Sandvik Mining CH440 Operators Manual - PDF DOWNLOAD

operator’s manual

Doc. no. S 223.543 en

SANDVIK CH440:01

This document is valid for:

Serial no. / Machine no.

Sign.

SANDVIK CH440:01 © Copyright 2006–2007 Sandvik SRP AB. All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints.

Document number: S 223.543 en Issue: yyyymmdd Version: 2

Sandvik SRP AB Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com

Table of contents

1. Introduction 1.1 Equipment information.......................................................... 6 1.1.1 Document information.............................................. 9 1.2 Operating principles of a cone crusher ............................... 10 1.2.1 Description ............................................................. 12

2. Safety precautions 2.1 Hazard information ............................................................. 16 2.1.1 Warning signs ........................................................ 16 2.1.2 Risk levels.............................................................. 16 2.1.3 Prohibition signs..................................................... 16 2.1.4 Mandatory signs..................................................... 16 2.2 Personnel............................................................................ 17 2.2.1 Personal protection ................................................ 18 2.3 General safety precautions................................................. 18 2.3.1 Machine safety guards........................................... 19 2.3.2 Electrical safety...................................................... 20 2.3.3 Welding .................................................................. 20 2.3.4 Hydraulic system.................................................... 21 2.3.5 Lifting and moving loads ........................................ 21 2.3.6 Feed and jams ....................................................... 22 2.4 Emissions ........................................................................... 22 2.4.1 Dust........................................................................ 22 2.4.2 Noise...................................................................... 23 2.4.3 Radioactivity........................................................... 23

3. Technical data 3.1 General data ....................................................................... 26 3.2 Processing data .................................................................. 26

4. Starting up the cone crusher 4.1 General ............................................................................... 28 4.2 Running-in .......................................................................... 28 4.2.1 Checking the setting with lead ............................... 29 4.2.2 Starting the main oil pump ..................................... 30 4.2.3 Bleeding air from the Hydroset system .................. 30 4.2.4 Maximum load........................................................ 31 CH440:01

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Table of contents 4.2.5

Starting a crusher in extremely low temperatures .. 32

5. Using the cone crusher 5.1 Starting and stopping .......................................................... 34 5.1.1 Starting the crusher ................................................ 34 5.1.2 Stopping the crusher .............................................. 34 5.2 Checking the setting ........................................................... 35 5.3 Changing oil ........................................................................ 35 5.3.1 Normal operating conditions .................................. 35 5.3.2 Operation at elevated temperatures....................... 36 5.3.3 Operation in low temperatures ............................... 37 5.4 Checking the V-belt tension ................................................ 38 5.5 Accumulator ........................................................................ 38 5.6 Clearing out the crushing chamber ..................................... 38

6. Inspection and care 6.1 Routine inspection and care ............................................... 40 6.1.1 Daily ....................................................................... 40 6.1.2 Weekly.................................................................... 41 6.1.3 Monthly................................................................... 42 6.1.4 Twice a year ........................................................... 42 6.1.5 Yearly ..................................................................... 43 6.2 Standard tool box ................................................................ 44 6.3 Bottomshell and mainshaft assembly ................................. 45 6.3.1 Dust seal ring ......................................................... 46 6.3.2 Scraper................................................................... 46 6.4 V-belts ................................................................................. 47 6.4.1 Direction of rotation ................................................ 47 6.4.2 V-belt tension ......................................................... 48 6.5 Topshell assembly............................................................... 49 6.6 Hydroset and lubrication system......................................... 49 6.7 Over-pressure dust sealing................................................. 49 6.7.1 Dust sealing principles ........................................... 50 6.7.2 Blower .................................................................... 51 6.7.3 Regulator assembly for compressed air................. 51

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Table of contents

7. Lubrication 7.1 Lubricant requirements ....................................................... 54 7.1.1 Miscibility................................................................ 54 7.1.2 Low temperatures .................................................. 54 7.1.3 High temperatures ................................................. 55 7.2 Oil for lubrication system .................................................... 55 7.3 Oil for Hydroset system ...................................................... 57 7.4 Oil for pinionshaft lubrication .............................................. 59 7.5 Grease for spider bearing lubrication.................................. 60

8. Hydroset and lubrication system 8.1 Overview............................................................................. 64 8.1.1 Tank unit................................................................. 64 8.1.2 Cabinet................................................................... 64 8.2 Main lubrication system ...................................................... 66 8.2.1 Cleaning the tank ................................................... 67 8.2.2 Dirt trap .................................................................. 67 8.2.3 Oil filter................................................................... 68 8.2.4 Oil pump................................................................. 68 8.2.5 Pressure gauge...................................................... 69 8.2.6 Pressure drop indicator.......................................... 69 8.2.7 Temperature gauge................................................ 70 8.2.8 Pressure relief valve .............................................. 70 8.2.9 Return oil flow switch ............................................. 70 8.2.10 Oil strainer.............................................................. 72 8.2.11 Thermostats ........................................................... 72 8.2.12 Oil heating.............................................................. 74 8.3 Exchanging main lubrication oil .......................................... 75 8.3.1 Draining the main lubrication system ..................... 75 8.3.2 Cleaning the dirt trap.............................................. 76 8.3.3 Changing filter elements ........................................ 77 8.3.4 Cleaning the return oil strainer and tank ................ 78 8.3.5 Cleaning the air/oil heat exchanger (option) .......... 79 8.3.6 Refilling the main lubrication system...................... 79 8.4 Pinionshaft lubrication system ............................................ 80 8.4.1 Oil filter................................................................... 80 8.4.2 Oil pump................................................................. 81 8.4.3 Pressure gauge...................................................... 81 8.4.4 Pressure drop indicator.......................................... 81 CH440:01

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Table of contents 8.5 Water/oil heat exchanger (option) ....................................... 82 8.6 Air/oil heat exchanger (option) ............................................ 83 8.7 Hydroset system ................................................................. 83 8.7.1 Hydroset pump....................................................... 84 8.7.2 Oil filter ................................................................... 84 8.7.3 Dirt trap (magnetic plug)......................................... 84 8.7.4 Control valve .......................................................... 85 8.7.5 Pressure gauge...................................................... 86

9. Accumulator 9.1 General ............................................................................... 88 9.2 Flow regulator ..................................................................... 89 9.3 Charging kit (option)............................................................ 89 9.3.1 Checking the gas pressure .................................... 90 9.3.2 Charging with nitrogen ........................................... 91

10. Topshell assembly 10.1 Exchanging the spider cap.................................................. 94 10.1.1 Removing the spider cap ....................................... 94 10.1.2 Spider cap removal checks .................................... 95 10.1.3 Installing the spider cap ......................................... 95 10.2 Inspection of crushing chamber .......................................... 96 10.3 Spider bearing..................................................................... 98 10.3.1 Inspecting the spider bearing ................................. 98

11. Setting measurement 11.1 General ............................................................................. 102 11.1.1 Checking the setting with lead ............................. 102

12. Troubleshooting 12.1 Faults and suggested corrective actions........................... 104

Appendix A: Inspection

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1. Introduction To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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1. Introduction

1.1 Equipment information Purpose The purpose of this Sandvik equipment is to be a crusher component in a crushing and screening unit or site within an aggregate or mining process.

The machine reduces the size of rocks, minerals and similar materials. This crusher component has been exclusively designed for this application.

Unless the crusher is part of a complete plant delivery, Sandvik SRP AB is not responsible for the complete aggregate or mining process. Sandvik SRP AB will not accept any liability for damage to equipment or injury to personnel caused by unauthorized or improper use or modification of this equipment.

Manufacturer This Sandvik equipment has been manufactured by: Sandvik SRP AB Stationsplan SE-233 81 Svedala Sweden www.sandvik.com For maintenance Contact the nearest Sandvik Rock Processing company, agent or representative, or the manufacturer directly: Sandvik SRP AB Service department SE-233 81 Svedala Sweden Telephone +46 (0)40 409000 Telefax +46 (0)40 409260

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1. Introduction Crusher identification The figure below shows an example of the crusher’s identification plate. The identification plate contains data needed when contacting Sandvik SRP AB concerning this specific equipment.

The “Type” number is a designation system that describes the product.

Identification plate 1 Type 2 Part number 3 Serial number 4 Mass (kg) 5 Order number 6 Manufacturer 7 Year of manufacture 8 CE mark Type: 9 Type and size of crusher 10 Crushing chamber (concave ring) 11 Mantle 12 Filler ring 13 Eccentric throw (mm) 14 Mark number

CH440:01

8 7

3

1 2

5

4

6

CH440-M/B/M-36/40/44/32:1 9

10 11

12

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14

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1. Introduction Tank unit identification The figure below shows an example of the tank unit’s identification plate.

The identification plate contains data needed when contacting Sandvik SRP AB concerning this specific equipment.

15 16 17 18 19 20 21 22

Type Part number Serial number Mass (kg) Order number Manufacturer Year of manufacture CE mark

22 21

15

16

17

18 19

20

CE marking This equipment complies with the basic health, environment and safety regulations of the European Union and European Economic Area. Sandvik SRP AB will not take responsibility for this compliance when customers modify any configuration of the cone crusher.

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1. Introduction

1.1.1 Document information Purpose of this Operator’s manual The purpose of this Operator’s manual is to provide the operator with information on how to handle and operate this Sandvik equipment.

It is important to: • keep the manual for the lifetime of the equipment • pass the manual on to any subsequent holder or user of the equipment Figures in this manual Some figures in this manual are based on the CH430 cone crusher, which is similar to the CH440. Details of less or no importance for instructions given can therefore differ from the CH440 design.

Document compliance The instructions in this document are in accordance with the design and construction of the equipment at the time it was delivered from the Sandvik SRP manufacturing plant.

Technical publications Technical publications related to installation and operation of this equipment are: • Installation manual (IM) • Wear parts catalog (WPC) • Operator’s manual (OM) When ordering technical publications, always specify the language and quote the machine identity number.

Technical publications related to maintenance of this equipment are: • Maintenance manual (MM) • Spare parts catalog (SPC) These publications are only available to trained maintenance personnel.

Sandvik SRP AB can provide adequate training and authorize personnel.

Read more about the document structure and accompanying work roles in section 2.2 Personnel.

Number of pages This document contains a total of 112 pages.

Feedback If you have comments on this Operator’s manual or problems connected to the crusher’s documentation, send an e-mail to: manuals.srp@sandvik.com

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1. Introduction

1.2 Operating principles of a cone crusher In a cone crusher the process material is crushed between two rigid surfaces.

The motion of the moving surface is independent of the load on the crusher.

The crushing action is achieved by an eccentric gyratory movement of the mainshaft (6). Individual pieces of process material (e. g. rock or ore) are nipped, compressed and crushed between the mantle (4) and the concave ring (3).

The quality and quantity of the produced process material is a product of the interaction between the crusher and the process material. The crushing chamber’s geometry, the crusher’s dynamics and the process material are the most important factors.

The concave ring, mantle, eccentric assembly (5) and the location of the pivot point determine the chamber geometry of the cone crusher. The crusher’s drive motor rotates the eccentric assembly at a constant speed through a gear transmission. The rotation of the eccentric assembly causes the lower end of the mainshaft to gyrate. At the top of the mainshaft is the spider bearing (1) that acts as the pivot point for this gyrating motion. The mantle is fixed to the mainshaft and the concave ring is fixed to the topshell (2). The gyration of the mainshaft means that the distance between the mantle and the concave ring continually varies. When this distance decreases the incoming process material will be subjected to a compressing stress and will be crushed. When the mantle moves away from the concave ring, the process material is able to flow down through the chamber.

The mantle and the concave ring must be replaced regularly as they are continuously worn. The rate of which this wear occurs depends on the characteristics of the process material. Read more in section 10.2 Inspection of crushing chamber.

1 2 3 4 5 6

10

Spider bearing Topshell Concave ring Mantle Eccentric assembly Mainshaft

1 2 3 4 5 6

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1. Introduction Setting adjustment Due to the need to compensate for wear and the need to produce different product sizes the crusher has a setting control system. It basically consists of a robust hydraulic jack, named Hydroset, which supports the mainshaft and adjusts its position. By moving the mainshaft up and down, the discharge setting can be changed and the size of the crushed material can thereby be changed. Read more in section 11. Setting measurement. setting decrease = finer product

setting increase = coarser product

=

=

Auxiliary lubrication systems There are two separate circulatory lubrication systems – the main lubrication system and the pinionshaft lubrication system. The main lubrication system is described in section 8.2 Main lubrication system. The pinionshaft lubrication system is described in section 8.4 Pinionshaft lubrication system.

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1. Introduction

1.2.1 Description The following figures show an overview of the cone crusher’s nomenclature and components. Grey areas indicate cross-sections.

Cone crusher – intersected view

1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Spider cap Spider bushing Head nut Mantle Concave ring Mainshaft with headcentre Eccentric wearing plate Bottomshell bushing Eccentric Eccentric bushing Step bearing Hydroset piston Pinionshaft housing Pinionshaft Dust collar Locating bar Dust seal ring Bottomshell Topshell Filler ring

2 3 4 5 6

7 8

9 10 11

20 19 18 17 16 15

14 13 12

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1. Introduction Cone crusher – side view

21 21 22 23 24

Hole for level indicator Inspection door Feed hopper Inspection hatch

22 23

24

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1. Introduction Tank unit and auxiliary equipment

25 26 27 28 29 30

25

Over-pressure blower Over-pressure air regulator Tank unit Water/oil heat exchanger Air/oil heat exchanger Charging kit for accumulator

26 27 28 29

30

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2. Safety precautions To ensure maximum safety, always read this section carefully before doing any work on the equipment or making any adjustments.

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2. Safety precautions

2.1 Hazard information 2.1.1 Warning signs

General danger

Dangerous voltage

Risk of crushing

Hanging load

Risk of crushing

Flying fragments

2.1.2 Risk levels Throughout the manual, levels of risk is indicated as “DANGER”, “WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels are accompanied by a warning sign (see above).

Failure to observe information marked “DANGER!” can result in lifethreatening injuries!

DANGER! Failure to observe information marked “WARNING!” can result in personal injury and/or serious damage to, or destruction of, equipment!

WARNING! CAUTION!

Failure to observe information marked “Caution!” can result in damage to equipment!

2.1.3 Prohibition signs

Do not remove guards

2.1.4 Mandatory signs

Disconnect current before any work

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Read the manual

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2. Safety precautions

2.2 Personnel All work on the equipment is to be carried out only by trained or authorized personnel.

– “Trained” means that the person in question has been given practical instruction by an authorized person on how the various tasks are to be carried out.

– “Authorized” means that a person has undergone a theoretical and practical test of knowledge, organized by Sandvik SRP AB. He/she is therefore judged to have the knowledge and competence to carry out the tasks assigned to the appropriate role.

