Operators Manual CH420-01 - OM - S223.498.en-01

operator’s manual Doc. no. S 223.
498 en
SANDVIK CH420:01
This document is valid for:
Serial no. / Machine no. Sign.
SANDVIK CH420:01
© Copyright 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 223.498 en

Issue: 20070516
Version: 1
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
CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 1

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
2 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

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 Water/oil heat exchanger (option)....................................... 80
8.5 Air/oil heat exchanger (option)............................................ 81
8.6 Hydroset system ................................................................. 81
8.6.1 Hydroset pump....................................................... 82
8.6.2 Oil filter................................................................... 82

Table of contents
8.6.3 Dirt trap (magnetic plug)......................................... 82

8.6.4 Control valve .......................................................... 83
8.6.5 Pressure gauge...................................................... 84
9. Accumulator
9.1 General ............................................................................... 86
9.2 Flow regulator ..................................................................... 87
9.3 Charging kit (option)............................................................ 87
9.3.1 Checking the gas pressure .................................... 88
9.3.2 Charging with nitrogen ........................................... 89
10. Topshell assembly

10.1 Exchanging the spider cap.................................................. 92
10.1.1 Removing the spider cap ....................................... 92
10.1.2 Spider cap removal checks .................................... 93
10.1.3 Installing the spider cap ......................................... 93
10.2 Inspection of crushing chamber .......................................... 94
10.3 Spider bearing..................................................................... 96
10.3.1 Inspecting the spider bearing ................................. 96
11. Setting measurement

11.1 General ............................................................................. 100
11.1.1 Checking the setting with lead ............................. 100
12. Troubleshooting
12.1 Faults and suggested corrective actions........................... 102
Appendix A: Inspection

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

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

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 8
7 Year of manufacture 7
8 CE mark
Type:
9 Type and size of crusher
10 Crushing chamber (concave ring) 1 2 3 4 5 6
11 Mantle
12 Filler ring CH420-F/B/C-25/28/22:1
13 Eccentric throw (mm)
14 Mark number
9 10 12 13 14
11

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 Type
16 Part number
17 Serial number 22
18 Mass (kg)
21
19 Order number
20 Manufacturer
21 Year of manufacture
22 CE mark
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.

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 CH420. Details of less or no importance for instructions given
can therefore differ from the CH420 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 110 pages.
Feedback
If you have comments on this Operator’s manual or problems connected to
the crusher’s documentation, send an e-mail to: [email protected]

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
1 Spider bearing 3
2 Topshell 4
3 Concave ring 5
4 Mantle
5 Eccentric assembly
6
6 Mainshaft

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 is a separate circulatory lubrication system – the main lubrication
system – which is described in section 8.2 Main lubrication system.

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 Spider cap 2
2 Spider bushing
3 Head nut
4 Mantle
3
5 Concave ring
4 20
6 Mainshaft with headcentre
7 Eccentric wearing plate 5
6 19
8 Bottomshell bushing
9 Eccentric 18
10 Eccentric bushing
11 Step bearing 17
12 Hydroset piston 7 16
13 Pinionshaft housing 8 15
14 Pinionshaft
15 Dust collar
16 Locating bar
17 Dust seal ring
18 Bottomshell
19 Topshell
20 Filler ring 9 14
10
13
11
12

1. Introduction
Cone crusher – side view
21
21 Hole for level indicator
22 Inspection door
22
23 Feed hopper 23
24 Inspection hatch
24

1. Introduction
Tank unit and auxiliary equipment
25 Over-pressure blower
25
26 Over-pressure air regulator
27 Tank unit
28 Water/oil heat exchanger 26
29 Air/oil heat exchanger
30 Charging kit for accumulator
27
28
29
30

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

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 life-

threatening 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 Read the manual

before any work

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.

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

Falling stones
Clear the feed arrangement from process material before any
maintenance work is carried out inside or below the crusher, to
WARNING! 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)

Avoid remaining on the crusher, unless necessary for maintenance work.
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
DANGER! crushed.
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
WARNING! 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!
Flying fragments
Fragments ejected upwards may fall down in the vicinity of the
crusher. Provide adequate guards and warning signs at appropriate
WARNING! 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.

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 sim-

ilar 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.
Toxic gases
Inhalation of welding fumes can be dangerous to health. Always follow
instructions provided by the welding equipment supplier.
WARNING! Some parts of the crusher are made of manganese steel. Long-term
exposure to manganese oxide can affect the nervous system.

2.3.4 Hydraulic system

CAUTION! Only personnel certified in hydraulics are permitted to perform opera-
tions on the hydraulic system.
Oil pressure
Pressurized oil is dangerous if released incorrectly. Relieve all
pressure before carrying out maintenance or repair work on the
WARNING! 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.

