SANDVIK CH440:01
Serial no. / Machine no. Sign.
SANDVIK CH440:01
© Copyright 2006–2007 Sandvik SRP AB.
All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints.
Document number: S 223.543 en
Issue: yyyymmdd Version: 2
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 ... 182.3 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 ... 264.2.5 Starting a crusher in extremely low temperatures .. 32
5. Using the cone crusher
5.1 Starting and stopping ... 345.1.1 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 ... 406.1.1 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
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 ... 557.2 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... 648.1.1 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
8.5 Water/oil heat exchanger (option) ... 82
8.6 Air/oil heat exchanger (option) ... 83
8.7 Hydroset system ... 83
8.7.1 Hydroset pump... 84
8.7.2 Oil filter ... 84
8.7.3 Dirt trap (magnetic plug)... 84
8.7.4 Control valve ... 85
8.7.5 Pressure gauge... 86
9. Accumulator
9.1 General ... 889.2 Flow regulator ... 89
9.3 Charging kit (option)... 89
9.3.1 Checking the gas pressure ... 90
9.3.2 Charging with nitrogen ... 91
10. Topshell assembly
10.1 Exchanging the spider cap... 9410.1.1 Removing the spider cap ... 94
10.1.2 Spider cap removal checks ... 95
10.1.3 Installing the spider cap ... 95
10.2 Inspection of crushing chamber ... 96
10.3 Spider bearing... 98
10.3.1 Inspecting the spider bearing ... 98
11. Setting measurement
11.1 General ... 10211.1.1 Checking the setting with lead ... 102
1. Introduction
To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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 7 Year of manufacture 8 CE mark Type:
9 Type and size of crusher
10 Crushing chamber (concave ring) 11 Mantle 12 Filler ring 13 Eccentric throw (mm) 14 Mark number
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9 10 12 13 14
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CH440-M/B/M-36/40/44/32:1
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.
CE marking
This equipment complies with the basic health, environment and safety regulations of the European Union and European Economic Area. Sandvik SRP AB will not take responsibility for this compliance when customers modify any configuration of the cone crusher.
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15 Type 16 Part number 17 Serial number 18 Mass (kg) 19 Order number 20 Manufacturer 21 Year of manufacture 22 CE mark1. Introduction
1.1.1 Document information
Purpose of this Operator’s manual
The purpose of this Operator’s manual is to provide the operator with information on how to handle and operate this Sandvik equipment. It is important to:
• keep the manual for the lifetime of the equipment
• pass the manual on to any subsequent holder or user of the equipment
Figures in this manual
Some figures in this manual are based on the CH430 cone crusher, which is similar to the CH440. Details of less or no importance for instructions given can therefore differ from the CH440 design.
Document compliance
The instructions in this document are in accordance with the design and construction of the equipment at the time it was delivered from the Sandvik SRP manufacturing plant.
Technical publications
Technical publications related to installation and operation of this equipment are:
• Installation manual (IM) • Wear parts catalog (WPC) • Operator’s manual (OM)
When ordering technical publications, always specify the language and quote the machine identity number.
Technical publications related to maintenance of this equipment are: • Maintenance manual (MM)
• Spare parts catalog (SPC)
These publications are only available to trained maintenance personnel. Sandvik SRP AB can provide adequate training and authorize personnel. Read more about the document structure and accompanying work roles in section 2.2 Personnel.
Number of pages
This document contains a total of 112 pages.
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 Spider bearing 2 Topshell 3 Concave ring 4 Mantle 5 Eccentric assembly 6 Mainshaft
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6
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.
Auxiliary lubrication systems
There are two separate circulatory lubrication systems – the main lubrication system and the pinionshaft lubrication system. The main lubrication system is described in section 8.2 Main lubrication system. The pinionshaft
lubrication system is described in section 8.4 Pinionshaft lubrication system.
setting decrease = finer product setting increase = coarser product
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 Spider cap 2 Spider bushing 3 Head nut 4 Mantle 5 Concave ring
6 Mainshaft with headcentre 7 Eccentric wearing plate 8 Bottomshell bushing 9 Eccentric 10 Eccentric bushing 11 Step bearing 12 Hydroset piston 13 Pinionshaft housing 14 Pinionshaft 15 Dust collar 16 Locating bar 17 Dust seal ring 18 Bottomshell 19 Topshell 20 Filler ring
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1. Introduction
Cone crusher – side view
21 Hole for level indicator 22 Inspection door 23 Feed hopper 24 Inspection hatch
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Tank unit and auxiliary equipment
25 Over-pressure blower 26 Over-pressure air regulator 27 Tank unit
28 Water/oil heat exchanger 29 Air/oil heat exchanger 30 Charging kit for accumulator
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2. Safety precautions
To ensure maximum safety, always read this section carefully before doing any work on the equipment or making any adjustments.