All expected work tasks on this production equipment have been defined by Sandvik SRP AB as belonging to one of three categories – work roles – based on different competence profiles. These three work roles are: • Installation • Operation • Maintenance Sandvik SRP AB provides technical documentation appropriate to all three work roles: • Installation manual • Operator’s manual and Wear parts catalog • Maintenance manual and Spare parts catalog Sandvik SRP AB can provide adequate training for all three work roles and can carry out authorization of trained personnel.

The technical documentation from Sandvik SRP AB covers only work on the production equipment itself – it does not cover work tasks associated with other equipment or routines at the site.

It is the responsibility of the plant management to assign responsibility for: • The production equipment and the work area around the equipment • All personnel in the vicinity of the equipment • Compliance with national and local safety regulations • Checking that all safety devices are fully operational Sandvik SRP AB declines all responsibility for injury or damage resulting from non-compliance with the instructions in this manual.

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2. Safety precautions

2.2.1 Personal protection Sandvik SRP AB strongly recommends that personal protective equipment is always worn when working in the vicinity of the equipment.

The Sandvik SRP AB recommendation for personal protective equipment includes:

Ear protection

Safety helmet

Eye protection

Protective gloves

Safety boots

Mask or breathing apparatus

2.3 General safety precautions

WARNING!

Falling stones Clear the feed arrangement from process material before any maintenance work is carried out inside or below the crusher, to prevent stones from falling down.

Always switch off power and lock out the equipment (secure it cannot be switched on) before any maintenance work is started. Also ensure that it is not possible for anyone else to switch the power on while maintenance work is being done.

(Continued)

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2. Safety precautions Avoid remaining on the crusher, unless necessary for maintenance work.

DANGER!

Risk of crushing Never remain on the crusher while crushing. Moving parts constitute a risk of crushing. Falling into the crusher implies danger of being crushed.

WARNING!

Risk of crushing If the crusher is mounted on rubber dampers, there is a risk of crushing between the oscillating parts of the crusher and the stationary frame.

Ejection Never look into the crusher while crushing. Fragments and possibly harmful substances fed to the crusher may be ejected.

WARNING!

2.3.1 Machine safety guards Do not remove guards Make sure that all guards are in place and functioning, to prevent exposure to flying fragments and rotating parts. Never operate the PROHIBITION! equipment unles guards are mounted.

Rotating parts Exposure to rotating parts of the equipment shall be prevented by guards. Always attach guards after maintenance work.

WARNING!

WARNING!

Flying fragments Fragments ejected upwards may fall down in the vicinity of the crusher. Provide adequate guards and warning signs at appropriate places around the danger zone.

Upwardly ejected fragments may fall down in the vicinity of the crusher.

Therefore Sandvik SRP AB recommends additional protection.

Platforms with guard rails shall be installed around the crusher’s feed opening. Walkways, stairs and ladders must be designed in accordance with applicable regulations. (These parts are not included in the crusher’s standard specification).

Make sure all defective guards and dust sealing components are checked, repaired and replaced before starting the equipment.

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2. Safety precautions

2.3.2 Electrical safety CAUTION!

Only electrical personnel working according to European Standard EN 50110 or similar are permitted to perform electrical operations on the crusher.

Dangerous voltage Personnel must regard all electrical equipment as live until it is proven dead by proper testing procedures.

DANGER!

Make sure all broken or damaged electrical cables and connectors are checked, repaired and replaced before starting the equipment.

Control cabinets must be lockable.

2.3.3 Welding CAUTION!

Welding on the crusher is only permitted when and as described in the manual. For all other welding operations on the crusher local Sandvik Rock Processing service personnel must be consulted.

CAUTION!

Only welders qualified according to European Standard EN 287 or similar are permitted to perform welding operations on the crusher.

If welding an item to the crusher, ground must be attached to the item itself.

If a crusher component is to be welded, ground should be attached as near to the welding area as possible.

WARNING!

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Toxic gases Inhalation of welding fumes can be dangerous to health. Always follow instructions provided by the welding equipment supplier.

Some parts of the crusher are made of manganese steel. Long-term exposure to manganese oxide can affect the nervous system.

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2. Safety precautions

2.3.4 Hydraulic system CAUTION!

Only personnel certified in hydraulics are permitted to perform operations on the hydraulic system.

WARNING!

Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system.

CAUTION!

Never adjust pressure relief valves beyond the recommended values.

Oil temperature Hydraulic oil can get very hot in operation. Allow the oil to cool before working on the hydraulic system.

WARNING!

Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.

2.3.5 Lifting and moving loads CAUTION!

Only personnel with adequate lifting training are permitted to perform lifting operation.

Hanging load Never work or stand underneath a crane that is lifting material. Keep a safe distance from a hanging load.

DANGER!

Make sure that the capacity of the lifting equipment is adequate and that the equipment itself is in good working order.

If a lifting tackle has to be made up by joining separate components, make sure that the joints are secure and have the same lifting capacity as the rest of the tackle.

NOTE!

Always use lifting tackle certified in accordance with local conditions.

Always engage the safety clips on lifting hooks to prevent the tackle from slipping off.

Use ropes or poles to steady and maneuver loads. Do not use hands or feet.

Make sure that the route and the destination are free from obstacles before moving a suspended load. It must be possible to lower the load to the floor quickly and safely in an emergency.

When depositing loads, keep the lifting equipment in place until the stability of the load has been checked.

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2. Safety precautions

2.3.6 Feed and jams CAUTION!

When the crushing chamber is empty, avoid feeding solitary round rocks.

CAUTION!

Never feed combustible process material into the crusher.

WARNING!

Flying fragments Never use wedges etc. to clear jams in the feed opening. Stones and fragments can be thrown out at high speed from the crushing chamber.

WARNING!

DANGER!

Explosives Never remove blocking boulders from the crusher by blasting.

Blasting may cause personal injury and seriously damage bearings or other parts. Sandvik SRP AB takes no responsibility for injury to personnel or damage to the equipment when blasting is used.

Risk of crushing Never stand inside the crusher when a blockage is removed. You might be pulled forcefully and suddenly downwards together with the material in the crushing chamber and be crushed.

In some cases it is possible to increase the CSS (closed side setting) temporarily to clear a jam.

Always follow local regulations when attempting to clear a jam.

2.4 Emissions 2.4.1 Dust Health hazard Crushing and processing material will create dust. Such dust can be more or less dangerous to the health. Use a breathing mask.

DANGER!

Sandvik SRP AB strongly recommends using additional equipment for dust suppression. Examples are dust extraction (vacuum) and dust encapsulation by water spray or foam. Such equipment is not included in the crusher’s standard specification.

Sandvik SRP AB declines all responsibility for any health hazards caused by dust, generated when processing minerals in the crusher.

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2. Safety precautions

2.4.2 Noise Health hazards Crushing and processing material will create noise. Such noise can be more or less dangerous to the hearing. Use ear protection.

WARNING!

2.4.3 Radioactivity

DANGER!

Health hazards Radon is a radioactive gas that occurs naturally in bedrock. Radon may cause lung cancer. Mineral type, ventilation and water are all factors that influence the contents of radon gases.

Sandvik SRP AB declines all responsibility for any health hazards caused by the release of radon or any other harmful substances when processing minerals in the crusher.

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2. Safety precautions

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3. Technical data To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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3. Technical data

3.1 General data The data presented below are typical values. Specific data may vary depending on installation and machine configuration.

Characteristics

Data

Model

CH440

Type

Cone crusher

Application

Mineral processing

Total weight

14 300 kg

Length

2.35 m (3.59a m)

Width

2.10 m (2.19b m)

Height

2.96 m

Eccentric speed

320 rpm

Pinionshaft speed

1475 rpm

Max. motor power

250 kW / 335 hp

Drive

V-belts

a. With subframe

3.2 Processing data Characteristics (depending on crushing chamber)

Data

Max. feed size

35 to 230 mm

CSS min–max

6 to 44 mm

Nominal capacity

80 to 455 tonnes/h

The data above are typical. The capacity of the cone crusher is dependent on the crushing chamber, the eccentric throw, the crusher’s setting and the feed material’s bulk density, crushability, size analysis, moisture content, etc.

Consult Sandvik SRP AB regarding application of the crusher.

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4. Starting up the cone crusher This section describes how to start up the cone crusher.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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4. Starting up the cone crusher

4.1 General Each cone crusher delivered by Sandvik Rock Processing has been assembled, test run and checked in our factory before shipping. The test run is carried out without load to discover any mechanical faults.

4.2 Running-in The appropriate parts of this section apply also after repair work and the fitting of new parts. a) Start the main lubrication oil pump and pinionshaft oil pump. b) When the “Ready for start” signal is obtained, start the crusher’s drive motor. c) Check and adjust the setting. See section 4.2.1 Checking the setting with lead. d) Start the feed to the crusher. Feed the crusher carefully and gradually increase the load rate until it reaches 75 % of the maximum level for power draw or Hydroset pressure. See section 4.2.4 Maximum load. The load is altered by changing the setting.

CAUTION!

If possible the crushing chamber should be full. The crusher will not be run-in by idling. The crusher is normally run-in after approximately 16 hours operating at 75 % load. Thereafter increase the load gradually up to full load. Depending on the availability of material, and for other process engineering reasons, running-in can take longer. It is important that items e–g are followed carefully during the entire running-in procedure.

e) Check the return oil temperature regularly. This temperature should normally lie between 40°C (104°F) and 45°C (113°F). f) Check that the cooling system cuts in and out at the correct oil temperatures, see section 8.2.11 Thermostats.

NOTE!

If operating conditions differ from normal (Oil = ISO VG 150 viscosity), set the thermostats according to section 8.2.11 Thermostats and section 8.2.12 Oil heating. g) Inspect and clean the oil strainer regularly, see section 8.2.10 Oil strainer. Quite often, a small quantity of fine steel and bronze particles can be found on the oil strainer during the initial running-in period.

(Continued)

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4. Starting up the cone crusher h) Bleed the Hydroset system. See section 4.2.3 Bleeding air from the Hydroset system. i) Check that there is no movement between the topshell and bottomshell.

Put a finger between the topshell and bottomshell to feel possible vibrations. j) Check that there are no oil leaks from the lubrication and Hydroset lines. k) Check that the indicating pointer of the Hydroset pressure gauge moves steadily. See section 8.7.5 Pressure gauge. l) Check the temperature outside the pinionshaft housing with a suitable thermometer, e.g. infrared camera. The normal temperature is 50–60°C (122–140°F). m) Check that the feed is correctly distributed around the crushing chamber.

See the Installation manual. n) Check the power consumption and Hydroset pressure. See section 4.2.4 Maximum load and section 8.7.5 Pressure gauge. o) Check and record the main lubrication oil pressure, see section 8.2 Main lubrication system. Also check and record the pinionshaft oil pressure, see section 8.7 Hydroset system. p) Check for a ringing sound during crushing, it can indicate a loose mantle or concave ring. q) Check that there are no grease leaks from the spider bearing. r) After running-in is completed, check the tightness of all bolts and retension the V-belts. See section 6.4.2 V-belt tension.

4.2.1 Checking the setting with lead The CSS (Closed Side Setting) can easily be checked by using a lump of lead fastened to a steel wire and lowering it slowly into the discharge area of the crushing chamber. The lead lump will be squeezed and its thickness will then correspond to the setting. Make sure the lead lump is large enough to get a proper thickness measurement.

The CSS should occasionally be checked at 4 points, evenly spaced around the crushing chamber. This will enable you to detect uneven wear, which indicates an unsatisfactory feed arrangement. See section 11. Setting measurement.

CAUTION!

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The setting must never be so small that the power drawn by the crusher or the Hydroset pressure exceed limits given in section 4.2.4 Maximum load.

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4. Starting up the cone crusher

4.2.2 Starting the main oil pump Before the main oil pump is started check the oil level. When the pump is started, the oil tank must be full of oil so that the pump does not operate dry.

4.2.3 Bleeding air from the Hydroset system The air bleed measuring nipple (1) is mounted on the throat of the accumulator.

1 Measuring nipple 2 Air bleed hose 3 L1 push button box

3 1

2

a) Raise the mainshaft a few millimetres (mm) by using the L1 push button box (3), which is located in the vicinity of the cone crusher. b) Prepare to connect the air bleed hose (2) to the measuring nipple (1). c) Position the free end of the air bleed hose in a suitable receptacle. d) Screw the hose onto the measuring nipple. The non-return valve in the measuring nipple will automatically open when the hose is screwed on. e) When bubble-free oil comes out of the air bleed hose, raise the mainshaft a few millimeters (mm) more. f) Unscrew the hose from the measuring nipple. The non-return valve in the measuring nipple will automatically close. g) If necessary, repeat the air bleeding procedure until completely bubblefree oil flows out.

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4. Starting up the cone crusher

4.2.4 Maximum load The power drawn by the crusher and the Hydroset pressure during operation are dependent on the crushing chamber, the eccentric throw, the crusher’s setting and the feed material’s crushability, size analysis, moisture content, etc.

• •

The maximum average power drawn by the crusher must not exceed 250 kW. The maximum average Hydroset pressure must not exceed following values.

Crushing chamber

Pressure

EF

4.2 MPa (609 p.s.i.)

F

4.2 MPa (609 p.s.i.)

MF

4.0 MPa (580 p.s.i.)

M

4.0 MPa (580 p.s.i.)

MC

3.8 MPa (551 p.s.i.)

C

3.6 MPa (522 p.s.i.)

EC

3.4 MPa (493 p.s.i.)

Average power The following are typical values for the average power draw measured on the motor shaft, depending on eccentric throw and crushing chamber. The average power draw can be higher if it is even and without peaks, but the values above for maximum average power and maximum average Hydroset pressure must not be exceeded.

Power (kW)

Crushing chamber

Throw

EF

F

MF

M

16 mm 20 mm

CH440:01

109

MC

C

96

99

EC 104

115

119

125

24 mm

114

119

127

133

139

145

28 mm

129

136

145

152

159

166

32 mm

145

145

152

163

171

179

187

36 mm

161

161

169

180

190

198

208

209

218

40 mm

176

176

185

198

44 mm

192

192

202

216

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4. Starting up the cone crusher

4.2.5 Starting a crusher in extremely low temperatures In extremely low temperatures it may be found that lubrication oil overflows over the dust collar when the main lubrication pump is started (before normal operating temperature is reached). a) Start and stop the oil pump repeatedly at 10 second intervals until the “Ready for start” signal is obtained. Then start the crusher and allow it to run idle. Check that the oil flow is normal.

• For more information about avoiding problems when operating in low temperature, see the Installation manual – Operating in low temperatures.

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CH440:01

5. Using the cone crusher This section describes basic procedures when using the cone crusher.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

CH440:01

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5. Using the cone crusher

5.1 Starting and stopping Normally, the crusher is controlled by a control system which restricts the ways in which it can be started. Read complementary information from the manufacturer of the control system. Nevertheless, follow or check that the control system follows the start and stop procedures below.

NOTE!