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.
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
WARNING! chamber.
Explosives
Never remove blocking boulders from the crusher by blasting.
Blasting may cause personal injury and seriously damage bearings or
WARNING! 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
DANGER! 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.

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
Health hazards
Radon is a radioactive gas that occurs naturally in bedrock. Radon
may cause lung cancer. Mineral type, ventilation and water are all
DANGER! 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.

This page is intentionally left blank

3. Technical data

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 CH420
Type Cone crusher
Application Mineral processing
Total weight 5 300 kg
Length 1.55 m (2.38a m)
Width 1.55 m (1.64a m)
Height 2.16 m
Eccentric speed 395 rpm
Pinionshaft speed 1 475 rpm
Max. motor power 90 kW / 120 hp
Drive V-belts
a. With subframe
3.2 Processing data

Characteristics (depending on crushing chamber) Data
Max. feed size 18 to 150 mm
CSS min–max 4 to 32 mm
Nominal capacity 25 to 145 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.

4. Starting up the cone
crusher
This section describes how to start 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.
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 proce-
dure.
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)

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 8.6.5 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 8.6.5 Pressure gauge.
o) Check and record the main lubrication oil pressure, see section 8.2 Main
lubrication 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) Check the oil level in the pinionshaft housing when the crusher is
standing still. See section 7.4 Oil for pinionshaft lubrication.
s) After running-in is completed, check the tightness of all bolts and re-
tension 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! 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.

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.
3
1 Measuring nipple
2 Air bleed hose
3 L1 push button box
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 bubble-
free oil flows out.

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
90 kW.
• The maximum average Hydroset pressure must not exceed following
values.
Crushing chamber Pressure
EF 3.5 MPa (507 p.s.i.)
F 3.5 MPa (507 p.s.i.)
MF 3.2 MPa (464 p.s.i.)
M 3.2 MPa (464 p.s.i.)
C 3.0 MPa (435 p.s.i.)
C 2.8 MPa (406 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 C EC
13 mm 45 51 54
16 mm 47 50 54 61 65
18 mm 52 55 59 67 71
20 mm 56 60 65 74 78
22 mm 61 61 65 70 80 85
25 mm 68 68 73 78 90
28 mm 75 75 80

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.

This section describes basic procedures when 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.
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.
NOTE! The oil heating should run for 24 hours a day. The heating elements are
automatically controlled by the oil heating thermostat.

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

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
WARNING! supplier’s instructions and safety directions when handling oils and
greases.
NOTE! 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 8.6.2 Oil filter and section 8.6.3 Dirt
trap (magnetic plug).
d) Exchange the oil in the pinionshaft housing. Use the same oil as in the
main lubrication system, see section 7.4 Oil for pinionshaft lubrication.
e) 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.

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.
trap (magnetic plug).
e) 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.

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.
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.
e) 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.
f) 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.

5.4 Checking the V-belt tension

The procedure for checking the V-belt tension is described in section 6.4.2 V-
belt 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 8.6.5 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.
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 man-
ual.
CAUTION! Never start the crusher with a loose topshell.

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

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 8.6
Check that the shut-off valves between the tanks and pumps Before starting the pumps and –
are fully open. 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 After starting the lubrication 8.2
clean. pump
Check that the oil lines do not leak. After starting the pumps –
Check the CSS. Running idle 4.2.1
Check that material has not jammed in the feed hopper or Running idle –
splitter and blocked the feed opening.
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 While crushing 8.6
damping is correct.
Check the temperature of the pinionshaft housing. Use an While crushing –
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).
Check the oil pressure of the main lubrication system at nor- While crushing 8.2.5
mal operating temperature.
Check that there is no oil leakage. While crushing –
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 With crusher stopped 10.2
the spider (i.e. the A-dimension).
Check that there is no contamination increase or change on With crusher and lubrication 8.3.4
the return oil strainer, e.g. an abnormal amount of metal parti- pump stopped
cles.
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.
Inspect the oil filter (check if the red button on the pressure With crusher and lubrication 8.2.3, 8.3.3
drop sensor protrudes). pump stopped
Clean the dirt trap and inspect the oil tank of the main lubrica- With crusher and lubrication 8.2.1, 8.2.2,
tion system. pump stopped 8.3
Inspect the crushing liners for wear and damage. With crusher stopped 10.2
Measure the setting at four points around the crushing cham- Running idle 4.2.1, 11.1
ber to check for uneven wear.
Check the pumps for abnormal noise and wear. While crushing. 8.2.4, 8.6.1
Check wear and tension of the V-belts. With crusher stopped –
Check the oil level in the pinionshaft housing. With crusher stopped 7.4
Check the cooler core of the air/oil heat exchanger (option). With crusher and lubrication 8.5
pump stopped
Clean the damping valve for the Hydroset pressure gauge. With crusher stopped 8.6.5
Check the air pressure (blower running or regulator working) of Running idle 6.7
the over-pressure dust sealing.
Check the hose and filter of the over-pressure dust sealing With crusher stopped 6.7
and that the covers on the tank unit are air tight.