2.1 Hazard information
2.1.1 Warning signs
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).
CAUTION! Failure to observe information marked “Caution!” can result in damage to equipment!
2.1.3 Prohibition signs
2.1.4 Mandatory signs
General danger Dangerous voltage Risk of crushing
Hanging load Risk of crushing Flying fragments
DANGER!
Failure to observe information marked “DANGER!” can result in life-threatening injuries!
WARNING!
Failure to observe information marked “WARNING!” can result in personal injury and/or serious damage to, or destruction of, equipment!
Do not remove guards
2. Safety precautions
2.2 Personnel
All work on the equipment is to be carried out only by trained or authorized personnel.
– “Trained” means that the person in question has been given practical instruction by an authorized person on how the various tasks are to be carried out.
– “Authorized” means that a person has undergone a theoretical and practical test of knowledge, organized by Sandvik SRP AB. He/she is therefore judged to have the knowledge and competence to carry out the tasks assigned to the appropriate role.
All expected work tasks on this production equipment have been defined by Sandvik SRP AB as belonging to one of three categories – work roles – based on different competence profiles. These three work roles are: • Installation
• Operation • Maintenance
Sandvik SRP AB provides technical documentation appropriate to all three work roles:
• Installation manual
• Operator’s manual and Wear parts catalog • Maintenance manual and Spare parts catalog
Sandvik SRP AB can provide adequate training for all three work roles and can carry out authorization of trained personnel.
The technical documentation from Sandvik SRP AB covers only work on the production equipment itself – it does not cover work tasks associated with other equipment or routines at the site.
It is the responsibility of the plant management to assign responsibility for: • The production equipment and the work area around the equipment • All personnel in the vicinity of the equipment
• Compliance with national and local safety regulations • Checking that all safety devices are fully operational
Sandvik SRP AB declines all responsibility for injury or damage resulting from non-compliance with the instructions in this manual.
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:
2.3 General safety precautions
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)
Ear protection Safety helmet Eye protection
Protective gloves Safety boots Mask or breathing
apparatus
WARNING!
Falling stones
Clear the feed arrangement from process material before any maintenance work is carried out inside or below the crusher, to prevent stones from falling down.
2. Safety precautions
Avoid remaining on the crusher, unless necessary for maintenance work.
2.3.1 Machine safety guards
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,
DANGER!
Risk of crushing
Never remain on the crusher while crushing. Moving parts constitute a risk of crushing. Falling into the crusher implies danger of being crushed.
WARNING!
Risk of crushing
If the crusher is mounted on rubber dampers, there is a risk of crushing between the oscillating parts of the crusher and the stationary frame.
WARNING!
Ejection
Never look into the crusher while crushing. Fragments and possibly harmful substances fed to the crusher may be ejected.
PROHIBITION!
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 equipment unles guards are mounted.
WARNING!
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 places around the danger zone.
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.
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.
DANGER!
Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven dead by proper testing procedures.
WARNING!
Toxic gases
Inhalation of welding fumes can be dangerous to health. Always follow instructions provided by the welding equipment supplier.
Some parts of the crusher are made of manganese steel. Long-term exposure to manganese oxide can affect the nervous system.
2. Safety precautions
2.3.4 Hydraulic system
CAUTION! Only personnel certified in hydraulics are permitted to perform opera-tions on the hydraulic system.
CAUTION! Never adjust pressure relief valves beyond the recommended values.
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.
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.
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
WARNING!
Oil pressure
Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system.
WARNING!
Oil temperature
Hydraulic oil can get very hot in operation. Allow the oil to cool before working on the hydraulic system.
DANGER!
Hanging load
Never work or stand underneath a crane that is lifting material. Keep a safe distance from a hanging load.
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.
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
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.
WARNING!
Flying fragments
Never use wedges etc. to clear jams in the feed opening. Stones and fragments can be thrown out at high speed from the crushing
chamber.
