembly, 33” EFM00101-0033
9 1 Tee, Run, JIC#16-JIC#16-JIC#16 Swivel EFM00101-0035
10 2 Tee, Branch 8 JIC-8 ORB-8 JIC EFM00101-0038
11 2 90° Elbow 8 JIC-8 ORB EFM00101-0039
12 4 Hose Assembly, 87” EFM00101-0041
13 1 Hose Assembly, 275” EFM00101-0042
14 1 Hose Assembly, 275” EFM00101-0043
15 4 Safety Blocks (Not Shown) EFM00101-0064
16 1 Reducer( 2406-16-12) EFM00101-0066
17 4 Support, Clearing Cylinder EFM00101-0072
18 16 Tramp Cylinder EFM00101-0073
19 16 Bottom Cylinder Retainer EFM00101-0074
20 16 Cylinder Support EFM00101-0075
21 16 Support Pad EFM00101-0076
22 4 Accumulator, 10 Gallon EFM00101-0077
23 4 Accumulator Mount EFM00101-0078
24 16 Adapter Block EFM00101-0079
25 16 Dust Boot EFM00101-0080
26 1 Adapter, Tee #8JIC X #8JIC X #8JIC EFM00101-0081
27 8 Hose Assembly, 100” EFM00101-0082
28 1 Hardware Kit EFM00101-5002-HWK
29 2 Strut, Mounting XL000-0191-001
30 2 Clamp, 13/16 DIA. Hose Mounting XL1003-0079
31 1 Nitrogen Charging Kit (Not Shown) XL-9429-0022
32 1 Manual EFM00101-5002-INST

May 2013 EFM-SO#106134

 Part# EFM00101-5002-INST

Place the power unit within 10 feet of the Crusher.

Operator must be able to see the warning lights on
top of the hydraulic power unit

EFM-SO#106134
 Part# EFM00101-5002-INST

EFM-SO#106134
 Part# EFM00101-5002-INST

NOTES:
USE E7018 WELDING ROD ON ALL WELDS
1. Remove the existing spring clusters and lower spring segments as described in
the Symons Crusher Instruction manual.

2. Clean the underside of the main frame where the springs make contact, three
spring positioners will need to be cut off. This will ensure good contact between
the adapter block and the main frame.

3. Clean the lower spring segments. If the segment had pads for the springs, turn
the segment upside down to provide a flat surface for mounting.

4. Spring bolts will be reused. Therefore, clean the threads and nuts.

5. Assemble the tramp cylinders where the springs were located.

EFM-SO#106134
Hydraulic Bowl Turning Kit
7 Ft. Symons Crusher ®

Hydraulic Gear Drive

Kit contains all necessary hoses, hydraulic drives, gearbox mounts,

and fasteners. Gear Drive is accomplished by replacing the existing
rams with hydraulic motor/gearbox assemblies driving the pinion
that engages a ring welded to the existing adjustment cap.

Part# EFM00301-5000 INST

May 2013
Bill of Materials Part# EFM00301-5000 INST

Item # Qty. Description Part #

1 4 GUSSET EFM00301-0026
2 8 HHCS, M24 X 110, CL 8.8 EFM00301-0027
3 9 HHCS, M24 X 40, CL 8.8 EFM00301-0028
4 8 Hex Nut M24 x 3 EFM00301-0029
5 4 ADAPTER, STRAIGHT, #12 JIC-#10 ORB EFM00301-0030
6 4 ADAPTER, SWIVEL 90 DEGREE #12JIC X #12 JIC EFM00301-0031
7 1 ADAPTER, TEE #6JIC X #6JIC X #6JIC EFM00301-0049
8 2 ADAPTER, TEE #12JIC X #12JIC X #12JIC EFM00301-0048
9 2 ADAPTER,90 DEGREE #8 JIC X #6 ORB EFM00301-0021
10 4 STRUT, MOUNTING 5” LG EFM00301-0035
11 8 Strut Mount Clamp 1 1/4 XL1003-0080
12 4 CLAMP, 13/16 DIA. HOSE MOUNTING XL1003-0079
13 2 ASSEMBLY, HOSE #6 X 124 LG EFM00301-0046
14 4 ASSEMBLY,HOSE #12 X 130 LG EFM00301-0047
15 3 WELDMENT, SPLICE PLATE EFM00301-0040
16 9 Spring Lock Washer, M24 EFM00301-0051
17 1 Ring-Drive XL-0010000
18 1 Assembly Shuttle Valve EFM00101-0058
19 1 Plate, Legend Close EFM00101-0047
20 1 Plate, Legend Open EFM00101-0048
21 1 Plate, Legend Bowl Drive EFM00101-0049
22 2 ASSY, DRIVE SYMONS 7’ EFM00301-5501
23 1 Manual EFM00301-5000-INST