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 air vent nipple 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 Operator 6.3.2
dust collar.
Check the tightness of all bolts. Operator –
Check the play between the mainshaft sleeve and the spider Operator 10.1, 10.3
bushing.
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 Service personnel See MM
the mantle and between the topshell and the concave ring.
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.
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 Operator 8.6.2, 8.6.3
Hydroset system.
Check the play in the spider bearing. Operator 10.1, 10.3

6.1.5 Yearly
These inspections should be carried out yearly or after every 2000 hours of
operation. The crusher must be stopped.
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 bottom- Service personnel See MM
shell.
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 Service personnel See MM
wear and scratches.
Check the gears for wear. Service personnel See MM
Check the Hydroset cylinder bushing for wear and scratches. Service personnel See MM
Change oil in the pinionshaft housing. Operator 7.4
Check the function of the temperature gauge. Operator 8.2.7
Check the function of the protective thermostat TG 1 and the Operator 8.2.11
thermostat for heat exchanger TG 2

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 Part. no. Used for
Lifting tool 442.6520-00 Eccentric bushing
Lifting tool 442.6640-00 Bottomshell bushing
Lowering rod with nut M24×500 843.1330-00 Piston
Nut M6M M24 845.0012-00 Lowering rod
Piston stop plate 442.9994-00 Holding piston
Eye bolt 442.6340-01 Mainshaft step
Eye bolt M36 899.0132-00 Mainshaft
Eye bolt M16 899.0147-00 Dust collar
Eye bolt M12 899.0155-00 Eccentric unit
Eye bolt M10 899.0099-00 Bottomshell bushing / Eccentric bushing
Eye bolt M8 899.0244-00 Eccentric bushing
Eye bolt M6 899.0243-00 Mainshaft sleeve
Ring spanner striking 55 mm 920.0109-00 Screw and nut M36
Ring spanner striking 36 mm 920.0151-00 Screw and nut M24
U-ring spanner 36 mm 920.0135-00 Screw and nut M24
Allen key 10 mm 920.0038-00 Screw MC6S M12
Allen key 5 mm 920.0035-00 Air bleed screw
Allen key 5/8" 920.0032-00 Spider cap plug
Chunk of lead 442.0800-90 CSS check
Feeler gauges 0.05–1 mm 923.0422-00 Spider bearing play, etc.

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

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 Retaining ring
3 Dust seal ring
4 Dust collar
5 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)
1.3/(0.051)
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.

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! 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 ac-
tion of the head nut.

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.
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.
F
2
1 F-scale 1
6
6 14 12 10 8
W
2 D-scale
D = deflection D
5
W = belt span F
4
F = deflection load 2
3
2
D
1

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 Dust collar 1400-0

1450-0 Inner dust seal ring 1450-0
4305-0 Dust seal ring
4350-0 Retaining ring 4305-0
4355-1 Scraper 4350-0
1 Dust
1
4355-1

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.)

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.
4 Blower 6
6 Filter
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 Pressure gauge
7 Air regulator
8 Filter
9 Compressed air connection
3 7 8 9


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

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! 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
WARNING! supplier’s instructions and safety directions when handling oils and
greases.
NOTE! 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.

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 tempera- Operation in low temperatures
tures
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 DIN 51 519 150 220 100
(104°F) in mm2/s (cSt)
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)
EP additives Sulphur/Phosphorus Sulphur/Phosphorus Sulphur/Phosphorus
(Continued)

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 Molub-Alloy Tribol 1100/150
ESSO Spartan EP 150 Shell Omala 150
Klüber Klüberoil GEM 1-150 Statoil LoadWay EP 150
Mobil Mobilgear 629 Texaco Meropa 150
For operation at elevated temperatures:
For operation in low temperatures:
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)

7. Lubrication
Oil quantity
Capacity
Lubrication oil tank 150 litres / (40 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 test-
running. 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 al-
ways 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

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.
(Continued)

7. Lubrication
Requirements for the Hydroset oil

Properties Requirement Test method
Base oil viscosity at 40°C 68 DIN 51 519
(104°F) in mm²/s (cSt)
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
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
NOTE! 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)

7. Lubrication
Oil quantity
Capacity
Hydroset oil tank 40 litres / (10.7 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