WARNING!
Explosives
Never remove blocking boulders from the crusher by blasting.
Blasting may cause personal injury and seriously damage bearings or other parts. Sandvik SRP AB takes no responsibility for injury to personnel or damage to the equipment when blasting is used.
DANGER!
Risk of crushing
Never stand inside the crusher when a blockage is removed. You might be pulled forcefully and suddenly downwards together with the
material in the crushing chamber and be crushed.
DANGER!
Health hazard
Crushing and processing material will create dust. Such dust can be more or less dangerous to the health. Use a breathing mask.
2. Safety precautions
2.4.2 Noise
2.4.3 Radioactivity
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.
WARNING!
Health hazards
Crushing and processing material will create noise. Such noise can be more or less dangerous to the hearing. Use ear protection.
DANGER!
Health hazards
Radon is a radioactive gas that occurs naturally in bedrock. Radon may cause lung cancer. Mineral type, ventilation and water are all factors that influence the contents of radon gases.
3. Technical data
To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
3.1 General data
The data presented below are typical values. Specific data may vary depending on installation and machine configuration.
3.2 Processing data
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.
Characteristics Data
Model CH440 Type Cone crusher Application Mineral processing Total weight 14 300 kg Length 2.35 m (3.59a m) a. With subframe Width 2.10 m (2.19b m) Height 2.96 m Eccentric speed 320 rpm Pinionshaft speed 1475 rpm Max. motor power 250 kW / 335 hp Drive V-belts
Characteristics (depending on crushing chamber) Data
Max. feed size 35 to 230 mm CSS min–max 6 to 44 mm Nominal capacity 80 to 455 tonnes/h
4. Starting up the cone
crusher
This section describes how to start up the cone crusher.
To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
4.1 General
Each cone crusher delivered by Sandvik Rock Processing has been
assembled, test run and checked in our factory before shipping. The test run is carried out without load to discover any mechanical faults.
4.2 Running-in
The appropriate parts of this section apply also after repair work and the fitting of new parts.
a) Start the main lubrication oil pump and pinionshaft oil pump.
b) When the “Ready for start” signal is obtained, start the crusher’s drive motor.
c) Check and adjust the setting. See section 4.2.1 Checking the setting with lead.
d) Start the feed to the crusher. Feed the crusher carefully and gradually increase the load rate until it reaches 75 % of the maximum level for power draw or Hydroset pressure. See section 4.2.4 Maximum load. The load is altered by changing the setting.
CAUTION! If possible the crushing chamber should be full. The crusher will not be run-in by idling. The crusher is normally run-in after approximately 16 hours operating at 75 % load. Thereafter increase the load gradually up to full load. Depending on the availability of material, and for other process engineering reasons, running-in can take longer. It is important that items e–g are followed carefully during the entire running-in 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.
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)
NOTE! If operating conditions differ from normal (Oil = ISO VG 150 viscosity), set the thermostats according to section 8.2.11 Thermostats and section
4. Starting up the cone crusher
h) Bleed the Hydroset system. See section 4.2.3 Bleeding air from the Hydroset system.
i) Check that there is no movement between the topshell and bottomshell. Put a finger between the topshell and bottomshell to feel possible vibrations.
j) Check that there are no oil leaks from the lubrication and Hydroset lines. k) Check that the indicating pointer of the Hydroset pressure gauge moves
steadily. See section 8.7.5 Pressure gauge.
l) Check the temperature outside the pinionshaft housing with a suitable thermometer, e.g. infrared camera. The normal temperature is 50–60°C (122–140°F).
m) Check that the feed is correctly distributed around the crushing chamber. See the Installation manual.
n) Check the power consumption and Hydroset pressure. See section 4.2.4 Maximum load and section 8.7.5 Pressure gauge.
o) Check and record the main lubrication oil pressure, see section 8.2 Main lubrication system. Also check and record the pinionshaft oil pressure, see section 8.7 Hydroset system.
p) Check for a ringing sound during crushing, it can indicate a loose mantle or concave ring.
q) Check that there are no grease leaks from the spider bearing.
r) After running-in is completed, check the tightness of all bolts and 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
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.
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.
1 Measuring nipple 2 Air bleed hose 3 L1 push button box
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1 2
4. Starting up the cone crusher
4.2.4 Maximum load
The power drawn by the crusher and the Hydroset pressure during operation are dependent on the crushing chamber, the eccentric throw, the crusher’s setting and the feed material’s crushability, size analysis, moisture content, etc.