Regarding running-in and after repair work or fitting of new parts, see section 4.2 Running-in.

NOTE!

Follow the routine inspection and care procedures described in section 6.1 Routine inspection and care, e.g. daily check the items under section 6.1.1 Daily.

5.1.1 Starting the crusher NOTE!

For starting the crusher in extremely low temperatures, see section 4.2.5 Starting a crusher in extremely low temperatures and the Installation manual. b) Start the main lubrication oil pump and pinionshaft oil pump. c) When the “Ready for start” lamp lights up, start the crusher’s drive motor. d) Check and adjust the setting. See section 4.2.1 Checking the setting with lead. e) Start the feeder. The crusher should be choke fed without segregation.

CAUTION!

The setting must never be so small that the power drawn by the crusher or the Hydroset pressure exceed limits given in section 4.2.4 Maximum load.

5.1.2 Stopping the crusher a) Stop the feeder, but let the crusher run until the crushing chamber is free of processing material. b) Stop the crusher’s drive motor. c) Stop the main lubrication oil pump and pinionshaft oil pump.

NOTE!

34

The oil heating should run for 24 hours a day. The heating elements are automatically controlled by the oil heating thermostat.

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5. Using the cone crusher

5.2 Checking the setting The procedure for checking the CSS setting is described in section 4.2.1 Checking the setting with lead. See also section 11. Setting measurement.

5.3 Changing oil

WARNING!

NOTE!

Risk of fire and toxic gases Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier’s instructions and safety directions when handling oils and greases.

Never mix different brands or types of lubricants. A bad mixture may cause precipitation and lose its lubricant characteristics. Consult your lubricant supplier.

Normally the old lubricant must be flushed out very carefully before a change is made. The lubricant manufacturer(s) can provide information on whether mixing can take place.

5.3.1 Normal operating conditions Normal operating conditions Ambient air temperature

Max. 32°C (90°F)

a) Choose a main lubrication oil for normal operating conditions according to section 7.2 Oil for lubrication system. b) Exchange the main lubrication oil according to section 8.3 Exchanging main lubrication oil. Also change the filter element and clean the dirt trap, return oil strainer, tank and air/oil heat exchanger. c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system and exchange oil in the Hydroset system. Also change the filter element and clean the dirt trap, see section 8.7.2 Oil filter and section 8.7.3 Dirt trap (magnetic plug). d) If thermostats TG 1, TG 2 and TG 3 are not already set for normal operating conditions, reset them according to section 8.2.11 Thermostats and section 8.2.12 Oil heating.

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5. Using the cone crusher

5.3.2 Operation at elevated temperatures Operation at elevated temperatures Ambient air temperature

Max. 40°C (104°F)

If the ambient temperature is so high that the cooling system cannot keep the return oil temperature below 50°C (122°F), it may be necessary to permit operation at an elevated temperature. In such a case, contact Sandvik Rock Processing. At the same time, a change must be made to a lubricating oil with higher viscosity: a) Choose a main lubrication oil for operation at elevated temperatures according to section 7.2 Oil for lubrication system. b) Exchange the main lubrication oil according to section 8.3 Exchanging main lubrication oil. Also change the filter element and clean the dirt trap, return oil strainer, tank and air/oil heat exchanger. c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system and exchange oil in the Hydroset system. Also change the filter element and clean the dirt trap, see section 8.7.2 Oil filter and section 8.7.3 Dirt trap (magnetic plug). d) If thermostats TG 1, TG 2 and TG 3 are not already set for operation at elevated temperatures, reset them according to section 8.2.11 Thermostats and section 8.2.12 Oil heating.

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5. Using the cone crusher

5.3.3 Operation in low temperatures Operation in low temperatures Ambient air temperature

Below 0°C (32°F)

The oils viscosity increases at low temperatures, but normally it’s not necessary to change to a thinner oil during the winter as the oil tank is equipped with heating elements. Furthermore, there are several other ways to reduce the risk for freezing including e.g. insulation and extra heating. See the Installation manual and consult Sandvik Rock Processing.

Nevertheless, in extremely low temperatures it can sometimes be advisable to change to a less viscous oil: a) Choose a main lubrication oil for operation in low temperatures according to section 7.2 Oil for lubrication system. b) Exchange the main lubrication oil according to section 8.3 Exchanging main lubrication oil. Also change the filter element and clean the dirt trap, return oil strainer, tank and air/oil heat exchanger. c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system and exchange oil in the Hydroset system. Also change the filter element and clean the dirt trap, see section 8.7.2 Oil filter and section 8.7.3 Dirt trap (magnetic plug). It is normally unnecessary to change to a different grade of Hydroset oil. However, if conditions are so extreme that a less viscous oil or a heater in the Hydroset tank is needed, consult Sandvik Rock Processing. d) For operation under extreme ambient temperatures, consult the lubricant supplier regarding grease for spider bearing lubrication, see section 7.5 Grease for spider bearing lubrication. e) If thermostats TG 1, TG 2 and TG 3 are not already set for operation in low temperatures, reset them according to section 8.2.11 Thermostats and section 8.2.12 Oil heating.

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5. Using the cone crusher

5.4 Checking the V-belt tension The procedure for checking the V-belt tension is described in section 6.4.2 Vbelt tension.

5.5 Accumulator Checking the gas pressure and charging is described in section 9.3 Charging kit (option).

5.6 Clearing out the crushing chamber If the crusher stalls with the crushing chamber full of material, clear it out as follows: a) Make sure that the crusher’s feeding arrangement is switched off. b) If there is material in the discharge chute beneath the crusher, remove the material.

NOTE!

If there is an ASRi system, switch it off. The ASRi system must be disconnected to prevent an automatic raising or lowering of the mainshaft. c) Fully open the damping valve in the line to the Hydroset pressure gauge, see section 8.7.5 Pressure gauge. d) Use the L1 push button box to lower the mainshaft, keeping an eye on the Hydroset pressure. e) If the Hydroset pressure drops below 0.3 MPa, then raise the mainshaft again until the pressure gauge displays at least 0.5 MPa. (The mainshaft step may lose contact with the step washer if the pressure goes below zero.) f) Start the crusher.

38

NOTE!

Check for material build-up on the bottomshell arms. If damp, wet feed is causing packing, operate at a larger setting.

NOTE!

Check the interlocking between the feeding arrangement and discharge system. There must be room beneath the crusher for material in the crushing chamber and feed hopper, in case the discharge system stops.

CAUTION!

Do not start the crusher if it has stalled because of uncrushable material (metal, wood etc.). Empty the crusher manually or unbolt the topshell so that all material can leave the crushing chamber, see Maintenance manual.

CAUTION!

Never start the crusher with a loose topshell.

© Sandvik SRP AB – Doc. no. S 223.543 en Ver. 2

CH440:01

6. Inspection and care This section describes the routine inspection and care instructions for the cone crusher.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

CH440:01

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6. Inspection and care

6.1 Routine inspection and care Every cone crusher must be subjected to regular systematic checks. This will result in fewer and smaller repairs, less downtime and thus lower overall running costs.

NOTE!

A new crusher must be inspected often during the initial operating period.

The intervals between inspections can then be increased until a suitable frequency is found.

Keep a written log including the crusher’s operating conditions and loads, important data and details of adjustments made and any repairs carried out.

An example of such a record sheet can be found in appendix A: Inspection.

Since crushers operate under widely differing conditions, it is impossible to recommend an inspection and care schedule applicable to all crushers.

However, regular inspections are necessary. The following table describes an example.

6.1.1 Daily It’s in the operator’s role to be responsible for these inspections daily or after every 8 hours of operation.

Action

When

See section

Check the oil level in the lubrication tank.

Before starting the crusher

8.2

Check the oil level in the Hydroset tank.

Before starting the crusher

8.7

Check that the shut-off valves between the tanks and pumps are fully open.

Before starting the pumps and crusher

–

Check that no material has built up on the bottomshell arms.

Before starting the crusher

–

Check that lubricating oil returns to the tank and that the oil is clean.

After starting the lubrication pump

8.2

Check that the oil lines do not leak.

After starting the pumps

–

Check that the pinionshaft lubrication circuit is operating correctly.

Running idle

8.4

Check the CSS.

Running idle

4.2.1

Check that material has not jammed in the feed hopper or splitter and blocked the feed opening.

Running idle

–

Listen for abnormal noises in the crusher.

While crushing

–

Listen for abnormal noises in the lubrication pump.

While crushing and before

–

Check the return oil temperature.

While crushing

8.2.7

Check the drive motor current or power consumption.

While crushing

4.2.4

Check the Hydroset pressure and that the pressure gauge damping is correct.

While crushing

8.7

Check the temperature of the pinionshaft housing. Use an infrared camera or feel above the housing. If it’s too hot to touch, then the temperature is too high. Normal temperature is 50–60°C (122–140°F).

While crushing

–

Check the oil pressure of the main lubrication system and pinionshaft lubrication system at normal operating temperature.

While crushing

8.2.5, 8.4

Check that there is no oil leakage.

While crushing

–

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6. Inspection and care Action

When

See section

Check that no bolts have come loose.

While crushing

–

Check that the oil heaters are working.

With crusher stopped

8.2.12

Check the distance between the head nut and the underside of the spider (i.e. the A-dimension).

With crusher stopped

10.2

Check that there is no contamination increase or change on the return oil strainer, e.g. an abnormal amount of metal particles.

With crusher and lubrication pump stopped

8.3.4

6.1.2 Weekly It’s in the operator’s role to be responsible for these inspections weekly or after every 40 hours of operation.

Action

When

See section

Inspect the oil filter (check if the red button on the pressure drop sensor protrudes) of the main and pinionshaft lubrication systems.

With crusher and lubrication pumps stopped

8.2.3, 8.3.3, 8.7.2

Clean the dirt trap and inspect the oil tank of the main lubrication system.

With crusher and lubrication pump stopped

8.2.1, 8.2.2, 8.3

Inspect the crushing liners for wear and damage.

With crusher stopped

10.2

Measure the setting at four points around the crushing chamber to check for uneven wear.

Running idle

4.2.1, 11.1

Check the pumps for abnormal noise and wear.

While crushing.

8.2.4, 8.4.2, 8.7.1

Check wear and tension of the V-belts.

With crusher stopped

–

Check the cooler core of the air/oil heat exchanger (option).

With crusher and lubrication pump stopped

8.6

Clean the damping valve for the Hydroset pressure gauge.

With crusher stopped

8.7.5

Check the air pressure (blower running or regulator working) of the over-pressure dust sealing.

Running idle

6.7

Check the hose and filter of the over-pressure dust sealing and that the covers on the tank unit are air tight.

With crusher stopped

6.7

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6. Inspection and care

6.1.3 Monthly These inspections should be carried out monthly or after every 160 hours of operation. The crusher must be stopped.

Action

Responsible

See section

Clean the drain plug on the pinionshaft housing.

Operator

7.4

Check the dust seal ring for wear.

Operator

6.3.1

Check the condition of the scraper which rotates above the dust collar.

Operator

6.3.2

Check the tightness of all bolts.

Operator

–

Check the play between the mainshaft sleeve and the spider bushing.

Operator

10.1, 10.3

Check the grease level in the spider bearing.

Operator

7.5

Clean the air vent passages in the spider cap and topshell.

Operator

10.1

Check the quality of the lubrication oil.

Operator

7.2

Check the function of the return oil flow switch.

Operator

8.2.9

Check the backlash in the pinion and eccentric gear.

Service personnel

See MM

Check – using feeler gauges – between the headcentre and the mantle and between the topshell and the concave ring.

Service personnel

See MM

Check the spider bearing grease seal for wear.

Service personnel

See MM

6.1.4 Twice a year These inspections should be carried out twice a year or after every 1000 hours of operation. The crusher must be stopped.

Action

Responsible

See section

Check the gas pressure in the accumulator.

Operator

9.3

Clean out the oil tank.

Operator

8.2.1, 8.3

Change the oil filter element and clean the dirt trap of the Hydroset system.

Operator

8.7.2, 8.7.3

Check the play in the spider bearing.

Operator

10.1, 10.3

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6. Inspection and care

6.1.5 Yearly These inspections should be carried out yearly or after every 2000 hours of operation. The crusher must be stopped.

Action

Responsible

See section

Check the topshell and bottomshell for wear.

Service personnel

See MM

Check the chevron packing for wear.

Service personnel

See MM

Check the tapered contact faces of the topshell and bottomshell.

Service personnel

See MM

Check the mainshaft sleeve for wear and pitting.

Service personnel

See MM

Check the inner seal ring for wear.

Service personnel

See MM

Check the play between the locating bar and the gear hub.

Service personnel

See MM

Check the eccentric bushing for wear and scratches.

Service personnel

See MM

Check the eccentric for wear and scratches.

Service personnel

See MM

Check the eccentric wearing plate for wear.

Service personnel

See MM

Check the bottomshell bushing for wear and scratches.

Service personnel

See MM

Check the thickness of the step bearing assembly. Check for wear and scratches.

Service personnel

See MM

Check the gears for wear.

Service personnel

See MM

Check the Hydroset cylinder bushing for wear and scratches.

Service personnel

See MM

Check the function of the temperature gauge.

Operator

8.2.7

Check the function of the protective thermostat TG 1 and the thermostat for heat exchanger TG 2

Operator

8.2.11

CH440:01

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6. Inspection and care

6.2 Standard tool box The following is a list of the tools included in the standard tool box. They are intended for use during maintenance work.

Tool

Size

Lifting tool Lifting tool

Used for Eccentric bushing

442.7281-00

Bottomshell bushing

Lowering rod with nut

M24×600

843.1333-00

Piston

Nut

M6M M24

845.0012-00

Lowering rod

442.7284-00

Mainshaft step

Piston stop plate

442.9995-00

Holding piston

Eye bolt

442.7282-01

Mainshaft step

Lowering rod

Eye bolt

M48

899.0157-00

Mainshaft

Eye bolt

M20

899.0160-00

Spider bushing Dust collar

Eye bolt

M16

899.0147-00

Eye bolt

M12

899.0155-00

Eccentric unit

Eye bolt

M10

899.0099-00

Bottomshell bushing / Eccentric bushing

Eye bolt

M8

899.0244-00

Mainshaft sleeve Screw and nut M42

Ring spanner striking

65 mm

920.0110-00

Ring spanner striking

36 mm

920.0151-00

Screw and nut M24

U-ring spanner

46 mm

920.0131-00

Screw and nut M30

U-ring spanner

36 mm

920.0135-00

Screw and nut M24 Screw and nut M20

U-ring spanner

30 mm

920.0134-00

U-ring spanner

24 mm

920.0022-00

Screw and nut M16

U-ring spanner

18 mm

920.0244-00

Screw and nut M12

U-ring spanner

13 mm

920.0186-00

Screw and nut M8 Screw MC6S M20

Allen key

17 mm

920.0041-00

Allen key

10 mm

920.0038-00

Screw MC6S M12

Allen key

8 mm

920.0037-00

Screw MC6S M10

Allen key

5 mm

920.0035-00

Air bleed screw

Allen key

5/8"

920.0032-00

Spider cap plug

Chunk of lead Feeler gauges

44

Part. no.