Recommended Spares List

Qty. Description Part #
1 Adjustment Motor and Bracket Assembly With Pinion EFM00301-5501
1 Segmented Drive Ring XL-0010000
8 Nylon Brush for Drive Ring EFM00301-0009

May 2013 EFM-SO#106134

Installation Instructions
1. Position drive ring around adjustment cap and
bolt together using the drive ring adapter.
2. Center the drive ring to the adjustment cap and
tack weld together.
3. Weld the drive ring segments together.
4. Skip weld drive ring to adjustment cap on top
every other notch and on bottom 6.0[152] welds
every 36[914].
5. Position the drive assembly on the adjustment
cap making sure the pinion is perpendicular to the
drive ring within 1°.
6. Tack weld the drive assembly to the adjustment
ring.
7. Position gussets under drive assembly as shown
and tack weld together.
8. Once drive assembly is fully tacked to the
adjustment ring check position, if position is good
fully weld around all seams. If position is bad,
correct, then weld.
9. With the pinion guard removed, lower adjustment
cap & bowl onto the adjustment ring.
10. At the HPU install legend plates: (Bowl Open) over
Ram Open, (Bowl Closed) over Ram Closed, And
(Bowl Drive) over Ram.
May 2013 EFM-SO#106134
Part# EFM00301-5000 INST
11. Connect Assembly Shuttle Valve to HPU manifold
in positions “Lower B1” on BOTH blocks. This will
be connected to the brake on the side of the drive
assembly.
12. Cap Locations “A1” on both manifold blocks.
13. Route hydraulic lines from HPU locations “Upper
B1” on both manifold blocks to the assembly
drive.
14. Turn on HPU and make sure the pinion runs in the
proper direction when “Bowl Open” is pressed. If
this runs in reverse, de-pressurize & de-energize
HPU & switch lines at the drive motor.
15. Adjust pinion in towards the drive ring until an
optimum average between the drive ring and the
pinion is met.
16. On all welds on adjustment ring, preheat
adjustment ring to 120°F before welding. Use
7018 welding rod.
17. On all welds on drive ring, preheat drive ring to
250°F before welding. Use 8018 welding rod.
18. Replace pinion guard
 Part# EFM00301-5000-INST

EFM-SO#106134
 Part# EFM00301-5000-INST

EFM-SO#106134
 Hydraulic Power Unit
For Symons® & Gyradisc® Crushers

Skid mounted hydraulic power unit with 20hp motor, 45 gallon tank
and all necessary valves, warning lights, pressure gauges to monitor
and control our Hydraulic Tramp Release and Bowl Turning Kits.

May 2013 EFM-SO#106134

Hydraulic Power Unit Connections
Place power unit within 10 feet of the countershaft box.
Operator must be able to see the warning light on top
of the hydraulic power unit.

Hydraulic Fitting Sizes

3/4-16 37° Flare (JIC)
1-1/16-12 37° Flare (JIC)
3/4-16 37° Flare (JIC)
3/4-16 37° Flare (JIC)
1-1/16-12 37° Flare (JIC)
3/4-16 37° Flare (JIC)
3/4-16 37° Flare (JIC)
7/16-20 37° Flare (JIC)
Fitting on side of tank

May 2013 EFM-SO#106134

Hydraulic Power Unit Overview

11

Note: See next page for description

May 2013 EFM-SO#106134

Hydraulic Power Unit Overview
Tramp Release Switch
Crush - Pressurizes rod end of tramp cylinders
holding adjustment ring to main frame service
- used with clear button, pressurizes cap end of
tramp cylinders to raise bowl to clear crusher.
Off - Prevents tramp cylinders from extending or
retracting.
Lock Post Clamping Switch
Unclamp - Unclamps bowl from adjustment ring.
Clamp - Clamps bowl to adjustment ring.
Off - Prevents bowl clamping cylinders from
extending or retracting.
Ram Switch
Crush - Ram retracted
Emergency Stop Button
Pull out to run hydraulic unit, push in to stop
hydraulic unit.
Dirty Filter Light
Light illuminates when the filter cartridge needs
to be changed. (When filter differential is 43 PSI.)
Light will only function with fluid going through
filter.
High-Temp Light
Light illuminates when temperature of hydraulic
oil reaches 150º F and hydraulic unit shuts down.
To reset high temperature condition turn selector
switches 1, 2, and 3 to “off” position.
Low Oil Light
Light illuminates when oil level in tank reaches 8
inches from bottom.