Close to the pinionshaft there is a decal which shows the type of oil in the
pinionshaft housing when the crusher is delivered from the factory. Do not
mix different types of oil.
The oil used for pinionshaft lubrication must be the same as the oil in the
main circulatory lubrication system. See section 7.2 Oil for lubrication
system.
Oil quantity
Oil quantity
Pinionshaft housing 0.8 litre (0.21 US gal.)
There is a drain plug (4) and an oil level tube (3) mounted in the bottom of
the pinionshaft housing. When oil is added, the drain plug must be in place.
Slightly more than the required quantity should be added. When the oil level
has stabilized in the pinionshaft housing, drain out the excess oil through the
level tube by taking out the drain plug.
NOTE! Top up and drain off excess oil every time the oil level is to be checked since
there is otherwise a risk that a small amount of oil in the level tube will run
out and give the impression that the oil level is high, even though it is in fact
low.
1 Filler plug
2 Oil level
1
3 Level tube 2
4 Drain plug 3
4
(Continued)

7. Lubrication
Oil changes
Check the oil level regularly and change the oil after approximately 2000
operating hours or about once a year. Drain out the oil by unscrewing the
level tube and drain plug.
The filler plug on the top of the pinionshaft housing is fitted with an air vent
nipple. This nipple should be cleaned at intervals of about two months as
there is otherwise a risk of damage to the seals and leakage could then occur.
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.
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
Consistency 0 or 00 NLGI
Base oil viscosity at 40°C ≥ 400
(104°F) in mm2/s (cSt)
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.
(Continued)

7. Lubrication
Examples of greases
The examples listed below are greases which – according to the respective
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) Statoil GreaseWay LiCaX90
Molub-Alloy Tribol 3020/1000-00 Texaco Marfak 00 (01907)
Grease quantity
Grease quantity
Spider bearing 3–4 kg / (6.6–8.8 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 Grease pipe
2 Grease level
3 Observation hole
4 Spider bearing seal 1 5
5 Air vent line
2 4
3

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.

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

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 Hydroset tank cover
2 Lubrication tank cover 2
3 Identification plate
4 Cabinet
3
8.1.2 Cabinet
The cabinet contains components of the main lubrication system and
Hydroset system.

In subsequent figures, the interior of the cabinet is divided into different

views:
Main lubrication system Hydroset system
Thermostats and heaters

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
1 Pressure drop lamp 2
2 Temperature gauge 3
3 Pressure gauge 4
4 Lubrication oil pump unit 11
5
5 Pressure gauge connection 10
6
6 Pressure drop sensor 9
7 Oil filter 7
8
8 Dirt trap
9 Shut-off valve
10 Pressure relief valve
11 Shut-off valve
12 Lubrication inlet (from crusher)
13 Lubrication outlet (to crusher) 12
13

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 Dehydration plug, lubrication oil tank

15 Drain plug, lubrication oil tank
16 Drain plug, Hydroset oil tank
17 Dehydration plug, Hydroset oil tank
14 15 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 dam-
age. 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.
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.
18 Gauze element
19 Plug
18
19

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 element is of throw-away type. See section
8.3.3 Changing filter elements.
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.
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 l/min US gal./min
Supply frequency 50 Hz Normal capacity 33 8.7
Min. capacity 27 7.1
Supply frequency 60 Hz Normal capacity 40 10.6
Min. capacity 27 7.1
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.

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 element should be
changed. An abnormally low pressure can mean that the pump is worn, or
that the dirt trap is choked.
1 Pressure drop lamp
3 Pressure gauge 2
5
7 Oil filter 10
8 Dirt trap 6
9
9 Shut-off valve 7
8
11 Shut-off valve
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 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.

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

3 Pressure gauge 2
5
7 Oil filter 10
8 Dirt trap 6
9
9 Shut-off valve 7
8
11 Shut-off valve
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.
(Continued)

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
20 Float
21 Weir
21
22 Adjustable lower outlet 22
23 Oil strainer 23
24 Return oil chamber
24

8.2.10 Oil strainer

The oil strainer (23) separates coarser contaminants from the oil and
deaerates the oil.
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
20 Float
21 Weir
21
23 Oil strainer 23
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 Protective thermostat TG 1 26
27 Thermostat for heat exchanger TG 2
28 Oil heating thermostat TG 3
29 Level indicator, lubrication oil tank 27
30 Heating elements
28
29
30
(Continued)

CAUTION! It is important that the correct temperature settings are used. Set the
thermostats according to the tables below for different operating condi-
tions.
TG 1 Crusher drive motor shut-down function

Operating Normal operating Operating at elevated Operating at low
conditions conditions temperature temperatures
Ambient air tempera- Max. 32°C (90°F) Max. 40°C (104°F) Below 0°C (32°F)
ture
Protective thermostat TG 1
Basic setting 60°C (140°F) 65°C (149°F) 52°C (126°F)
Closes at 60°C (140°F) 65°C (149°F) 52°C (126°F)
Opens at 63°C (145°F) 68°C (154°F) 55°C (131°F)
Differential setting 1 1 1
CAUTION! 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 re-
started.
TG 2 Oil cooling control

Operating Normal operating Operating at elevated Operating at low
conditions conditions temperature temperatures
Ambient air tempera- Max. 32°C (90°F) Max. 40°C (104°F) Below 0°C (32°F)
ture
Thermostat for heat exchanger TG 2
Closes at 45°C (113°F) 51°C (124°F) 37°C (99°F)
Opens at 40°C (104°F) 47°C (117°F) 33°C (91°F)
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.