442.7283-00

0.05–1 mm

442.0800-91

CSS check

923.0422-00

Spider bearing play, etc.

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CH440:01

6. Inspection and care

6.3 Bottomshell and mainshaft assembly There are two inspection holes through the bottomshell through which the dust seal ring and dust collar can be inspected and checks can be made on liner condition and oil leakage.

Do not remove covers/guards Do not open the covers while the machine is crushing. Never put hands inside while the crusher is running.

PROHIBITION!

1 1 Cover / inspection hole

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6. Inspection and care

6.3.1 Dust seal ring The dust seal ring (3), which is supported beneath the headcentre, is free to move and has an easy sliding fit on the dust collar (4). It is the most important seal for the crusher’s oil system. The dust seal consists of the dust seal ring (3) and a retaining ring (2). The retaining ring (2) is screwed on the headcentre.

2 3 4 5

Retaining ring Dust seal ring Dust collar Scraper

5

4

3

2

Use a feeler gauges to check the play between the dust seal ring and the mainshaft.

Max. permissible play between dust seal ring and dust collar mm/(inches) 1.5/(0.060)

6.3.2 Scraper To prevent the accumulation of dust and material etc. on the outside of the dust collar (4), the crusher has a scraper (5) mounted on the underside of the retaining ring (2). The scraper consists of a rubber flap and a retaining plate which is bolted to the bottom of the retaining ring.

The scraper (5) ensures that there is always room for the downward movement of the mainshaft assembly, e.g. if tramp iron enters the crusher.

Check the condition of the scraper (5) at regular intervals. If necessary, clean out the area around the dust collar and the bottomshell arms.

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6. Inspection and care

6.4 V-belts Do not remove fixed guards Never operate the cone crusher unless the fixed guards around its moving parts are mounted.

PROHIBITION!

6.4.1 Direction of rotation CAUTION!

CH440:01

The crusher’s V-belt pulley must rotate in the direction indicated by the arrow on the bottomshell. This is necessary for the self-tightening action of the head nut.

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6. Inspection and care

6.4.2 V-belt tension During the first few days of operation, the belt tension must be checked frequently since new belts stretch. If the belts are not tensioned sufficiently, slipping can occur and belt life will be reduced considerably.

Proper belt tension can be determined with the help of the deflection load.

Check the deflection load with a spring balance or a special instrument, a tensiometer or its equivalent.

Recommended deflection load (F) F, kp/belt (lbf/belt) Belt profile

Normal

Max. (newly fitted belts)

SPC

7 (15.4)

12.0 (26.5)

8V

9 (19.8)

14.0 (30.9)

Checking the deflection load with a tensiometer: a) Measure the belt span (W) in meters, as shown below. b) Multiply the span by 1.5, to give the belt deflection (D) in cm. c) Set the top side of the lower O-ring to the correct deflection in cm on the meter’s lower scale.

6 14 12 10 8

W D

5

1

4

F

2

3

F-scale D-scale = deflection = belt span = deflection load

1

2

1 2 D W F

F

6

2

d) Push the upper O-ring up against the lower edge of the outer sleeve. e) Press the meter against the belt in the middle of the span and press sufficiently hard to bring the top side of the lower O-ring in level with the belt alongside. f) Remove the meter and read off the load (F) in kp (lbf) at the top side of the upper O-ring. The correct load is obtained from the table above, which should be reproduced on the meter. g) If the load is too low or too high on any of the belts, tighten or slacken them.

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D

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6. Inspection and care

6.5 Topshell assembly For further information about inspection and care of the topshell assembly, see section 10. Topshell assembly.

6.6 Hydroset and lubrication system For further information about inspection and care of the Hydroset and lubrication system, see section 8. Hydroset and lubrication system.

6.7 Over-pressure dust sealing The crusher has a dust seal ring (4305-0) to keep out dust, but air must be introduced into the crusher at a small over-pressure. This is because a slight under-pressure can otherwise occur inside the crusher when aerated lubricating oil runs back to the tank. The resultant under-pressure will draw dust into the crusher and a film of dust will collect on the inside of the dust collar (1400-0).

The lubricating oil will transport these dirt and dust around the lubrication system. This will result in rapid blockage of the filters, accelerated wear of step bearing components and sedimentation in the oil tank. Other components inside the crusher will also be subjected to unnecessarily heavy wear.

The over-pressure air (white arrows) can be provided by a blower (as described in section 6.7.2 Blower) or from a compressed air system (as described in section 6.7.3 Regulator assembly for compressed air).

1400-0 1450-0 4305-0 4350-0 4355-1 1

1400-0 1450-0 4305-0 4350-0 1 4355-1

Dust collar Inner dust seal ring Dust seal ring Retaining ring Scraper Dust

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6. Inspection and care

6.7.1 Dust sealing principles The condition of the dust seal ring (4305-0) is of decisive importance for the function of the seal against the dust collar (1400-0). A worn or oval dust seal ring gives a large gap to the dust collar and increases the possibility of dust and dirt entering the crusher.

A plastic hose is connected between the crusher and tank unit to accomplish pressure equalization. One end is connected to the T-connector (2) mounted on the crusher, just above the pinionshaft housing. The other end is connected to the sleeve (5) welded to the end wall of the tank, above the oil level.

2

4

5

2 T-connector 4 Blower 5 Sleeve

NOTE!

The covers on the tank unit must be air tight. Adjust or replace the sealing strips if necessary.

Dust is prevented from entering the crusher by creating an over-pressure inside the crusher and tank. This over-pressure is created by introducing air with the help of a blower or a regulator assembly for compressed air. See section 6.7.2 Blower and section 6.7.3 Regulator assembly for compressed air respectively. The over-pressure air is introduced through the same T-connector (2) on the crusher as is used for the pressure equalization hose to the tank.

Check When the crusher is operating, the air pressure – measured at the entry to the crusher – must be 600–1000 Pa (60–100 mm w.g.)

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6. Inspection and care

6.7.2 Blower The blower capacity at a pressure of 600 Pa (60 mm w.g.) must be at least 0.3 m3/min.

Check The blower (4) has an air filter (6) with a replaceable paper element. Inspect the filter element at regular intervals and change it when necessary.

6

4 Blower 6 Filter

4

6.7.3 Regulator assembly for compressed air The regulator assembly includes a pressure gauge (3) which measures the over-pressure at the entry to the crusher.

3 7 8 9

Pressure gauge Air regulator Filter Compressed air connection

3

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7

8

9

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6. Inspection and care

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7. Lubrication This section describes the requirements that must be put on the lubricants used in the cone crusher.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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7. Lubrication

7.1 Lubricant requirements If the crusher is to be utilized optimally, stringent demands must be made on the lubricants that are used.

NOTE!

WARNING!

NOTE!

Lubricants which do not meet Sandvik Rock Processing’s requirements must not be used during the warranty period.

Risk of fire and toxic gases Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier’s instructions and safety directions when handling oils and greases.

Changing the oil is described in section 5.3 Changing oil.

Check A change in oil colour may indicate the presence of water or dirt. Change the oil.

7.1.1 Miscibility NOTE!

Never mix different brands or types of lubricants, unless mixing is known to be appropriate. A bad mixture may cause precipitation and a loss of the lubricant’s characteristics.

Normally, old lubricants must be flushed out very carefully before replacing with new lubricants. The lubricant manufacturer(s) can provide information on whether mixing is appropriate.

7.1.2 Low temperatures The oils viscosity increases at low temperatures, but normally it’s not necessary to change to a thinner oil during the winter as the oil tank is equipped with heating elements. Furthermore, there are several other ways to reduce the risk for freezing including e.g. insulation and heaters. See the Installation manual and consult Sandvik Rock Processing.

Nevertheless, in extremely low temperatures it can sometimes be advisable to change to a less viscous oil. See section 5.3.3 Operation in low temperatures.

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7. Lubrication

7.1.3 High temperatures If the ambient temperature is so high that the cooling system cannot keep the return oil temperature below 50°C (122°F), it may be necessary to permit operation at an elevated temperature. In such a case, contact Sandvik Rock Processing. At the same time, a change must be made to a lubricating oil with higher viscosity. See section 5.3.2 Operation at elevated temperatures.

7.2 Oil for lubrication system The oil Sandvik Rock Processing recommends must have mild EP additives and must comply with the requirements specified in the table below.

Normally, an oil with ISO VG 150 viscosity is used.

Requirement specification The oil shall comply with the demands of DIN 51 517-CLP for the respective viscosity values and shall contain additives to prevent oxidation and foaming and also contain anti-wear additives. Copper alloys are used in the crusher’s bearings which is why the oil must be harmless for this material.

The table below specifies lubricating oil types for use under different operating conditions.

Oil requirements for different operating conditions Operating condition

Normal

Operation at elevated temperatures

Operation in low temperatures

Ambient air temperature

Max. 32°C (89.6°F)

Max. 40°C (104°F)

Below 0°C (32°F)

Oil viscosity

ISO VG 150

ISO VG 220

ISO VG 100

Specification

DIN 51 517-CLP 150

DIN 51 517-CLP 220

DIN 51 517-CLP 100

Properties

Test method

Requirement

Requirement

Requirement

Base oil viscosity at 40°C (104°F) in mm2/s (cSt)

DIN 51 519

150

220

100

Viscosity index

DIN ISO 2909

≥ 100

≥ 100

≥ 100

FZG

DIN 51 354

≥ 12

≥ 12

≥ 12

Lowest pour point

DIN ISO 3016

≤ –9°C (15.8°F)

≤ –6°C (21.2°F)

≤ –12°C (10.4°F)

Sulphur/Phosphorus

Sulphur/Phosphorus

Sulphur/Phosphorus

EP additives

(Continued)

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7. Lubrication Examples of lubricants The examples listed below are lubricants which – according to the respective manufacturer – comply with Sandvik Rock Processing’s requirements.

Local variations can occur in different countries. For safety’s sake, check with your supplier that the selected lubricant complies with the requirements in question.

In addition to the lubricants listed, a number of other brands and qualities meet Sandvik Rock Processing’s requirements and are accordingly also usable.

Mineral oils For operation under normal conditions: BP Energol GR-XP 150 ESSO Spartan EP 150 Klüber Klüberoil GEM 1-150 Mobil Mobilgear 629

Molub-Alloy Tribol 1100/150 Shell Omala 150 Statoil LoadWay EP 150 Texaco Meropa 150

For operation at elevated temperatures: BP Energol GR-XP 220 ESSO Spartan EP 220 Klüber Klüberoil GEM 1-220 Mobil Mobilgear 630

Molub-Alloy Tribol 1100/220 Shell Omala 220 Statoil LoadWay EP 220 Texaco Meropa 220

For operation in low temperatures: BP Energol GR-XP 100 ESSO Spartan EP 100 Klüber Klüberoil GEM 1-100 Mobil Mobilgear 627

Molub-Alloy Tribol 1100/100 Shell Omala 100 Statoil LoadWay EP 100 Texaco Meropa 100

Biologically degradable oil If a biologically degradable oil is to be used, Sandvik Rock Processing recommends that only a 100 % synthetic oil of ester type is selected. Due to the higher viscosity index of this type of oil, an ISO VG 150 grade can normally be used all year round.

If the ambient air temperature is over 32°C (90°F), it may still be necessary to reset thermostats TG 1 and TG 2 for “Operation at elevated temperatures” since TG 1 could otherwise trip because of excessively high oil temperature and thus stop the crusher, see section 8.2.11 Thermostats.

Example:

Tribol Bio Top 1418/150 (VI > 170) (Continued)

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7. Lubrication Oil quantity Capacity Lubrication oil tank

400 litres / (105 US gal.)

When the crusher is running, the oil level must be above the minimum level mark. See the oil level indicator in the tank unit.

When the crusher stops, a certain amount of oil will remain in the crusher and the oil supply lines. The tank should therefore be topped up after testrunning. To prevent flooding over the strainer when oil drains back to the tank after the crusher has been stopped, be very restrictive with topping up if the oil lines between the tank and the crusher are long.

CAUTION!

Make sure that the heating element tubes and their thermostat are always covered with oil during operation. This is to avoid overheating in the heating elements.

Oil changes To keep a check on the condition of the oil, it is advisable to send an oil sample to the oil supplier each month so that suitable oil change intervals can be established in cooperation with the supplier.

When oil is to be changed to a different brand or type, all of the oil must be changed. This is especially important if the change is from an oil with lead additives to an oil with sulphur/phosphorus additives. The oil which is trapped in the crusher must be drained out by breaking the supply line at a suitable point between the crusher and the lubrication oil tank unit. When this is done, the mainshaft must be raised to its highest position so that the oil in the Hydroset piston runs out.

7.3 Oil for Hydroset system Requirement specification The oil used in the Hydroset system must be miscible with the lubricating oil and comply with the same requirements. However, the viscosity must be according to ISO VG 68.

The oil must comply with DIN 51 517-CLP 68.

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7. Lubrication Requirements for the Hydroset oil Properties

Requirement

Test method

Base oil viscosity at 40°C (104°F) in mm²/s (cSt)

68

DIN 51 519

Viscosity index

≥ 100

DIN ISO 2909

FZG

≥ 12

DIN 51 354

Lowest pour point

≤ –15°C (5°F)

DIN ISO 3016

EP additives

Sulphur/Phosphorus

Examples of oils for Hydroset system The examples listed below are oils which – according to the respective manufacturer – comply with Sandvik Rock Processing’s requirements.

Local variations can occur in different countries. For safety’s sake, check with your supplier that the selected oil complies with the requirements in question.

In addition to the lubricants listed, a number of other brands and qualities meet Sandvik Rock Processing’s requirement and are accordingly also usable.

Mineral oils BP Energol GR-XP 68 ESSO Spartan EP 68 Klüber Klüberoil GEM 1-68 Mobil Mobilgear 626 NOTE!

Molub-Alloy Tribol 1100/68 Shell Omala 68 Statoil LoadWay EP 68 Texaco Meropa 68

Never use oil thicker than ISO VG 68, nor normal hydraulic oils.

There can be problems with crushers that operate outdoors in very low temperatures, with the normally recommended oil. If this is the case, contact Sandvik Rock Processing for information about changing to an oil with lower viscosity.

Biologically degradable oil If a biologically degradable oil is to be used, we recommend that only a 100 % synthetic oil of ester type is selected.

Example:

Tribol Bio Top 1448/68 (Continued)

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7. Lubrication Oil quantity Capacity Hydroset oil tank

85 litres / (22.5 US gal.)

When the Hydroset oil tank is filled, the mainshaft must be in its lowest position. If the tank is filled when the mainshaft is in its highest position, there may not be sufficient room in the tank for all of the oil when the mainshaft is lowered.