Adjust - Used with ram open and ram closed Emergency Stop Reset
buttons, must manually hold in this position To start the system, press and release after
pulling out the Emergency Stop Button.
Off - Ram will not extend or retract

Clear Button
Turn tramp release switch to service position,
press and hold button to raise adjustment ring.
Adjustment ring stays up as long as button is
depressed.

Ram Open Button

Turn lock post switch to “unclamp,” hold ram
switch in, adjust position, then press and hold
this button. This allows the ram to cycle back and
forth turning the bowl open.

Ram Closed Button

Turn lock post switch to “unclamp,” hold ram
switch in, adjust position then press and hold
button. This allows the rams to cycle back and
forth to turn the bowl closed.

May 2013 EFM-SO#106134

Hydraulic Power Unit Overview
Gauges & Charging Valves
Lock Post Hydraulic Pressure
Must always be above 2500 PSI during crusher
operation.
Lock Post Accumulator Pre-charge Pressure
Must always be above 1000 PSI. See procedure
to check pressure.
Lock Post Accumulator Charging Valve
See charging procedure.
System Hydraulic Pressure
Maximum of 3000 PSI with pump running.
Tramp Hydraulic Pressure
Must be between 1600 and 1900 PSI when the
crusher is running.
May 2013 EFM-SO#106134
Tramp Accumulator Pre-charge Pressure
Must be 1500 PSI. Used only with systems using
cylinders with internal accumulators. Systems
having cylinders with external accumulators
do not use this gauge. Accumulator pressure
must be checked at each accumulator. (See
“Maintenance”.)
Tramp Accumulator Charging Valve
Used only with systems using cylinders with
internal accumulators. (See “Maintenance”.)
Systems having external accumulators do not use
this valve. Charging is done at each accumulator.
Hydraulic Power Unit Overview

Warning Lights
Three lights on top of the hydraulic power unit display
status of unit during crushing.

Red Light
Steady light means high oil temperature in tank.
Stop crushing to determine cause of high oil
temperature.

Blinking light means pressure is low in either

tramp or lock post hydraulic circuit. Stop crushing
immediately or crusher damage may result.

Green Light
Steady light means tramp pressure is ok.

Blue Light
Steady light means lock post pressure is ok.

No Lights On - The Unit has lost electrical power.

Must stop crushing to troubleshoot the problem.

Lubrication
Unscrew the breather, fill power unit with 40 gallons
of hydraulic oil having the following specifications.
Use high-grade paraffin base (not naphthalene base)
industrial oil.

Oil specifications for normal year round

operating conditions:
Viscosity at 100° F.....................................140-160 SUS
Viscosity at 210° F...........................................40-50 SUS
Viscosity Index (VI.....................90 or higher ISO32 Oil

May 2013 EFM-SO#106134

Hydraulic Power Unit Overview

Two types of filters may be used depending on the model. Both are located under
the hood of the power unit.

Return Line Filter

Monitor the filter back pressure. If the pressure shown on the pressure gauge
is below 20 PSI, the filter does not need to be replaced. However, if the pressure
exceeds 20 PSI the filter should be replaced.

To Change Filter Cartridge

Turn the cartridge counter-clockwise until the cartridge drops off the threads.
Thread the new cartridge on the threads and hand tighten.

Pressure Line Filter

Monitor the filter differential pressure. The light will only function with fluid
going through the filter. If the light comes on, turn off power to the hydraulic
power unit. If the light comes on when power is restored and fluid is flowing,
then the filter must be changed.

• To change filter element:

• Turn tramp release, lock post and ram selector switches to “off.”
• Loosen and remove the filter housing by turning counterclockwise.
• Pull the dirty element from the housing and clean the housing
with a mild solvent.
• Place new element in housing. Center it on the element locator.
• Inspect the O-ring and if ok, hand tighten housing.

Electrical Connection at
Hydraulic Power Unit

Power from the customer-supplied 3-phase

electrical disconnect is connected on this
side of the fuse block. No other field electrical
connections are needed.