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 Protective thermostat TG 1 26
27 Thermostat for heat exchanger TG 2
28 Oil heating thermostat TG 3
29 Level indicator, lubrication oil tank 27
30 Heating elements
28
29
30
TG 3 Oil temperature
Operating Normal operating Operating at ele- Operating at low
conditions conditions vated temperature temperatures
Ambient air temperature Max. 32°C (90°F) Max. 40°C (104°F) Below 0°C (32°F)
Suitable temperature before 30°C (86°F) 37°C (99°F) 25°C (77°F)
crusher is started
Oil heating thermostat TG 3
Closes at 30°C (86°F) 37°C (99°F) 20°C (68°F)
Opens at 35°C (95°F) 42°C (108°F) 25°C (77°F)
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.

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 Lubrication inlet
(from crusher)
13 Lubrication outlet 12
(to crusher)
31 L1 push button box
31
13
(Continued)

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
8.3.2 Cleaning the dirt trap

a) Close the shut-off valve ahead of the dirt trap.
b) Have a bucket ready to catch the oil which runs out.
c) Unscrew the plug (19).
d) Take out and clean the gauze element (18).
e) Install the gauze element and the plug.
f) Open the shut-off valve.
18 Gauze element
19 Plug
18
19
NOTE! During the running-in period, and when the tank has been cleaned, check the
dirt trap daily.

8.3.3 Changing filter elements

a) Close the shut-off valve (11) between the filter (7) and the heat
exchanger.
b) Close the shut-off valve (9) between the tank and the dirt trap (8).
c) Change the filter element.
d) Inspect the old filter element 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! 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.

2 Temperature gauge
1
3 Pressure gauge 2
4 Lubrication oil pump 3
5
7 Oil filter 10
6
8 Dirt trap 9
9 Shut-off valve 7
8
11 Shut-off valve

8.3.4 Cleaning the return oil strainer and tank

a) Take off the cover over the lubrication oil tank.
b) Lift out the oil strainer (23).
c) Rinse contamination from the oil strainer with diesel oil or white spirit.
d) Blow the oil strainer clean with compressed air.
NOTE! 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
20 Float
21 Weir
21
23 Oil strainer 23
24

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) Refit the screw in the drain plug (15) beneath the lubrication oil tank.
b) Take off the cover over the lubrication oil tank.
c) Connect a hose to an oil drum.
d) Fill the tank with new oil (150 litres) through the oil strainer (23).
e) Check for possible leaks in connectors and valves.
f) Remove the hose from the lubrication tank.
g) Refit the cover over the lubrication oil tank and tighten the wing nuts.

14 15 16 17

8.4 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 Oil in
2 Water out 1
3 Water in
2
4 Oil out (to crusher)
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! Drain all water out of the heat exchanger if the crusher is shut down during
the winter (below 5°C/41°F).

8.5 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.
To provide the maximum cooling effect, the air must be sucked through the
heat exchanger core.
Air
Since there is a large oil flow through the heat exchanger, the oil inlet to the
1 radiator coil can be either at the top or the bottom. It is normally unnecessary
to bleed air from the heat exchanger.
1 Air/oil heat exchanger
The fan motor is controlled by the thermostat for heat exchanger TG 2. See
section 8.2.11 Thermostats.
8.6 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.
1
2
3
4
5
6
7
1 Pressure gauge
2 Oil filter
3 Hydroset pump unit
4 Damping valve
5 Control valve
6 Dirt trap (magnetic plug)
7 Hydroset connection

8.6.1 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.
8.6.2 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.
Exchanging the filter element
Change the filter element each time the Hydroset oil is changed or every six
months.
8
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.
8.6.3 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.

8.6.4 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 Pressure limiting valve 10

10 Pin 11
11 Cap

8.6.5 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.
1
1 Pressure gauge
2 Oil filter
2
3 Hydroset pump unit 3
4 Damping valve 4
5 Control valve 5
6 Dirt trap (magnetic plug)
6
7 Hydroset connection

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

9. Accumulator
9.1 General
Risk of explosion
A damaged accumulator entails a risk of explosion. Protect the
accumulator from mechanical or thermal damage (impact, welding,
WARNING! 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 Accumulator
2 Anti-extrusion valve
3 Air bleed screw
4 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.
(Continued)

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)

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.
WARNING!
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.