Oil changes The oil in the Hydroset system should be changed when the lubricating oil is changed. See section 5.3 Changing oil and section 7.2 Oil for lubrication system – Oil changes.

7.4 Oil for pinionshaft lubrication The pinionshaft bearings are lubricated by a separate circulatory system. A small flow of oil is bled off from the main lubrication system and is pumped to the oil inlet in the top of the pinionshaft housing.

Oil quantity Oil quantity Pinionshaft housing

1.3 litres / (0.34 US gal.)

The volume in the pinionshaft housing is limited by a level tube and excess oil returns to the main lubrication tank by gravity.

1 2 3 4

Oil inlet Oil level Level tube Drain plug

1 2

3 4 (Continued)

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7. Lubrication Cleaning Remove the drain plug (magnetic plug) and clean it at least twice a year. This will also drain out any sediment from the pinionshaft housing.

7.5 Grease for spider bearing lubrication The motion of the mainshaft in the spider bearing is both gyratory and rotary.

The speed is relatively low and the pressure is high. It is important that the correct grade of lubricant is used so that the grease can penetrate to the bearing surfaces.

Requirement specification The grease must comply with the demands in the table below in order to guarantee lubrication of the spider bearing for long periods, under conditions of vibration and extremely high loads. In addition, the grease must provide good protection against corrosion. The spider bearing contains components of alloyed steel, cast iron and nitrile rubber. The grease must therefore be harmless to these materials.

Requirements for spider bearing grease Properties

Requirements

Test method NLGI

Consistency

0 or 00

Base oil viscosity at 40°C (104°F) in mm2/s (cSt)

≥ 400

Thickening agent

Lithium or sodium

Drop point

≥ 140°C (284°F)

DIN ISO 2176

Corrosion protection

Approved

DIN 51 802 SKF Emcor

Other properties: – Must contain EP additives – Must be pumpable The recommended operating temperature range is –10°C to +100°C (14°F to 212°F). For operation under extreme ambient temperatures, contact the lubricant supplier.

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7. Lubrication Examples of greases The examples listed below are greases which – according to the respective manufacturer – comply with Sandvik Rock Processing’s requirements.

Local variations can occur in different countries. For safety’s sake, check with your supplier that the selected grease complies with the requirements in question.

In addition to the greases listed, a number of other brands and qualities meet Sandvik Rock Processing’s requirements and are accordingly also usable.

Mobil Mobilith SHC 007 (643569) Molub-Alloy Tribol 3020/1000-00

Statoil GreaseWay LiCaX90 Texaco Marfak 00 (01907)

Grease quantity Grease quantity Spider bearing

6–8 kg / (13.2–17.6 lbs.)

The spider bearing must be filled with grease up to the correct level (2). This corresponds to approximately the amount given in the table above. When the spider bearing is being greased, the mainshaft must be in its lowest position.

Grease can be pumped in through a pipe (1) inside one of the topshell spider arms.

1 2 3 4 5

Grease pipe Grease level Observation hole Spider bearing seal Air vent line

1

5

2

4

3

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7. Lubrication Checking and changing the grease During the first few weeks of operation, the grease level should be checked daily by unscrewing the plug in the spider cap.

Checking the grease level in the spider cap: a) Stop the crusher. b) Unscrew and remove the plug in the spider cap. c) Examine the grease level by sticking a finger into the observation hole and feeling the grease level, alternatively shine a flashlight into the hole and observe the level.

If an unusually large quantity of grease is observed on the mainshaft beneath the spider bearing, it is possible that the spider bearing seal has been damaged. It is important to keep the mainshaft free of grease and stone dust accumulations to prevent such contamination being pressed into the spider bearing through the spider bearing seal (4) each time the mainshaft is raised.

The grease level (2) should be checked frequently and new grease should be added when necessary. If it is damaged, the spider bearing seal (4) must be replaced as quickly as possible. See the Maintenance manual.

Alongside the grease nipple on one of the topshell arms there is a decal which shows the type of grease pumped into the spider bearing before delivery. Do not mix different types of greases.

When a new mantle and/or concave is fitted, the spider bearing and seal should be carefully cleaned and then filled with new grease. To avoid unscheduled stoppages, it is recommended that the spider bearing seal (4) is changed each time the liners are changed.

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8. Hydroset and lubrication system This section describes the care procedures for the Hydroset and lubrication system of the cone crusher.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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8. Hydroset and lubrication system

8.1 Overview 8.1.1 Tank unit The tank unit consists of a cabinet containing the motor-driven pumps, filters etc. and at the rear lubrication and Hydroset oil tanks.

1 1 2 3 4

Hydroset tank cover Lubrication tank cover Identification plate Cabinet

2 3 4

8.1.2 Cabinet The cabinet contains components of the main lubrication system, pinionshaft lubrication system and Hydroset system.

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8. Hydroset and lubrication system In subsequent figures, the interior of the cabinet is divided into different views: Main lubrication system

Pinionshaft lubrication system

Hydroset system

Thermostats and heaters

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8. Hydroset and lubrication system

8.2 Main lubrication system In the main lubrication circuit, oil is pumped from the tank through the filter (7) and heat exchanger to the crusher’s main lubrication inlet. Oil entering the crusher is pressed through the step bearing, up between the eccentric bushing and the mainshaft, and between the bottomshell bushing and the eccentric to lubricate these bearings. The oil lubricates the wearing plate and the bevel gears before running back to the tank unit by gravity.

1 2 3 4 5 6 7 8 9 10 12 13

Pressure drop lamp Temperature gauge Pressure gauge Lubrication oil pump unit Pressure gauge connection Pressure drop sensor Oil filter Dirt trap Shut-off valve Pressure relief valve Lubrication inlet (from crusher) Lubrication outlet (to crusher)

1 2 3 4 5 6 7

10 9 8

12

13

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8.2.1 Cleaning the tank Contaminants such as stone dust, water etc, which enter the lubricating oil, will, to a certain degree, sink towards the bottom of the tank. This should therefore be cleaned out at least twice a year. This periodical cleaning prevents sludge following the oil withdrawn from just above the tank bottom.

See section 8.3.4 Cleaning the return oil strainer and tank.

14 15 16 17

Dehydration plug, lubrication oil tank Drain plug, lubrication oil tank Drain plug, Hydroset oil tank Dehydration plug, Hydroset oil tank

15

14

16

17

Condensation can be removed by taking out the screw in the dehydration plug (14) beneath the lubrication oil tank. This must be done regularly to avoid too high a percentage of water in the oil.

CAUTION!

Stop the pump when the oil level has dropped to just above the suction inlet (tank outlet), as there will otherwise be a major risk of pump damage. Never let the pump operate dry.

8.2.2 Dirt trap The dirt trap (8) protects the oil pump (4) and is mounted ahead of it.

18 19

CAUTION!

Clean the dirt trap regularly. If it is allowed to clog, cavitation will occur in the pump, which can result in pump breakdown. See section 8.3.2 Cleaning the dirt trap.

CAUTION!

The gauze element (19) must not, under any circumstances, be left out or replaced by another with a different mesh.

Gauze element Plug

18 19

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8. Hydroset and lubrication system

8.2.3 Oil filter The type of oil filter used is full-flow, which means that all oil pumped to the crusher is filtered. The filter elements are of throw-away type. See section 8.3.3 Changing filter elements.

The filter elements must be changed when the pressure drop across the filter exceeds 0.22 MPa (32 psi) at normal operating temperature.

There is a by-pass valve on the filter. It opens when the pressure drop across the filter exceeds 0.35 MPa (51 p.s.i.). When the valve is open, part of the oil flow by-passes the filter and is thus not filtered.

NOTE!

If filter elements have to be changed often, the crusher’s dust sealing system must be checked.

8.2.4 Oil pump Normally the lubrication oil pump (4) requires no special attention. Wear can, however, be considerable if the oil contains stone dust or similar contaminants. The most usual sign of pump wear is a reduction in oil flow.

CAUTION!

When the pump is started, the oil tank must be full of oil so that the pump does not operate dry. Before starting the pump, check that the shut-off valve (9) ahead of the dirt trap (8) is open.

Exchange The pump’s capacity at normal operating temperature and pressure is shown in the table below. (If the motor is connected to a 60 Hz supply instead of a 50 Hz supply, the pump speed will be 20 % higher and the flow will increase).

Exchange the oil pump when the flow has dropped below the minimum value in the table below.

Lubricant flow Supply frequency 50 Hz

Supply frequency 60 Hz

l/min

US gal./min 21.7

Normal capacity

82

Min. capacity

70

18.5

Normal capacity

98

25.9

Min. capacity

70

18.5

Check Check oil delivery by measuring the return oil flow. Position a bucket with a known volume beneath the opening in the return oil chamber and measure the time taken to fill the bucket.

Example: It takes 20 seconds to fill a 10 litre bucket. The oil flow is thus: (10×60)/20 = 30 l/min.

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8.2.5 Pressure gauge The pressure gauge (3) gives the pressure measured by the pressure gauge connection (5) between the oil pump (4) and the filter (7).

Check Check the pressure at regular intervals and keep a record of the readings. At operating temperature, the pressure in the main system is normally 0.15– 0.5 MPa (21.8–72.5 p.s.i.), depending on tank installation. If the pressure ahead of the oil filter rises, this is a sign that the filter elements should be changed. An abnormally low pressure can mean that the pump is worn, or that the dirt trap is choked.

1 2 3 4 5 6 7 8 9 10

Pressure drop lamp Temperature gauge Pressure gauge Lubrication oil pump unit Pressure gauge connection Pressure drop sensor Oil filter Dirt trap Shut-off valve Pressure relief valve

1 2 3 4 5 6 7

10 9 8

8.2.6 Pressure drop indicator The pressure drop sensor (6) monitors the pressure drop across the filter and gives a signal when the pressure drop exceeds 0.22 MPa (32 p.s.i.). This signal indicates that the filter elements should be changed.

The signal is given both electrically – to a pressure drop lamp (1) on the outside of the tank unit – and in the form of a red button which protrudes (about 4 mm) from the top of the sensor.

NOTE!

During a cold start, the indicator can incorrectly give a signal due to higher oil viscosity.

The electrical signal will automatically be reset when working temperature has been reached, but the mechanical signal (the red button) must be reset manually. If the red button jumps out again immediately, or if the lamp does not go out when working temperature has been reached, the filter elements must be changed.

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8. Hydroset and lubrication system

8.2.7 Temperature gauge A temperature gauge (2) monitors the return oil temperature. The return oil temperature is affected by the load of the crusher, the ambient air temperature and the viscosity of the lubricating oil. See section 8.2.11 Thermostats.

Check Check the gauge once a year against a reference thermometer to ensure that it reads correctly. Carry out this check at an oil temperature of 40–50°C (104– 122°F).

8.2.8 Pressure relief valve A pressure relief valve (10) is fitted between the oil filter (7) and the heat exchanger. Its duty is to decrease the pressure over the pump (4) and heat exchanger if the crusher is started at low temperature when the oil is more viscous.

CAUTION!

1 2 3 4 5 6 7 8 9 10

The valve setting must not be altered. The valve is set at 0.7 MPa (102 p.s.i.).

Pressure drop lamp Temperature gauge Pressure gauge Lubrication oil pump unit Pressure gauge connection Pressure drop sensor Oil filter Dirt trap Shut-off valve Pressure relief valve

1 2 3 4 5 6 7

10 9 8

8.2.9 Return oil flow switch The return oil flow is monitored by an oil flow switch inside the return oil chamber in the oil tank.

The return oil flow switch is connected in such a way that the crusher’s drive motor cannot be started unless sufficient oil is pumped to the crusher and thus back to the tank via the return oil flow switch. In addition, the lubrication oil pump (4) cannot be started unless the return oil flow switch is functioning properly.

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8. Hydroset and lubrication system The return oil flow switch is connected to a float (20) in the return oil chamber (24) in the tank and monitors whether the float is up or down. The return oil chamber has an adjustable lower outlet (22) and an overflow weir (21).

CAUTION!

The lower outlet has been adjusted at the factory before delivery and must not be altered.

When a sufficient flow of oil is returning to the tank, the oil level in the return chamber should be 5 mm (0.20") above the weir. With this oil level in the return chamber, the float is completely immersed in oil but the oil’s lifting force pushes the float up against its upper stop.

If the oil flow decreases, the oil level will drop in the return chamber. When the oil level has dropped about 15 mm (0.59"), the float will be floating on the oil about 5 mm (0.20") below the upper stop. In this position the microswitch opens and stops the crusher’s drive motor.

Check Check the level monitor by pushing the float down about 5 mm (0.20") from its upper stop. The crusher’s drive motor must then stop.

20 21 22 23 24 25

20 21 22 23

Float Weir Adjustable lower outlet Oil strainer Return oil chamber Deaeration screen

25

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8. Hydroset and lubrication system

8.2.10 Oil strainer The oil strainer (23) separates coarser contaminants from the oil and deaerates the oil.

In the tank beneath the oil strainer there is an additional deaeration screen (25). Its purpose is to any remove air bubbles in the oil returning to the tank and to prevent them going back to the crusher through the pump.

Check The oil strainer requires careful inspection, and especially during the running-in period, it should be checked daily. An abnormal amount of metal particles on the oil strainer can indicate trouble, and the cause should be investigated to forestall possible damage.

20 21 22 23 24 25

20 21 22 23

Float Weir Adjustable lower outlet Oil strainer Return oil chamber Deaeration screen

25

24

8.2.11 Thermostats Two thermostats have their sensing heads in the return oil chamber (24) in the oil tank. The thermostat for heat exchanger TG 2 controls the cooling of the oil pumped to the crusher, while the protective thermostat TG 1 shuts down the crusher’s drive motor if the oil temperature is too high.

26 27 28 29 30

Protective thermostat TG 1 Thermostat for heat exchanger TG 2 Oil heating thermostat TG 3 Level indicator, lubrication oil tank Heating elements

26 27 28 29 30 (Continued)

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8. Hydroset and lubrication system CAUTION!

It is important that the correct temperature settings are used. Set the thermostats according to the tables below for different operating conditions.

TG 1 Crusher drive motor shut-down function Operating conditions

Normal operating conditions

Operating at elevated temperature

Operating at low temperatures

Ambient air temperature

Max. 32°C (90°F)

Max. 40°C (104°F)

Below 0°C (32°F)

Oil viscosity

ISO VG 150

ISO VG 220

ISO VG 100

65°C (149°F) 65°C (149°F) 68°C (154°F) 1

52°C (126°F) 52°C (126°F) 55°C (131°F) 1

Protective thermostat TG 1 Basic setting Closes at Opens at Differential setting

CAUTION!

60°C (140°F) 60°C (140°F) 63°C (145°F) 1

The protective thermostat TG 1 shuts down the crusher when a serious fault occurs in the lubrication system so that the oil temperature rises excessively, for instance if the cooling system doesn’t work correctly. It is therefore important that none of the components are by-passed.