May 2013 EFM-SO#106134

Bleeding & Pressure-Testing Hydraulic Circuits
Do not pressurize tramp or lock post hydraulic
circuits unless the associated accumulator has been
pre-charged with the correct nitrogen pressure.
Pressurizing the accumulator without pre-charging
will damage the accumulator bladder and require
replacement.
No attempt should ever be made to bleed any hydraulic
circuit when the circuit is fully pressurized. High
pressure oil will escape and may cause bodily harm.
Always wear suitable eye protection when bleeding any
circuit.
During the initial start-up or whenever hydraulic circuit
components have been disconnected, it is necessary to
remove air that may be trapped (bleeding).
When the hydraulic circuits are being pressurized for
the first time, monitor the oil level sight gauge and add
oil as necessary. Do a cleaning cycle before adding more
oil. If this is not done, the tank may overflow!
Two people in communication with each other are
required to bleed the hydraulic circuits.
May 2013 EFM-SO#106134
Bleed Tramp Circuit
To bleed the tramp circuit, it is necessary to run the
pump for short periods. Turn the lock post and ram
selector switch to “off.” Repeatedly turn the tramp
release selector switch from “off” to “crush” to maintain
a circuit pressure of 200 PSI (14bar). This pressure
will maintain a flow of oil necessary to bleed the circuit
without creating a hazardous high-pressure condition.
Bleed Clearing Circuit
To bleed the clearing circuit, it is necessary to run the
pump for short periods. Turn the lock post and ram
selector switch to “off.” Turn the tramp release selector
switch to “service” then repeatedly press “clear” to
maintain a circuit pressure of 200 PSI (14bar). This
pressure will maintain a flow of oil necessary to bleed
the circuit without creating a hazardous high-pressure
condition.
Bleed Lock Post Circuit
To bleed the lock post circuit, it is necessary to run
the pump for short periods. Turn the ram selector
switch to “off.” Turn the tramp release selector switch
to “service” then repeatedly press “clear” to maintain
a circuit pressure of 200 PSI (14bar). This pressure
will maintain a flow of oil necessary to bleed the circuit
without creating a hazardous high-pressure condition.
Bleed Ram Circuit
To bleed the ram circuit, it is necessary to run the pump
for short periods. Turn the tramp release selector
switch to “service.” Turn the lock post selector switch
to “unclamp.” Turn the ram selector switch to “adjust.”
Repeatedly press “ram open” and “ram closed” to
maintain a circuit pressure of 200 PSI (14bar). This
pressure will maintain a flow of oil necessary to bleed
the circuit without creating a hazardous high-pressure
condition.
Hydraulic Power Unit Adjustments
Pressure Relief
Valve RV1A
Clearing the crusher
set at 2000 PSI

Flow Control Valve

Setting is site specific

Pressure Relief
Valve RV2A
Tramp pressure set
at 2000 PSI

Manual Pressure
Dump of Tramp
Pressure

Manual Pressure
Dump of Bowl
Clamping Pressure

Pressure Relief
Valve RV2
Lock post pressure set
at 3000 PSI

The hydraulic power unit was set up and tested prior to
delivery. It will not be necessary to change any relief or
pressure sensor settings.
It will be necessary to adjust (item 2) the flow control
valve which controls the lowering of the adjustment ring
to the main frame. This valve can only be adjusted after
the power unit is filled with oil, all hydraulic hoses are
connected and bled, and electrical power is available to
the unit.
To set the flow control valve, turn the tramp release
selector switch to “service,” raise the adjustment ring
by holding in the “clear” button. Loosen the lock nut
on the flow control valve (item 2) and slowly turn the
adjustment screw until the adjustment ring begins to
gradually lower to the main frame.

Safety Blocks
Safety blocks must be cut to fit the crusher application.
To determine the length of block, do a clearing cycle as
described in “Operation” and cut the safety block to fit in
the location as shown below.