9. Accumulator
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
1
2 10 11
8 7
3 6 12
4
5
1 Protective cap 7 Screw connector
2 Protective cap 8 Bleed valve
3 Nipple 9 Spindle
4 O-ring 10 Connector
5 Adaptor 11 Charging hose
6 Hexagon screw 12 Connector

9. Accumulator
9.3.2 Charging with nitrogen

Accumulator charging pressure Tolerance
Without ASR / With ASR Plus 4.2 MPa (610 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! Recheck the charging pressure after 1, 2 and 3 weeks and thereafter at 6-
month intervals.

9. Accumulator

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

10.1 Exchanging the spider cap

Replaceable parts:
Description Cat. no. Qty. Remarks
Spider cap 5650-0 1 weight 80 kg
O-ring 5651-0 1
Screw M6S 16×45 5655-0 4
Washer TBRB 17x30 5655-2 4
NOTE! 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 a) Clean off processing material from the spider cap (5650-0).
Lifting tackle and chain b) Remove the four screws (5655-0) and washers (5655-2) that hold the
Lifting sling spider cap to the topshell (5005-0).
Mobile crane
c) Position the hook of a crane vertically above the spider cap (5650-0).
Feeler gauge
Rags d) Attach the lifting hook to the lifting eye (3) on the spider cap (5650-0).
24 mm Open end wrench 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
DANGER! spider cap. Keep clear of hanging loads, see section 2. Safety
precautions.
f) Carefully lift the spider cap from the topshell.

g) Remove the O-ring (5651-0) from the spider cap (5650-0).
h) Place the spider cap (5650-0) on the ground.
i) Clean out all grease from the spider bearing.
3
3 Lifting eye 5651-0
5651-0 O-ring 5655-0,
5655-0 Screw 5655-2
5655-2 Washer
5650-0 Spider cap
5650-0

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
– 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.
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
DANGER! 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.

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-dimension A
B Groove
C Groove
B

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! 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.
NOTE! 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 6–16 mm (0.24–0.63").
If the crusher runs with 6 mm (0.24") setting, the smallest A-dimension
15 mm (0.6") will be reached faster than if the crusher runs with 16 mm
(0.63") 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.

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.
10.3.1 Inspecting the spider bearing

Max. permissible play and distance above pivot point
S mm/(inches) L mm/(inches)
1.6/(0.063) 75/(3.0)
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)

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.


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

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 bear-
ing 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.

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.

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 No “Ready for start” signal and oil Check electrical circuits and starter of pump motor.
will not start pump not running Start the pump.
No “Ready for start” signal and If the return oil flow is low, wait a few minutes to see
lubrication oil flow low 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 Check operation of return oil flow switch, see 8.2.9.
“Ready for start” signal. If protective thermostat TG 1 shuts down crusher,
check operation of thermostat, see 8.2.11.
Oil pump running and “Ready for Check starter of crusher’s drive motor and other
start” signal obtained electrical circuits. See Installation manual.
Oil does not return to tank (in low Start oil pump. Let it run approx. 30 s. Bridge over
temperature) 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.
2 Crusher stops Oil pump not running Check electrical circuits and starter of pump motor.
when idling or Start pump.
with material Low lubrication oil flow Check that oil does not overflow over dust collar.
in the cham- Check oil lines and remove obstacles if return line is
ber blocked.
element, see 8.3.3.
Normal lubrication oil flow Check operation of return oil flow switch, see 8.2.9.

12. Troubleshooting

2 Crusher stops Oil too hot See No. 3. Lubrication oil temperature too high.
when idling or V-belts slipping Adjust V-belt tension. Change V-belts if necessary.
with material
in crushing Reduce load on crusher. See “Crusher’s drive motor
chamber 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 crush- Lower the mainshaft to remove the obstruction.
ing chamber. 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 neces-
sary to loosen topshell bolts. See Maintenance man-
ual.
3 Lubrication oil Protective thermostat TG 1 shuts Check operation of oil cooling system and thermostat
temperature down crusher for heat exchanger TG 2, see 8.2.11.
too high For a water/oil heat exchanger, check that water
channels are not blocked, see 8.4.
For an air/oil heat exchanger, check fan motor and
starter. Clean radiator core. Check that there is suffi-
cient cooling air. See 8.5.
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 continu- See “Protective thermostat TG 1 shuts down the
ously. 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.
element, see 8.3.3.