Check the cause of the stoppage and correct it before the crusher is restarted.

TG 2 Oil cooling control Operating conditions

Normal operating conditions

Operating at elevated temperature

Operating at low temperatures

Ambient air temperature

Max. 32°C (90°F)

Max. 40°C (104°F)

Below 0°C (32°F)

Oil viscosity

ISO VG 150

ISO VG 220

ISO VG 100

47°C (117°F) 51°C (124°F) 47°C (117°F) 3

33°C (91°F) 37°C (99°F) 33°C (91°F) 3

Thermostat for heat exchanger TG 2 Basic setting Closes at Opens at Differential setting

40°C (104°F) 45°C (113°F) 40°C (104°F) 4

Check Check the thermostat for heat exchanger TG 2 by holding a thermometer near the sensing head and note the temperatures at which the cooling fan or water pump starts and stops or at which the water valve opens and closes.

Check the protective thermostat TG 1 by immersing the sensing head in a slowly warmed oil bath together with a thermometer. Note the temperature at which the contacts break and then allow the oil to cool and note the temperature at which the contacts close.

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8. Hydroset and lubrication system

8.2.12 Oil heating The oil should be heated to the temperature given in the table below before the crusher is started. This is to prevent oil overflowing the dust collar.

The standard oil tank unit is fitted with electrical immersion oil heaters (29).

The heating elements are installed in tubes so that the oil is heated indirectly.

There is a separate oil heating thermostat TG 3 (28) which controls the heating elements.

26 27 28 29 30

Protective thermostat TG 1 Thermostat for heat exchanger TG 2 Oil heating thermostat TG 3 Level indicator, lubrication oil tank Heating elements

26 27 28 29 30

TG 3 Oil temperature Operating conditions

Normal operating conditions

Operating at elevated temperature

Operating at low temperatures

Ambient air temperature

Max. 32°C (90°F)

Max. 40°C (104°F)

Below 0°C (32°F)

Oil viscosity

ISO VG 150

ISO VG 220

ISO VG 100

Suitable temperature before crusher is started

30°C (86°F)

37°C (99°F)

25°C (77°F)

30°C (86°F) 30°C (86°F) 35°C (95°F) 3

37°C (99°F) 37°C (99°F) 42°C (108°F) 3

20°C (68°F) 20°C (68°F) 25°C (77°F) 3

Oil heating thermostat TG 3 Basic setting Closes at Opens at Differential setting

NOTE!

The oil heating should run for 24 hours a day. The heating elements are automatically controlled by the oil heating thermostat.

Check Check that the heating elements and the sensor of the oil heating thermostat are always covered by oil during operation.

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8.3 Exchanging main lubrication oil NOTE!

The following instructions can with advantage be followed in a sequence.

8.3.1 Draining the main lubrication system a) Disconnect the oil line from the lubrication outlet (13) on the tank.

NOTE!

This must be done at the lowest point – usually at the oil tank connection. b) Drain all oil from the crusher. c) Raise the mainshaft by using the L1 push button box (31), which is located in the vicinity of the cone crusher, and drain the oil from the piston. d) Reconnect the oil line to the lubrication outlet (13). e) Empty the oil from the heat exchanger by disconnecting the oil line at the lowest point.

NOTE!

The lowest point is usually at the oil tank connection. f) Drain all oil from the heat exchanger. g) Reconnect the disconnected oil line.

12 13 31

Lubrication inlet (from crusher) Lubrication outlet (to crusher) L1 push button box

31

12

13 (Continued)

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8. Hydroset and lubrication system h) Drain the lubrication oil tank by taking out the screw in the drain plug (15) beneath the lubrication oil tank.

14 15 16 17

Dehydration plug, lubrication oil tank Drain plug, lubrication oil tank Drain plug, Hydroset oil tank Dehydration plug, Hydroset oil tank

15

14

16

17

8.3.2 Cleaning the dirt trap a) b) c) d) e) f) 18 19

Close the shut-off valve ahead of the dirt trap.

Have a bucket ready to catch the oil which runs out.

Unscrew the plug (19).

Take out and clean the gauze element (18).

Install the gauze element and the plug.

Open the shut-off valve.

Gauze element Plug

18 19 NOTE!

76

During the running-in period, and when the tank has been cleaned, check the dirt trap daily.

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8.3.3 Changing filter elements a) b) c) d)

Close the shut-off valve between the filter (7) and the heat exchanger.

Close the shut-off valve (9) between the tank and the dirt trap (8).

Change the filter elements.

Inspect the old filter elements to check for larger particles on the filter material, as this indicates damaged or worn components in the lubrication system. e) Open the shut-off valve between the tank and the dirt trap. f) Open the shut-off valve between the filter and the heat exchanger.

Checks Check the pressure drop across the filter (7) regularly so that new filter elements can be ordered in good time before the next change.

NOTE!

1 2 3 4 5 6 7 8 9 10

When the fan of the air/oil heat exchanger is running, the pressure in the oil system generally rises. Avoid reading off the pressure at such times.

Pressure drop lamp Temperature gauge Pressure gauge Lubrication oil pump Pressure gauge connection Pressure drop sensor Oil filter Dirt trap Shut-off valve Pressure relief valve

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8.3.4 Cleaning the return oil strainer and tank a) b) c) d) NOTE!

Take off the cover over the lubrication oil tank.

Lift out the oil strainer (23).

Rinse contamination from the oil strainer with diesel oil or white spirit.

Blow the oil strainer clean with compressed air.

Replace the oil strainer with a new one if it is damaged. e) Check the bottom of the oil tank. If sediment is discovered, clean out contamination from the bottom of the tank with diesel oil or white spirit. f) Put the oil strainer back into place in the tank.

20 21 22 23 24 25

20 21 22 23

Float Weir Adjustable lower outlet Oil strainer Return oil chamber Deaeration screen

25

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8.3.5 Cleaning the air/oil heat exchanger (option) When the lubrication oil is changed, flush out the air/oil heat exchanger with diesel oil. a) Pour diesel oil into the oil tank.

NOTE!

The return oil line from the heat exchanger should be detached from the crusher line and arranged so that the diesel oil runs back to the tank without passing through the crusher. b) Pump the diesel oil through the heat exchanger.

8.3.6 Refilling the main lubrication system NOTE!

Before filling the tank with new oil, flush out the tank, oil lines and heat exchanger with clean new oil to remove any remaining diesel oil. a) b) c) d) e) f) g)

14 15 16 17

Refit the screw in the drain plug (15) beneath the lubrication oil tank.

Take off the cover over the lubrication oil tank.

Connect a hose to an oil drum.

Fill the tank with new oil (400 litres) through the oil strainer (23).

Check for possible leaks in connectors and valves.

Remove the hose from the lubrication tank.

Refit the cover over the lubrication oil tank and tighten the handles.

Dehydration plug, lubrication oil tank Drain plug, lubrication oil tank Drain plug, Hydroset oil tank Dehydration plug, Hydroset oil tank

15

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8.4 Pinionshaft lubrication system The pinionshaft bearings are lubricated by a separate circulatory system. A small flow of oil is bled off from the main lubrication system and is pumped to the oil inlet in the top of the pinionshaft housing. The volume in the pinionshaft housing is limited by a level tube and excess oil returns to the main lubrication tank by gravity.

1 2 3 4 5 6 1 2 3 4 5 6 7

Pressure drop lamp Pressure gauge Pinionshaft oil pump unit Pressure gauge connection Pressure drop sensor Oil filter Pinionshaft outlet (to crusher)

7

8.4.1 Oil filter The type of oil filter (6) used is full-flow, which means that all oil pumped to the pinionshaft housing is filtered. The filter element is of throw-away type.

The filter element must be changed when the pressure drop across the filter exceeds 0.22 MPa (32 psi) at normal operating temperature.

There is a by-pass valve on the filter. It opens when the pressure drop across the filter exceeds 0.35 MPa (51 p.s.i.). When the valve is open, part of the oil flow by-passes the filter and is thus not filtered.

Check Check the pressure drop across the filter (6) regularly so that new filter elements can be ordered in good time before the next change.

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8.4.2 Oil pump The pinionshaft oil pump unit (3) has a capacity of 0.7 l/min. (0.18 US gal./ min.) at normal operating temperature and pressure, when the motor is connected to a 50 Hz supply. (If the motor is connected to a 60 Hz supply, the flow will be 0.8 l/min. (0.21 US gal./min.)).

Exchange Exchange the pinionshaft oil pump (3) when the flow has dropped below 0.5 l/min. (0.13 US gal./min.).

Check Check oil delivery by disconnecting the outlet line (7) from the pinionshaft housing and measuring the time taken to fill a bucket with a known volume.

Carry out this check above the opening of the main lubrication oil tank – after removing the cover – to avoid oil spillage.

8.4.3 Pressure gauge The pressure gauge (2) gives the pressure measured by the pressure gauge connection (4) between the oil pump (3) and the filter (6).

Check Check the pressure at regular intervals and keep a record of the readings. If the pressure ahead of the oil filter rises, this is a sign that the filter should be changed. An abnormally low pressure can mean that the pump is worn.

8.4.4 Pressure drop indicator The pressure drop sensor (5) monitors the pressure drop across the filter and gives a signal when the pressure drop exceeds 0.22 MPa (32 p.s.i.). This signal indicates that the filter element should be changed.

The signal is given both electrically – to a pressure drop lamp (1) on the outside of the tank unit – and in the form of a red button which protrudes (about 4 mm) from the top of the sensor.

NOTE!

During a cold start, the indicator can incorrectly give a signal due to higher oil viscosity.

The electrical signal will automatically be reset when working temperature has been reached, but the mechanical signal (the red button) must be reset manually. If the red button jumps out again immediately, or if the lamp does not go out when working temperature has been reached, the filter element must be changed.

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8.5 Water/oil heat exchanger (option) Plate-type heat exchangers normally need no maintenance. When the lubrication oil is changed – or if the oil channels are blocked up – flush out the heat exchanger by pumping diesel oil through the oil channels.

1 2 3 4

Oil in Water out Water in Oil out (to crusher)

1 2

3 4 If the water channels are blocked by dirt, flush them out by reversing the water flow direction. If the water channels are blocked by lime, clean them out with a deliming agent, e.g. a 15 % hydrochloric acid solution which is then neutralized with a 5 % soda solution and finally flushed out with clean water.

NOTE!

Ventilate the heat exchanger when a deliming agent is used, to provide ventilation for any gas which may be produced.

To control the temperature, the thermostat for heat exchanger TG 2 can be used to start and stop a water pump. If instead the supply pipe is connected via a solenoid water valve, thermostat TG 2 can be used to open and close the valve. The amount of water required depends on the water temperature, etc.

NOTE!

If a water/oil heat exchanger is used, set the thermostats TG 1, TG 2 and TG 3 at the values given for “normal operating conditions”, whatever the ambient air temperature. See section 8.2.11 Thermostats and section 8.2.12 Oil heating.

Use clean fresh water. If only contaminated water is available, contact Sandvik Rock Processing first!

NOTE!

82

Drain all water out of the heat exchanger if the crusher is shut down during the winter (below 5°C/41°F).

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8.6 Air/oil heat exchanger (option) Keep the cooling efficiency as high as possible by regularly blowing the air/ oil heat exchanger coil clear with compressed air. If vibration occurs in the fan, it should be cleaned or replaced, to avoid damage to the heat exchanger.

Air

1 1 Air/oil heat exchanger

To provide the maximum cooling effect, the air must be sucked through the heat exchanger core.

Since there is a large oil flow through the heat exchanger, the oil inlet to the radiator coil can be either at the top or the bottom. It is normally unnecessary to bleed air from the heat exchanger.

The fan motor is controlled by the thermostat for heat exchanger TG 2. See section 8.2.11 Thermostats.

8.7 Hydroset system The Hydroset system makes it possible to change the crusher’s setting. The setting of the crusher is changed by raising (setting decrease) or lowering (setting increase) the Hydroset piston and the mainshaft assembly (complete with mantle) which is supported by the Hydroset piston. When the setting is decreased, oil is pumped into the Hydroset cylinder. When the setting is increased, oil is pumped back to the Hydroset tank. The tank has a pressure gauge (1) which indicates the pressure in the Hydroset system.

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Pressure gauge Oil filter Hydroset pump unit Damping valve Control valve Dirt trap (magnetic plug) Hydroset connection

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8. Hydroset and lubrication system

8.7.1 Hydroset pump The Hydroset pump (3) is a reversible gear pump.

When the pump is started, the tank must be filled with oil up to the right level.

8.7.2 Oil filter The type of oil filter used is full-flow, which means that the oil passing through is filtered. The filter element is of throwaway type.

8

Exchanging the filter element Change the filter element each time the Hydroset oil is changed or every six months. a) Relieve the pressure in the system by lowering the mainshaft and Hydroset piston to their bottom positions by using the L1 push button box (8) which is located in the vicinity of the cone crusher. b) Unscrew the filter element (2) and replace it with a new one.

8.7.3 Dirt trap (magnetic plug) The purpose of the magnetic plug (6) is to remove magnetic particles from the system.

Cleaning Clean the dirt trap each time the Hydroset oil is changed or every six months. a) Relieve the pressure in the system by lowering the mainshaft and Hydroset piston to their bottom positions by using the L1 push button box (8). b) Have a bucket ready for escaping oil. c) Unscrew and clean the magnetic plug.

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8.7.4 Control valve Between the crusher and the Hydroset pump is the control valve (5), which is a flow-actuated non-return valve. A relief valve is incorporated to protect the pump.

Emergency manual valve actuation The control valve (5) has a manual actuation facility for emergency use if contamination in the oil has blocked the valve so that normal motorised setting increase is impossible.

Manual operation is carried out as follows: a) Unscrew the cap (11). b) Push in the pin (10). If this cannot be done by hand, place a Ø10 mm ball or other suitable object in the cap and screw it back on so that the pin is pushed in. c) Start the pump for setting increase (by using the L1 push button box (8)) and lower the mainshaft to the desired position. d) Stop the pump.

NOTE!

If the valve does not operate correctly, it must be removed and cleaned. If the valve does operate correctly, replace the cap (11).

Always keep the Hydroset system clean to reduce the risk that contamination interferes with the valve.

9 10 11

9 Pressure limiting valve 10 Pin 11 Cap

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8. Hydroset and lubrication system

8.7.5 Pressure gauge The pressure gauge (1) displays the Hydroset pressure, measured at the control valve (5).

A damping valve (4) between the Hydroset line and the pressure gauge provides a smoother pressure reading when the crusher is in operation.

Cleaning Open the damping valve (4) once each week to clean out the needle valve.

When this has been done, close the damping valve until the pointer of the pressure gauge (1) moves smoothly during normal operation.