Adjustment Ring
Main Frame Pin
Safety Block (Cut to Fit)
Main Frame Bushing
Main Frame

May 2013 EFM-SO#106134

Operation Maintenance

Crusher Mode Checking Lock Post

Once the unit has been installed and oil pressures Accumulator Pressure
have been checked, the crusher is ready to be put into
operation. Inspect the installation to ensure that there
are no oil leaks and the hydraulic hoses are routed in 1. Stop the crusher and lock out power to the
a manner to prevent them from becoming frayed or hydraulic power unit starting circuit.
damaged. Make certain the electrical voltage is always
supplied to the power unit when the crusher is operating 2. Turn the lock post selector switch to the “off”
and the selector switches on the power unit are in the position.
“crush” and “clamp” positions.
3. Open the dump valve (turn screw in) (item 5,
Start the crusher and operate it just as you have done “Hydraulic Power Unit Adjustments”) to drop the
in the past. As crushing continues, the pressure in
hydraulic pressure to 0 PSI.
the base of the cylinders will bleed down slowly. The
operating pressure range of the system is between
1500 and 1700 PSI. When the pressure in the base 4. Read nitrogen pressure on lock post pre-charge
of the cylinders falls below 1500 PSI, the unit will start pressure gauge (item 2, “Gauges & Charging
to automatically pressurize the circuit to 1700 PSI, Valves”). Correct pressure is 1000 PSI ± 50.
then shut off. This action is normal. If you notice the If it is ok, screw dump valve adjustment screw
unit cycling more and more often, either the dump valve out, turn lock post selector switch to “clamp,”
is not properly closed or one of the cylinders is leaking apply power to unit (power unit will start to
hydraulic oil. re-pressurize circuit), then start the crusher. If
charging is required, see steps below.
If for some reason the operating pressure drops below
1400 PSI, the red strobe light will begin to flash and you
must stop crushing. Operating with reduced clamping
pressure can and will damage the crusher.

Service/Clear Mode Charging Lock Post Accumulator

If the crusher stalls due to overload or tramp material,
turn the tramp release selector switch to “service”
mode. Make sure that no one is near or on the crusher.
Then hold in the “clear” button to raise the adjustment
ring and bowl assembly off the main frame. The total
travel is approximately 6 inches. Immediately after the
adjustment ring travels the full height, position safety Use only nitrogen gas to charge accumulator. Use
blocks in between the adjustment ring and main frame. of any other gas may be explosive or may produce
This ensures that the raised adjustment ring does not explosive mixtures in the system.
accidentally come down while the crusher cavity is being DO NOT USE OXYGEN!
cleared. After the cavity is cleared, remove the safety
blocks and make sure everyone is away from the crusher. 1. Before attaching charging kit to the power unit,
You are now ready to go back to crush mode by turning
loosen (turn counter-clockwise) tee handle on the
the tramp release selector switch to “crush.”
hose unit.

2. Crack open the valve on the nitrogen bottle to

purge air from the line. Shut off the valve.

3. Attach the hose adapter to lock post charging

valve (item 3, “Gauges & Charging Valves) on
power unit. Tighten to 50 in-lbs.

May 2013 EFM-SO#106134

Maintenance
Checking Tramp Accumulator Pressure
(Accumulators in Cylinders)

1. Stop the crusher and lock out power to the

hydraulic power unit starting circuit.

2. Turn the tramp release selector switch to the

“off” position.

3. Open the dump valve (turn screw in) (item 4,

“Hydraulic Power Unit Adjustments”) to drop
hydraulic pressure to 0 PSI.

4. Read the nitrogen pressure on the tramp

pre-charge pressure gauge (item 6, “Gauges
& Charging Valves”). The correct pressure is
1500 PSI ± 50. If it is ok, screw the dump valve
adjustment screw out, turn the tramp selector
switch to “crush,” apply power to unit (power
unit will start to re-pressurize circuit), then start
Tee Handle crusher. If charging is required, see steps below.

5/8” Hex Jam Nut

4. Loosen 5/8” hex jam nut on the charging valve Charging Tramp Accumulators
(Accumulators in Cylinders)
mounted on the power unit and slowly open the
valve on the nitrogen bottle to allow gas to enter
the system. Since operating pressure of the
system is about 3/4 pressure in a new bottle,
multiple bottles may be required to fully charge
system.
Use only nitrogen gas to charge accumulator. Use
5. Continue charging until the lock post pre-charge of any other gas may be explosive or may produce
gauge (item 2, “Gauges & Charging Valves) reads explosive mixtures in the system.
1000 PSI. Tighten the tramp pre-charge charging DO NOT USE OXYGEN!
valve jam nut, close the valve on the nitrogen
bottle, remove charging valve. Screw the dump
1. Before attaching charging kit to power unit,
valve adjustment screw out, turn the tramp
loosen (turn counter-clockwise) the tee handle on
release selector switch to “clamp,” apply power to
the hose unit.
unit (power unit will start to re-pressurize circuit),
then start the crusher.
2. Crack open the valve on the nitrogen bottle to
purge air from the line. Shut off the valve.