12. Troubleshooting

4 Crusher will Low Hydroset pressure Check capacity of Hydroset pump. If necessary,
not hold a change pump.
constant Leakage in Hydroset system Check Hydroset oil lines. If possible – without going
CSS, or prod- below the smallest A-dimension (see 10.2) – raise
uct is over- mainshaft until liners have metal-to-metal contact.
sized Don’t exceed maximum Hydroset pressure (see
4.2.4). Check Hydroset pressure gauge to see if
pressure is falling. Seal or replace relevant compo-
nents.
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, Clean or replace Hydroset control valve.
see 8.6.4 Setting increase has
caused oil level to rise in Hydro-
set tank.
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 accu- Bleed air from Hydroset system, see 4.2.3.
mulator gas pressure too low. Charge accumulator to correct pressure, see 9.3.
CSS increases during crushing Replace accumulator bladder or complete accumula-
but returns to pre-set value dur- tor if necessary.
ing idling.
Accumulator bladder damaged. Replace accumulator bladder or complete accumula-
Mainshaft “climbs” to metal-to- tor. Bleed air from Hydroset system, see 4.2.3.
metal position when crusher is
idling, or nitrogen leaking from
accumulator bladder gives milky
white colour in Hydroset oil.
Crusher’s feed not evenly distrib- Change feed arrangement. Crusher should be choke
uted. Hydroset pump cannot fed without segregation. See Installation manual.
reduce CSS because of pressure
peaks.
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 differ-
ence 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.

12. Troubleshooting

5 Points to High temperature inside and out- Check that level tube and drain plug do not leak, see
watch regard- side pinionshaft housing. 7.4. Check that there are no other leaks.
ing pinion- If oil level is too low in the pinionshaft housing, fill to
shaft correct level. If oil level keeps dropping, this can indi-
assembly cate a damaged inner seal. Recheck oil level. See
7.4.
Remove pinionshaft assembly for inspection. If nec-
essary, replace worn bearing and seal components.
See Maintenance manual.
Oil leakage through outer bearing Check if outer seal ring, spacer ring or O-ring is worn
cover. or damaged. Remove pinionshaft assembly for
inspection. If necessary, replace worn bearing and
seal components. See Maintenance manual.
Abnormal noise in pinionshaft Remove pinionshaft assembly for inspection. If nec-
assembly. Incipient bearing fail- essary, replace worn bearing and seal components.
ure. See Maintenance manual.
Vibration in crusher or pinionshaft Check V-belt pulleys. Clean off any collected dust.
housing. Check V-belt tension. Check if they are flapping.
Remove pinionshaft assembly for inspection. If nec-
essary, replace worn bearing and seal components.
See Maintenance manual.
Excessive axial play in bearings Check frequently for increasing noise or rising tem-
because of heavy wear on rollers perature in pinionshaft assembly. Schedule removal
and races and bearing replacement for a convenient time.
Change oil in pinionshaft housing, see 7.4.
6 Abnormal Incorrectly fitted bevel gears or Remove pinionshaft assembly. Measure correct gas-
noise in incorrect gear meshing causing ket thickness. Adjust backlash. See Maintenance
crusher noise from gears. Insufficient manual.
backlash emitting a high-fre-
quency rattle.
Heavy wear on eccentric wearing Strip down crusher and replace eccentric wearing
plate leading to reduced back- plate. Readjust backlash. See Maintenance manual.
lash. Insufficient backlash emit- If eccentric wearing plate wear accelerates, see no.
ting a high-frequency rattle. 8. Increasing bearing component wear.
Crushing liner loose Check and tighten concave ring bolts. Check if there
is play between headcentre and mantle. See Installa-
tion manual.

12. Troubleshooting

6 Abnormal Unusual noise from spider bear- Check grease level and add more frequently if nec-
noise in ing when material is fed essary, see 7.5 and 10.3.
crusher 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 compo- Reduce crusher’s operating load. Extend running-in
nents 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 Check operating conditions and CSS. Increase set-
liners “metal to metal” ting.
Check for liner ovality.
Movement between flanges of Check with a feeler gauge if there is play between
topshell and bottomshell 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 “ski-
slopes” on the mantle and concave. Change liners.
7 Crusher’s “Ski-slope” formed on liners. Check feed arrangement. Make sure crusher is
capacity choke fed. Check top size and bottom size of
drops crusher’s feed. There must not be a large proportion
of material smaller than CSS. See 10.2 and Installa-
tion manual.
Extremely large play in spider Check spider bearing play, see 10.1 and 10.3. If
bearing. 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 Altered fraction length and material hardness can
been changed. lead to changes in capacity. See Installation manual.
Bridging or blocking in crushing Check material level in feed hopper. If possible, limit
chamber. top size of feed. See Installation manual.