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Pressure gauge Oil filter Hydroset pump unit Damping valve Control valve Dirt trap (magnetic plug) Hydroset connection

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9. Accumulator This section describes the care procedures for the accumulator of the cone crusher.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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9. Accumulator

9.1 General

WARNING!

Risk of explosion A damaged accumulator entails a risk of explosion. Protect the accumulator from mechanical or thermal damage (impact, welding, etc.).

The accumulator (1) is a cylindrical steel pressure vessel which contains a rubber bladder fixed at the top of the vessel by a charging valve. The rubber bladder is filled with Nitrogen.

1 2 3 4

Accumulator Anti-extrusion valve Air bleed screw Flow regulator

1 2 3 4

Increase of setting due to overload Oil is forced out of the Hydroset cylinder and into the accumulator, allowing the mantle to sink far enough to let the tramp iron pass through the crushing chamber. The gas pressure in the accumulator forces the oil back into the Hydroset cylinder as soon as the obstruction has left the crushing chamber.

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9. Accumulator Owner’s responsibility The crusher’s owner must arrange for re-certification of the accumulator (1) if there are grounds to suspect that the accumulator has been damaged. New components are best obtained from Sandvik.

9.2 Flow regulator The flow regulator (4) is a throttling check valve between the Hydroset cylinder and the accumulator (1). It prevents the mainshaft rising too quickly after the tramp iron has passed through the crusher. When oil flows from the crusher to the accumulator, it passes unhindered through the flow regulator.

When the oil returns from the accumulator, it is slowed down so that the mantle is slowly raised to its original position.

9.3 Charging kit (option)

WARNING!

Risk of explosion A mixture of air (oxygen) and oil under high pressure constitutes a risk of explosion. Use only nitrogen (N2) in the accumulator.

An optional charging kit (FPU-1) can be used to check the gas pressure in the accumulator and to add nitrogen when necessary. The charging kit consists of a connector assembly with pressure gauge and bleed valve, a hose and an adapter for connection to the accumulator.

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9.3.1 Checking the gas pressure Fitting the charging kit a) Unscrew the protective cap (1) and (2) from the accumulator’s charging valve. b) Unscrew the internal hexagon screw (6) so the cut on its side is visible over the top of the adaptor (5). c) Close the bleed valve (8). d) Attach the adaptor (5) to the accumulator’s charging nipple (3). Tighten by hand sufficiently to prevent gas leakage. e) Attach the screw connector (7) to the adaptor (5). Tighten by hand sufficiently to prevent gas leakage. f) Screw down the spindle (9) so that the valve in the accumulator opens. g) Read off the charging pressure on the pressure gauge.

Removing the charging kit h) Unscrew the spindle (9). i) Open the bleed valve (8). j) Unscrew the screw connector (7) and remove the charging kit (FBU-1). k) Unscrew the adaptor (5) and remove the adapter from the accumulator’s charging nipple (3). l) Check that there is no gas leakage from the valve. Use soapy water or oil for this check. m) Refit the protective caps on the accumulator’s charging valve.

9 FBU-1

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Protective cap Protective cap Nipple O-ring Adaptor Hexagon screw

10

8 7

11 12

6 5 7 8 9 10 11 12

Screw connector Bleed valve Spindle Connector Charging hose Connector

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9.3.2 Charging with nitrogen Accumulator charging pressure

Tolerance

Without ASR / With ASR Plus

5.0 MPa (725 p.s.i.)

±5 %

With ASRi

6.0 MPa (870 p.s.i.)

±5 %

a) Attach the screw connector (12) with the charging hose (11) to the nitrogen gas bottle. b) Unscrew the protective cap (1) and (2) from the accumulator’s charging valve. c) Unscrew the internal hexagon screw (6) so the cut on its side is visible over the top of the adaptor (5). d) Close the bleed valve (8). e) Attach the adaptor (5) to the accumulator’s charging nipple (3). Tighten by hand sufficiently to prevent gas leakage. f) Attach the screw connector (7) to the adaptor (5). Tighten by hand sufficiently to prevent gas leakage. g) Screw down the spindle (9) so that the valve in the accumulator opens. h) Carefully open the valve on the nitrogen gas bottle so that the bladder expands slowly inside the accumulator and closes the oil valve. Check that this is the case before raising the pressure to the full charging pressure given in the table above.

NOTE!

Take into account that the pressure in the accumulator will drop slightly when the compressed gas cools down. Charge the accumulator bladder to 20 % above the desired pressure. i)

Close the valve on the nitrogen gas bottle and wait for five minutes.

Check the pressure. If the pressure is too high, release gas through the bleed valve (8) until the correct pressure is reached. j) Unscrew the spindle (9). k) Open the bleed valve (8) l) Unscrew the screw connector (7) and remove the charging kit (FBU-1). m) Unscrew the adaptor (5) and remove the adapter from the accumulator’s charging nipple (3). n) Check that there is no gas leakage from the valve. Use soapy water or oil for this check. o) Refit the protective cap (1) and (2) on the accumulator’s charging valve. p) Remove the charging kit from the nitrogen gas bottle.

NOTE!

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Recheck the charging pressure after 1, 2 and 3 weeks and thereafter at 6month intervals.

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10. Topshell assembly This section describes the care procedures for the topshell assembly of the cone crusher.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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10. Topshell assembly

10.1 Exchanging the spider cap Replaceable parts:

NOTE!

Description

Cat. no.

Qty.

Remarks weight 180 kg

Spider cap

5650-0

1

O-ring

5651-0

1

Screw M6S 20×60

5655-0

4

Washer TBRB 21x36

5655-2

4

Remove the feed distributor (if fitted) and clean out the feed hopper from processing material before removing the spider cap.

10.1.1 Removing the spider cap Recommended tools Lifting tackle and chain Lifting sling Mobile crane Feeler gauge Rags 30 mm Open end wrench

DANGER!

a) Clean off processing material from the spider cap (5650-0). b) Remove the four screws (5655-0) and washers (5655-2) that hold the spider cap to the topshell (5005-0). c) Position the hook of a crane vertically above the spider cap (5650-0). d) Attach the lifting hook to the lifting eye (3) on the spider cap (5650-0). e) Take up the slack in the lifting tackle.

Hanging load Be aware of the weight of the spider cap, see table above. Handle the spider cap with care. The tackle should now be tight but not lifting the spider cap. Keep clear of hanging loads, see section 2. Safety precautions.

f) g) h) i) 3 5651-0 5655-0 5655-2 5650-0

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Lifting eye O-ring Screw Washer Spider cap

Carefully lift the spider cap from the topshell.

Remove the O-ring (5651-0) from the spider cap (5650-0).

Place the spider cap (5650-0) on the ground.

Clean out all grease from the spider bearing.

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10.1.2 Spider cap removal checks – Measure the play at the pivot point. See section 10.3 Spider bearing for further information. Record the play and compare with earlier measurements.

S

L

– Clean and check the O-ring (5651-0) and the rim of the spider cap (5650-0) and topshell where the O-ring fits. If the O-ring is damaged it must be replaced.

– Check for wear on the spider cap (5650-0). If worn, weld on wear protection or exchange the spider cap.

– Clean and check the air vent passages in the spider cap and topshell.

– Check that the lubrication passage through the topshell is unobstructed.

10.1.3 Installing the spider cap a) Position the hook of a crane vertically above the spider cap (5650-0). b) Attach the lifting hook to the lifting eye (3) on the spider cap (5650-0). c) Take up the slack in the lifting tackle.

DANGER!

Hanging load Be aware of the weight of the spider cap, see table above. Handle the spider cap with care. The tackle should now be tight but not lifting the spider cap. Keep clear of hanging loads, see section 2. Safety precautions.

d) Carefully lift the spider cap from the ground. e) Grease the O-ring (5651-0) and position it on the spider cap. f) Place the spider cap on the topshell. Install the four screws (5655-0) and washers (5655-2). g) Fill with grease, in accordance with section 7.5 Grease for spider bearing lubrication.

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10.2 Inspection of crushing chamber •

Inspect the liners at the correct intervals. See section 6.1 Routine inspection and care. A new machine must be inspected frequently. After two liner changes, the intervals between inspections can be successively increased.

• These routine inspections will give an indication of when the liners must be changed. It is difficult to give an exact limit at which the liners are worn out. They are probably worn out when capacity drops off or when the thickness has been reduced so much that indentations or cracks have occurred.

Extreme operating conditions can require liner replacement before the liners are “worn out”. One reason can be incorrect feeding so that increased wear occurs over a certain section of the concave ring. This may also mean that the setting varies according to where measurement is carried out around the crushing chamber. Examples of different feed arrangements are given in the Installation manual.

A

A A-dimension B Groove C Groove

B C

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10. Topshell assembly Inspect the liners to avoid: a) Expensive damage to the contact surfaces of the topshell and the headcentre. b) Loss of production due to reduced capacity, an incorrect final product or an unscheduled shut-down.

Problems similar to those caused by an incorrect feeding arrangement can also be experienced if the feed material is not an evenly graded mixture. If a large proportion of the feed is close to the maximum size, crushing will be concentrated to the upper portion of the chamber. This can give rise to an annular groove around the entire crushing chamber (B groove). A large proportion of fine material in the feed concentrates crushing to the lower part of the chamber (C groove).

The benefits gained by continuing to crush with worn liners are small in comparison with the disadvantages described above. Planned liner replacement at the right time always gives optimum operating economics.

In addition, the liners must be replaced if the maintenance of the desired setting entails raising the mainshaft so high that the distance between the head nut and the underside of the spider (A-dimension) is less than 15 mm (0.6").

Liner wear is compensated for by hydraulically raising the mainshaft so that the desired setting can be maintained.

The A-dimension is an indication of the position of the mainshaft inside the crusher.

CAUTION!

NOTE!

Never raise the mainshaft so far that the A-dimension is ≤ 15 mm (0.6").

If the mainshaft is raised further it can caused damage to the spider bearing in the topshell.

The liners are normally worn out before this limit is reached.

Each crushing chamber is designed for a specific setting interval.

Example: MF (medium fine) chamber The crushing chamber’s theoretical setting interval is 10–32 mm (0.39–1.3").

If the crusher runs with 10 mm (0.39") setting, the smallest A-dimension 15 mm (0.6") will be reached faster than if the crusher runs with 32 mm (1.3") setting. With larger settings the liners are worn out long before the smallest A-dimension is reached.

It is difficult to estimate the A-dimension at which the liners are worn out, since this depends on the wear profile of the crushing chamber (see above).

Experience with the crusher and visual inspections are necessary to determine when the liners should be changed.

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10.3 Spider bearing The spider bearing is in level with the pivot point for the gyratory movement of the mainshaft. The spider bushing is hourglass-shaped with a tapered outer surface.

S

L

10.3.1 Inspecting the spider bearing Max. permissible play and distance above pivot point S mm/(inches)

L mm/(inches)

2.1/(0.083)

165/(6.5)

Check the play in the spider bearing (S) each time the liners are changed or at least twice per year (1000 h). Check the play more frequently if the material being crushed is abrasive.

If the play (S) is close to the maximum permissible, and it is decided to keep running with the old bushing, the lubricant must be checked and topped up more frequently than normal. See also section 7.5 Grease for spider bearing lubrication.

(Continued)

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10. Topshell assembly When the play (S) is being measured, the mainshaft must be pushed in the direction in which it is inclined and the measurement should then be made on the opposite side with a feeler gauge. Measure on a level with the pivot point (L). Feeler gauges are included in the tool kit supplied with the crusher.

NOTE!

Avoid damaging the spider bearing seal and the scraper with the feeler gauge.

If the play exceeds the maximum permissible value, the spider bushing and/ or the mainshaft sleeve must be replaced. When the bearing is dismantled, the old components can be measured and compared with the measurements obtained from new components to determine which item is most worn and whether acceptable play can be obtained if just one item is replaced.

If the play considerably exceeds the maximum permissible value, the mainshaft has been given an abnormal inclination during crushing and has thus worn the eccentric bushing at an incorrect angle.

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11. Setting measurement This chapter describes the measurement of the CSS, the discharge setting.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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11. Setting measurement

11.1 General The setting adjustment system is designed to compensate for mantle and concave wear and to change the CSS (close side setting) of the cone crusher.

The frequency with which the CSS must be checked normally depends on the rate at which the crushing liners wear. A more abrasive stone will require frequent checks, whereas a non-abrasive material will require only occasional checks.

Regular inspection of the concave ring is recommended to make sure that it has not been worn unevenly or has become oval. Also look for any localized wear or other damage in the crushing chamber. If the crushing liners are worn, the mantle (on the mainshaft) cannot be raised so high that it comes into contact with the concave ring without a risk of the mainshaft’s head nut contacting the underside of the crusher’s spider hub. This occurs relatively early in the case of a coarse crusher which operates with a large CSS. CAUTION!

Never raise the mainshaft so far that the A-dimension is ≤ 15 mm (0.6").

If the mainshaft is raised further it can cause damage to the spider bearing in the topshell. See section 10.2 Inspection of crushing chamber.

setting decrease = finer product

setting increase = coarser product

=

=

11.1.1 Checking the setting with lead See section 4.2.1 Checking the setting with lead.

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12. Troubleshooting This chapter comprises a guide for correcting various problems that can appear during operation.

It is not intended that personnel belonging to the Operator’s work role should carry out corrective actions. The Operator’s work role is to identify the fault or error and report to a supervisor. The supervisor decides on the appropriate action.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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12. Troubleshooting

12.1 Faults and suggested corrective actions The following table shows possible causes and suggested corrective actions for a number of different fault conditions.

No.

Fault

Check

Corrective action

1

Cone crusher will not start

No “Ready for start” signal and oil pump not running

Check electrical circuits and starter of pump motor.

Start the pump.

No “Ready for start” signal and lubrication oil flow low

If the return oil flow is low, wait a few minutes to see if it stabilizes.

Check that oil does not overflow over dust collar.

Check oil lines and remove obstacles if return line is blocked.

Clean dirt trap, see 8.3.2. If necessary, change filter element, see 8.3.3.

Check pump capacity. See 13. Low or no oil capacity.

Normal lubrication oil flow, but no “Ready for start” signal.

Check operation of return oil flow switch, see 8.2.9.

If protective thermostat TG 1 shuts down crusher, check operation of thermostat, see 8.2.11.

If pinionshaft oil pump is not running, check electrical circuits and starter of pump motor. Start pinionshaft oil pump.

2

Oil pump running and “Ready for start” signal obtained

Check starter of crusher’s drive motor and other electrical circuits. See Installation manual.

Oil does not return to tank (in low temperature)

Start oil pump. Let it run approx. 30 s. Bridge over return oil flow switch so that “Ready for start” signal is obtained. Start crusher. Let it run approx. 20 s.

Remove bridge over return oil flow switch after approx. 40 s. If crusher still will not start, repeat sequence again after a couple of minutes. See also 4.2.5 and Installation manual.