May 2013 EFM-SO#106134

Maintenance
3. Attach the hose adapter to the tramp charging
valve (see item 7, Gauges & Charging Valves”) on
the power unit. Tighten to 50 in-lbs.
4. Loosen 5/8” hex jam nut on the charging valve
mounted on the power unit and slowly open the
valve on the nitrogen bottle to allow gas to enter
the system. Since operating pressure of the
system is about three-quarter the pressure in a
new bottle, mulitple bottles are required to full
charge the system.
Tee Handle
5/8” Hex Jam Nut
5. Continue charging until the tramp pre-charge
gauge (item 6, “Gauges & Charging Valves”) reads
1500 PSI. Tighten tramp pre-charge charging the
valve jam nut, close valve on the nitrogen bottle,
and remove the charging valve. Screw the dump
valve adjustment screw out, turn tramp release
selector switch to “clamp,” apply power to the
unit (power unit will start to re-pressurize circuit),
then start crusher.
May 2013 EFM-SO#106134
Checking Tramp
Accumulator Pressure
(External Accumulators)
1. Stop the crusher and lock out power to the
hydraulic power unit starting circuit.
2. Turn the tramp release selector switch to the
“off” position.
3. Open the dump valve (turn screw in) (item 4,
“Hydraulic Power Unit Adjustments”) to drop the
hydraulic pressure to 0 PSI.
4. Read nitrogen pressure on the charging
assembly gauge. The correct pressure is 1500
PSI ± 50. If it is ok, screw the dump valve
adjustment screw out, turn the tramp selector
switch to “crush,” apply power to the unit (power
unit will start to re-pressurize the circuit), then
start the crusher. If charging is required, see
steps below.
Charging Tramp Accumulators
(External Accumulators)
Use only nitrogen gas to charge accumulator. Use
of any other gas may be explosive or may produce
explosive mixtures in the system.
DO NOT USE OXYGEN!
1. Use charging and checking assembly shown at
the right.
2. Remove the valve cap from the accumulator.
3. Before mounting the assembly to the
accumulator, turn the T-handle on the air chuck
out (counter-clockwise) until it no longer can be
turned.
4. Close the bleeder valve on the assembly.
Maintenance
5. Turn the swivel on the air chuck onto the valve
stem until it is hand tight, then tighten ¼ turn
more using a small wrench.

6. Turn T-handle on air chuck in until gas flows and

pressure registers on gauge. Do not screw
T-handle in until it stops, as this bends the valve
core.

7. Pressure above the recommended setting can be

bled off using the bleeder valve.

8. If the pressure is below the recommended

minimum, connect the assembly while it is still
attached to the accumulator to a cylinder of
nitrogen gas using 10’ hose and adapter.

9. Slowly open the valve on the nitrogen bottle and

screw in (clockwise) the T-handle on the assembly
until the gas flows to the accumulator.

10. When charge pressure reaches 1500 PSI

[103bar], screw out the T-handle, close the valve
on the nitrogen bottle, and use the bleeder valve
to bleed off any pressure in the hose. Screw
Bleeder Valve
Gas Charging Valve
Pressure Gauge
T-Handle
Air Chuck
Swivel
Gas Valve Stem
Hydraulic
Charging Accumulator
Unit

May 2013 EFM-SO#106134

Maintenance Schedule

Event Daily Weekly Monthly 6 Months Yearly

Check Hydraulic Pressure X

Check Oil Reservoir Level X

Check Tramp Accumulator X

Pressure

Check Lock Post Accumulator X

Pressure

Inspect Oil Leaks X

Replace Oil Filter X*

Change Oil X

Grease Motor X

*Monitor the filter back pressure. The light will only function with fluid going through the filter. If the light comes on, turn off the
power to the hydraulic power unit. This action should reset the pressure light if the filter is still acceptable. If the filter is not
acceptable, the light will come on and it will be necessary to schedule some down time to replace the filter.

May 2013 EFM-SO#106134

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Pekin, Illinois • 61555-0400 • USA
Fax +1.309.347.1931 • sales@ExcelFoundry.com

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call 309.202.8300 to speak to an
Excel Professional anytime.

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