• The maximum average power drawn by the crusher must not exceed 250 kW.
• The maximum average Hydroset pressure must not exceed following values.
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.
Crushing chamber Pressure
EF 4.2 MPa (609 p.s.i.) F 4.2 MPa (609 p.s.i.) MF 4.0 MPa (580 p.s.i.) M 4.0 MPa (580 p.s.i.) MC 3.8 MPa (551 p.s.i.) C 3.6 MPa (522 p.s.i.) EC 3.4 MPa (493 p.s.i.)
Power (kW) Crushing chamber
Throw EF F MF M MC C EC 16 mm 96 99 104 20 mm 109 115 119 125 24 mm 114 119 127 133 139 145 28 mm 129 136 145 152 159 166 32 mm 145 145 152 163 171 179 187 36 mm 161 161 169 180 190 198 208 40 mm 176 176 185 198 209 218 44 mm 192 192 202 216
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
5. Using the cone crusher
This section describes basic procedures when using the cone crusher.
To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
5.1 Starting and stopping
5.1.1 Starting the crusher
b) Start the main lubrication oil pump and pinionshaft oil pump. c) When the “Ready for start” lamp lights up, start the crusher’s drive
motor.
d) Check and adjust the setting. See section 4.2.1 Checking the setting with lead.
e) Start the feeder. The crusher should be choke fed without segregation.
CAUTION! The setting must never be so small that the power drawn by the crusher or the Hydroset pressure exceed limits given in section 4.2.4 Maximum
load.
5.1.2 Stopping the crusher
a) Stop the feeder, but let the crusher run until the crushing chamber is free of processing material.
b) Stop the crusher’s drive motor.
c) Stop the main lubrication oil pump and pinionshaft oil pump.
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.
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.
NOTE! The oil heating should run for 24 hours a day. The heating elements are automatically controlled by the oil heating thermostat.
5. Using the cone crusher
5.2 Checking the setting
The procedure for checking the CSS setting is described in section 4.2.1 Checking the setting with lead. See also section 11. Setting measurement.
5.3 Changing oil
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
a) Choose a main lubrication oil for normal operating conditions according to section 7.2 Oil for lubrication system.
b) Exchange the main lubrication oil according to section 8.3 Exchanging main lubrication oil. Also change the filter element and clean the dirt trap, return oil strainer, tank and air/oil heat exchanger.
c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system and exchange oil in the Hydroset system. Also change the filter element and clean the dirt trap, see section 8.7.2 Oil filter and section 8.7.3 Dirt trap (magnetic plug).
d) If thermostats TG 1, TG 2 and TG 3 are not already set for normal operating conditions, reset them according to section 8.2.11 Thermostats and section 8.2.12 Oil heating.
WARNING!
Risk of fire and toxic gases
Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier’s instructions and safety directions when handling oils and greases.
NOTE! Never mix different brands or types of lubricants. A bad mixture may cause precipitation and lose its lubricant characteristics. Consult your lubricant supplier.
Normal operating conditions
5.3.2 Operation at elevated 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:
a) Choose a main lubrication oil for operation at elevated temperatures according to section 7.2 Oil for lubrication system.
b) Exchange the main lubrication oil according to section 8.3 Exchanging main lubrication oil. Also change the filter element and clean the dirt trap, return oil strainer, tank and air/oil heat exchanger.
c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system and exchange oil in the Hydroset system. Also change the filter element and clean the dirt trap, see section 8.7.2 Oil filter and section 8.7.3 Dirt trap (magnetic plug).
d) If thermostats TG 1, TG 2 and TG 3 are not already set for operation at elevated temperatures, reset them according to section
8.2.11 Thermostats and section 8.2.12 Oil heating.
Operation at elevated temperatures
5. Using the cone crusher
5.3.3 Operation in 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 extra heating. See the Installation manual and consult Sandvik Rock Processing.