12. Troubleshooting

8 Increasing Contaminated oil leading to Check oil condition regularly. Clean tank. Change oil
bearing com- increased wear on eccentric at regular intervals. See 8.3.
ponent wear wearing
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 sys- Inspect entire over-pressure system and check oper-
tem not working ation. See Maintenance manual.
9 Bearing fail- Mainshaft assembly rotates very Strip down crusher to inspect bearing components.
ure inside fast or at same speed as eccen- See Maintenance manual.
crusher tric. Seizure or incipient seizure
between mainshaft and eccentric
bushing.
Pinionshaft cannot be turned. If possible, take out bolts holding dust collar.
Seizure between eccentric and Remove mainshaft assembly and complete eccentric
bottomshell bushing. assembly. See Maintenance manual.
Pinionshaft cannot be turned. See Maintenance manual.
Bearing failure in pinionshaft
assembly.
Increased amount of swarf in Remove step bearing components. De-burr edges of
return oil strainer. Seizure in step oil grooves. Polish bearing surfaces of bushings and
bearing or bronze bushings. step bearing components. If necessary, replace step
bearing components. Inspect bearing surfaces of
bushings. See Maintenance manual.
Needle-like particles on the See Maintenance manual.
return oil strainer. Seizure or
wear in bevel gears.
Tin or lead flakes in return oil See no. 3. Lubrication oil temperature too high.
strainer. High temperature or
localized overheating and partial
seizure in bushings or step bear-
ing components.
10 Oil contami- Bronze particles on return oil Investigate possible incipient bearing failure. See
nated strainer 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 set-
ting or oversized product.
Dirt Check dust seal. A worn dust seal will allow dust into
the system.

12. Troubleshooting

11 Broken Incorrect torque Replace all bolts if any is defect. Use only bolts
Hydroset intended as Hydroset bolts. Tighten to recommended
bolts 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.
12 Broken con- Worn top shell Inspect seating area for concave during a concave
cave bolts change. Remove any upset metal that may stop the
concave from seating correctly in topshell.
Incorrectly tightened bolts Tighten bolts correctly. See Maintenance manual.
13 Low or no oil Pump sucks air through a leak Replace suction lines, if leaking.
capacity Replace shaft seal, if leaking.
Pump rotates in wrong direction Change direction of rotation. See Maintenance man-
ual.
High pressure but still low capac- Exchange oil, see 8.3.
ity because of wrong type of oil
Pump is dry Fill with oil.
Suction line blocked Remove obstruction.
Broken pump, e.g. cavitation in Replace pump.
pump or broken gear teeth.

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.
CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 A-1

A-2 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

Symbols to be marked in the squares: Week no: Week no: Week no: Week no:
X = No remarks
No. = See corresponding number in “Inspection notes” Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa
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.
SANDVIK CH420:01
Check that lubricating oil returns to tank and that oil is clean.
Inspection checklist
Check that oil lines do not leak.

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 at normal operating temperature.
Machine no:
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).
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 oil level in pinionshaft housing.
Check coil of air/oil heat exchanger (option).
Clean damping valve for Hydroset pressure gauge.
© Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1

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 air vent nipple on pinionshaft housing.
Serial No._________________ Y: _____ M: _____ D: _____
Check dust seal ring for wear.

Date (first day on this sheet):
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.
_________________h
Previous operating hours:
No. Remarks Sign.
1
10
11
12
13
14
15
16
17
18
19
© Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1

Operators Manual CH420-01 - OM - S223.498.en-01

Uploaded by

Copyright:

Available Formats

Operators Manual CH420-01 - OM - S223.498.en-01

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operators Manual CH420-01 - OM - S223.498.en-01

Uploaded by

Copyright:

Available Formats

operator’s manual Doc. no. S 223.

Serial no. / Machine no. Sign.

Document number: S 223.498 en

4. Starting up the cone crusher

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 1

4.2.5 Starting a crusher in extremely low temperatures .. 32

5. Using the cone crusher

6. Inspection and care

2 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

8. Hydroset and lubrication system

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 3

8.6.3 Dirt trap (magnetic plug)......................................... 82

10. Topshell assembly

11. Setting measurement

4 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 5

1.1 Equipment information

6 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 7

Tank unit identification

8 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

1.1.1 Document information

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 9

1.2 Operating principles of a cone crusher

10 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

Auxiliary lubrication systems

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 11

12 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

Cone crusher – side view

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 13

Tank unit and auxiliary equipment

14 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 15

2.1 Hazard information

General danger Dangerous voltage Risk of crushing

Hanging load Risk of crushing Flying fragments

2.1.2 Risk levels

Failure to observe information marked “DANGER!” can result in life-

2.1.3 Prohibition signs

2.1.4 Mandatory signs

Disconnect current Read the manual

16 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 17

2.2.1 Personal protection

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or breathing

2.3 General safety precautions

18 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

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

2.3.1 Machine safety guards

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 19

2.3.2 Electrical safety

CAUTION! Only welders qualified according to European Standard EN 287 or sim-

20 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 CH420:01

2.3.4 Hydraulic system

2.3.5 Lifting and moving loads

CH420:01 © Sandvik SRP AB – Doc. no. S 223.498 en Ver. 1 21

2.3.6 Feed and jams

CAUTION! Never feed combustible process material into the crusher.