Crusher stops Oil pump not running when idling or with material Low lubrication oil flow in the chamber

Check electrical circuits and starter of pump motor.

Start pump.

Check that oil does not overflow over dust collar.

Check oil lines and remove obstacles if return line is blocked.

Clean dirt trap, see 8.3.2. If necessary, change filter element, see 8.3.3.

Check pump capacity. See 13. Low or no oil capacity.

Normal lubrication oil flow

104

Check operation of return oil flow switch, see 8.2.9.

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CH440:01

12. Troubleshooting No.

Fault

Check

Corrective action

2

Crusher stops Oil too hot when idling or Pinionshaft oil pump not running with material in crushing V-belts slipping chamber

See No. 3. Lubrication oil temperature too high.

Check electrical circuits and starter of pump motor.

Start pinionshaft oil pump.

Adjust V-belt tension. Change V-belts if necessary.

Reduce load on crusher. See “Crusher’s drive motor overloaded” below.

Crusher’s drive motor overloaded Check that eccentric throw and crushing chamber are correct for chosen CSS and material being crushed. Increase setting if too small.

Check for bearing failure or seizure in the crusher, see No. 9. Bearing failure inside crusher.

Packing in crushing chamber

See 5.6.

Tramp iron or blockage in crushing chamber.

Lower the mainshaft to remove the obstruction.

Check the liners for damage or looseness. Reset drive motor and overload protection. Check V-belt tension and adjust if necessary.

If lowering mainshaft doesn’t help, it might be necessary to loosen topshell bolts. See Maintenance manual.

3

Lubrication oil temperature too high

Protective thermostat TG 1 shuts down crusher

Check operation of oil cooling system and thermostat for heat exchanger TG 2, see 8.2.11.

For a water/oil heat exchanger, check that water channels are not blocked, see 8.5.

For an air/oil heat exchanger, check fan motor and starter. Clean radiator core. Check that there is sufficient cooling air. See 8.6.

Protect heat exchanger and tank unit from direct sunlight.

Check that pressure relief valve does not leak so that heat exchanger will be by-passed, see 8.2.8.

If there is a contamination increase in return oil strainer, investigate possible incipient bearing failure.

See 8.2.10 and No. 8. Increasing bearing component wear.

Heat exchanger cooling continuously.

See “Protective thermostat TG 1 shuts down the crusher” above.

If lubrication oil viscosity is incorrect, change oil. See 7.2 and 8.3.

Low lubrication oil flow

Check oil lines and remove obstacles.

Clean dirt trap, see 8.3.2. If necessary, change filter element, see 8.3.3.

Check pump capacity. See 13. Low or no oil capacity.

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105

12. Troubleshooting No.

Fault

Check

Corrective action

4

Low Hydroset pressure Crusher will not hold a constant Leakage in Hydroset system CSS, or product is oversized

Check capacity of Hydroset pump. If necessary, change pump.

Check Hydroset oil lines. If possible – without going below the smallest A-dimension (see 10.2) – raise mainshaft until liners have metal-to-metal contact.

Don’t exceed maximum Hydroset pressure (see 4.2.4). Check Hydroset pressure gauge to see if pressure is falling. Seal or replace relevant components.

Pressure relief valve leaking. Set- If there are overload pressure peaks, change feed ting increase has caused oil level arrangement. Crusher should be choke fed without to rise in Hydroset tank. segregation. See Installation manual.

If there are no overload pressure peaks, change pressure relief valve.

Hydroset control valve leaking, see 8.7.4 Setting increase has caused oil level to rise in Hydroset tank.

Clean or replace Hydroset control valve.

Hydroset packing leaking

Check if oil level has risen in lubrication oil tank.

Replace Hydroset packing. Check Hydroset cylinder bushing, replace if necessary.

Air in Hydroset system or accumulator gas pressure too low.

CSS increases during crushing but returns to pre-set value during idling.

Bleed air from Hydroset system, see 4.2.3.

Accumulator bladder damaged.

Mainshaft “climbs” to metal-tometal position when crusher is idling, or nitrogen leaking from accumulator bladder gives milky white colour in Hydroset oil.

Replace accumulator bladder or complete accumulator. Bleed air from Hydroset system, see 4.2.3.

Charge accumulator to correct pressure, see 9.3.

Replace accumulator bladder or complete accumulator if necessary.

Crusher’s feed not evenly distrib- Change feed arrangement. Crusher should be choke fed without segregation. See Installation manual. uted. Hydroset pump cannot reduce CSS because of pressure peaks.

106

Liners worn

Check liners for wear or looseness.

Liner ovality

Check setting at 4 points evenly spaced around the crushing chamber, as described in 4.2.1. The difference between the largest and smallest reading is an indication of the ovality.

Headcentre loose

Check if there is too much play between headcentre and mainshaft. See Maintenance manual.

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12. Troubleshooting No.

Fault

5

High temperature inside and outPoints to watch regard- side pinionshaft housing. ing pinionshaft assembly

Check that level tube and drain plug do not leak, see 7.4. Check that there are no other leaks.

Oil leakage through outer bearing cover.

Check if outer seal ring, spacer ring or O-ring is worn or damaged. Remove pinionshaft assembly for inspection. If necessary, replace worn bearing and seal components. See Maintenance manual.

Abnormal noise in pinionshaft assembly. Incipient bearing failure.

Remove pinionshaft assembly for inspection. If necessary, replace worn bearing and seal components.

See Maintenance manual.

Vibration in crusher or pinionshaft housing.

Check V-belt pulleys. Clean off any collected dust.

Check V-belt tension. Check if they are flapping.

Remove pinionshaft assembly for inspection. If necessary, replace worn bearing and seal components.

See Maintenance manual.

Excessive axial play in bearings because of heavy wear on rollers and races

Check frequently for increasing noise or rising temperature in pinionshaft assembly. Schedule removal and bearing replacement for a convenient time.

Incorrectly fitted bevel gears or incorrect gear meshing causing noise from gears. Insufficient backlash emitting a high-frequency rattle.

Remove pinionshaft assembly. Measure correct gasket thickness. Adjust backlash. See Maintenance manual.

Heavy wear on eccentric wearing plate leading to reduced backlash. Insufficient backlash emitting a high-frequency rattle.

Strip down crusher and replace eccentric wearing plate. Readjust backlash. See Maintenance manual.

If eccentric wearing plate wear accelerates, see no.

8. Increasing bearing component wear.

Crushing liner loose

Check and tighten concave ring bolts. Check if there is play between headcentre and mantle. See Installation manual.

6

Abnormal noise in crusher

CH440:01

Check

Corrective action

Check that pinionshaft lubrication pump is running and that oil reaches pinionshaft housing.

Remove pinionshaft assembly for inspection. If necessary, replace worn bearing and seal components.

See Maintenance manual.

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12. Troubleshooting No.

Fault

Check

Corrective action

6

Abnormal noise in crusher

Unusual noise from spider bearing when material is fed

Check grease level and add more frequently if necessary, see 7.5 and 10.3.

Measure play at pivot point. If more than permissible, replace spider bushing and/or mainshaft sleeve. If permissible play is considerably exceeded, it might also be necessary to replace eccentric bushing. See 10.1, 10.3 and Maintenance manual.

“Grating” step bearing components

Reduce crusher’s operating load. Extend running-in period, see 4.2.

If there is a contamination increase in return oil strainer, investigate possible incipient bearing failure.

See 8.2.10 and No. 8. Increasing bearing component wear.

Check for liner ovality.

Packing in crushing chamber or liners “metal to metal”

Check operating conditions and CSS. Increase setting.

Check for liner ovality.

7

108

Crusher’s capacity drops

Movement between flanges of topshell and bottomshell

Check with a feeler gauge if there is play between flanges. Tighten bolts. If there is still movement between topshell and bottomshell flanges, tapered joint needs machining. Contact Sandvik Rock Processing. See Maintenance manual.

Excessive Hydroset action

Check lower section of crushing chamber for “skislopes” on the mantle and concave. Change liners.

“Ski-slope” formed on liners.

Check feed arrangement. Make sure crusher is choke fed. Check top size and bottom size of crusher’s feed. There must not be a large proportion of material smaller than CSS. See 10.2 and Installation manual.

Extremely large play in spider bearing.

Check spider bearing play, see 10.1 and 10.3. If there is exceptionally large play in spider bearing, check condition of eccentric bushing.

V-belts slipping

Adjust V-belt tension. Change V-belts if necessary.

Inspect grooves in V-belt pulleys. See Maintenance manual.

Feed material or composition has been changed.

Altered fraction length and material hardness can lead to changes in capacity. See Installation manual.

Bridging or blocking in crushing chamber.

Check material level in feed hopper. If possible, limit top size of feed. See Installation manual.

© Sandvik SRP AB – Doc. no. S 223.543 en Ver. 2

CH440:01

12. Troubleshooting No.

Fault

Check

Corrective action

8

Increasing bearing component wear

Contaminated oil leading to increased wear on eccentric wearing

Check oil condition regularly. Clean tank. Change oil at regular intervals. See 8.3.

Oil filter blocked

Change filter elements, see 8.3.3.

Dust seal ring worn or damaged

If play between dust collar and dust seal ring exceeds value given in 6.3.1, replace dust seal ring.

Over-pressure dust sealing system not working

Inspect entire over-pressure system and check operation. See Maintenance manual.

Mainshaft assembly rotates very fast or at same speed as eccentric. Seizure or incipient seizure between mainshaft and eccentric bushing.

Strip down crusher to inspect bearing components.

See Maintenance manual.

Pinionshaft cannot be turned.

Seizure between eccentric and bottomshell bushing.

If possible, take out bolts holding dust collar.

Remove mainshaft assembly and complete eccentric assembly. See Maintenance manual.

Pinionshaft cannot be turned.

Bearing failure in pinionshaft assembly.

See Maintenance manual.

Increased amount of swarf in return oil strainer. Seizure in step bearing or bronze bushings.

Remove step bearing components. De-burr edges of oil grooves. Polish bearing surfaces of bushings and step bearing components. If necessary, replace step bearing components. Inspect bearing surfaces of bushings. See Maintenance manual.

Needle-like particles on the return oil strainer. Seizure or wear in bevel gears.

See Maintenance manual.

Tin or lead flakes in return oil strainer. High temperature or localized overheating and partial seizure in bushings or step bearing components.

See no. 3. Lubrication oil temperature too high.

Bronze particles on return oil strainer

Investigate possible incipient bearing failure. See 8.2.10 and No. 8. Increasing bearing component wear.

High return oil temperature

See No. 3. Too high lubrication oil temperature.

Excessive Hydroset pressures

See No. 4. Crusher will not hold a constant CSS setting or oversized product.

Dirt

Check dust seal. A worn dust seal will allow dust into the system.

9

10

Bearing failure inside crusher

Oil contaminated

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12. Troubleshooting No.

Fault

Check

Corrective action

11

Broken Hydroset bolts

Incorrect torque

Replace all bolts if any is defect. Use only bolts intended as Hydroset bolts. Tighten to recommended torque.

High Hydroset pressure

Operating crusher with excessive tramp metal in the circuit can cause Hydroset bolts to fail. Remove tramp metal ahead of crusher.

Worn top shell

Inspect seating area for concave during a concave change. Remove any upset metal that may stop the concave from seating correctly in topshell.

Incorrectly tightened bolts

Tighten bolts correctly. See Maintenance manual.

Pump sucks air through a leak

Replace suction lines, if leaking.

12

13

Broken concave bolts

Low or no oil capacity

Replace shaft seal, if leaking.

Pump rotates in wrong direction

Change direction of rotation. See Maintenance manual.

High pressure but still low capac- Exchange oil, see 8.3. ity because of wrong type of oil

110

Pump is dry

Fill with oil.

Suction line blocked

Remove obstruction.

Broken pump, e.g. cavitation in pump or broken gear teeth.

Replace pump.

© Sandvik SRP AB – Doc. no. S 223.543 en Ver. 2

CH440:01

Appendix A: Inspection Make a copy of the inspection checklist and inspection notes in this appendix and use them together with section 6.1 Routine inspection and care.

To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.

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A-1

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A-2

© Sandvik SRP AB – Doc. no. S 223.543 en Ver. 2

CH440:01

DAILY: Check oil level in lubrication tank.

Check oil level in Hydroset tank.

Check that shut-off valves between tanks and pumps are fully open.

Check that no material has built up on bottomshell arms.

Check that lubricating oil returns to tank and that oil is clean.

Check that oil lines do not leak.

Check that pinionshaft lubrication circuit is operating correctly.

Check CSS. Check that material has not jammed in feed hopper or distributor and blocked feed opening.

Listen for abnormal noises in crusher.

Listen for abnormal noises in lubrication pump.

Check return oil temperature.

Check drive motor current or power consumption.

Check Hydroset pressure and that pressure gauge damping is correct.

Check temperature of pinionshaft housing.

Check oil pressure of main lubrication system and pinionshaft lubrication system at normal operating temperature.

Check that there is no oil leakage.

Check that no bolts have come loose.

Check that oil heaters are working.

Check distance between head nut and underside of spider (i.e. A-dimension).

Check that there is no contamination increase or change on return oil strainer, e.g. an abnormal amount of metal particles.

WEEKLY: Inspect oil filter (check if red button on pressure drop sensor protrudes) of main and pinionshaft lubrication systems.

Clean dirt trap and inspect oil tank of main lubrication system.

Inspect crushing liners for wear and damage.

Measure setting at four points around crushing chamber to check for uneven wear.

Check pumps for abnormal noise and wear.

Check wear and tension of V-belts.

Check coil of air/oil heat exchanger (option).

Clean damping valve for Hydroset pressure gauge.

Check air pressure (blower running or regulator working) of over-pressure dust sealing.

Check hose and filter of over-pressure dust sealing and that covers on tank unit are air tight.

MONTHLY: Clean drain plug on pinionshaft housing.

Check dust seal ring for wear.

Check condition of scraper which rotates above dust collar.

Check tightness of all bolts.

Check play between mainshaft sleeve and spider bushing.

Check grease level in spider bearing.

Clean air vent passages in spider cap and topshell.

Check quality of lubrication oil.

Check function of return oil flow switch.

Check backlash in pinion and eccentric gear.

Check – using feeler gauges – between headcentre and mantle and between topshell and concave ring.

Check spider bearing grease seal for wear.

Symbols to be marked in the squares: X = No remarks No. = See corresponding number in “Inspection notes”

Week no: Su Mo Tu We Th Fr

Week no: Sa Su Mo Tu We Th Fr

Week no: Sa Su Mo Tu We Th Fr

Week no: Sa Su Mo Tu We Th Fr

Sa

Inspection checklist SANDVIK CH440:01 Machine no: SW ___________________ Date (first day on this sheet): Y: _____ M: _____ D: _____

© Sandvik SRP AB – Doc. no. S 223.543 en Ver. 2

Previous operating hours: _________________h

No.

Remarks

Sign.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

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17

18

19

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