Nevertheless, in extremely low temperatures it can sometimes be advisable to change to a less viscous oil:
a) Choose a main lubrication oil for operation in low temperatures according to section 7.2 Oil for lubrication system.
b) Exchange the main lubrication oil according to section 8.3 Exchanging main lubrication oil. Also change the filter element and clean the dirt trap, return oil strainer, tank and air/oil heat exchanger.
c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system and exchange oil in the Hydroset system. Also change the filter element and clean the dirt trap, see section 8.7.2 Oil filter and section 8.7.3 Dirt trap (magnetic plug). It is normally unnecessary to change to a different grade of Hydroset oil. However, if conditions are so extreme that a less viscous oil or a heater in the Hydroset tank is needed, consult Sandvik Rock Processing.
d) For operation under extreme ambient temperatures, consult the lubricant supplier regarding grease for spider bearing lubrication, see section 7.5 Grease for spider bearing lubrication.
e) If thermostats TG 1, TG 2 and TG 3 are not already set for operation in low temperatures, reset them according to section 8.2.11 Thermostats and section 8.2.12 Oil heating.
Operation in low temperatures
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.
c) Fully open the damping valve in the line to the Hydroset pressure gauge, see section 8.7.5 Pressure gauge.
d) Use the L1 push button box to lower the mainshaft, keeping an eye on the Hydroset pressure.
e) If the Hydroset pressure drops below 0.3 MPa, then raise the mainshaft again until the pressure gauge displays at least 0.5 MPa. (The mainshaft step may lose contact with the step washer if the pressure goes below zero.)
f) Start the crusher.
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-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.
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.
6. Inspection and care
This section describes the routine inspection and care instructions for the cone crusher.
To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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.
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.
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.
Action When See section
Check the oil level in the lubrication tank. Before starting the crusher 8.2
Check the oil level in the Hydroset tank. Before starting the crusher 8.7
Check that the shut-off valves between the tanks and pumps are fully open.
Before starting the pumps and crusher
– Check that no material has built up on the bottomshell arms. Before starting the crusher – Check that lubricating oil returns to the tank and that the oil is
clean.
After starting the lubrication pump
8.2
Check that the oil lines do not leak. After starting the pumps – Check that the pinionshaft lubrication circuit is operating
cor-rectly.
Running idle 8.4
Check the CSS. Running idle 4.2.1
Check that material has not jammed in the feed hopper or splitter and blocked the feed opening.
Running idle –
Listen for abnormal noises in the crusher. While crushing – Listen for abnormal noises in the lubrication pump. While crushing and before – Check the return oil temperature. While crushing 8.2.7
Check the drive motor current or power consumption. While crushing 4.2.4
6. Inspection and care
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.
Check that no bolts have come loose. While crushing – Check that the oil heaters are working. With crusher stopped 8.2.12
Check the distance between the head nut and the underside of the spider (i.e. the A-dimension).
With crusher stopped 10.2
Check that there is no contamination increase or change on the return oil strainer, e.g. an abnormal amount of metal parti-cles.
With crusher and lubrication pump stopped
8.3.4
Action When See section
Inspect the oil filter (check if the red button on the pressure drop sensor protrudes) of the main and pinionshaft lubrication systems.
With crusher and lubrication pumps stopped
8.2.3, 8.3.3,
8.7.2
Clean the dirt trap and inspect the oil tank of the main lubrica-tion system.
With crusher and lubrication pump stopped
8.2.1, 8.2.2,
8.3
Inspect the crushing liners for wear and damage. With crusher stopped 10.2
Measure the setting at four points around the crushing cham-ber to check for uneven wear.
Running idle 4.2.1, 11.1
Check the pumps for abnormal noise and wear. While crushing. 8.2.4, 8.4.2,
8.7.1
Check wear and tension of the V-belts. With crusher stopped – Check the cooler core of the air/oil heat exchanger (option). With crusher and lubrication
pump stopped
8.6
Clean the damping valve for the Hydroset pressure gauge. With crusher stopped 8.7.5
Check the air pressure (blower running or regulator working) of the over-pressure dust sealing.
Running idle 6.7
Check the hose and filter of the over-pressure dust sealing and that the covers on the tank unit are air tight.
With crusher stopped 6.7
6.1.3 Monthly
These inspections should be carried out monthly or after every 160 hours of operation. The crusher must be stopped.
6.1.4 Twice a year
These inspections should be carried out twice a year or after every 1000 hours of operation. The crusher must be stopped.
Action Responsible See section
Clean the drain plug on the pinionshaft housing. Operator 7.4
Check the dust seal ring for wear. Operator 6.3.1
Check the condition of the scraper which rotates above the dust collar.
Operator 6.3.2
Check the tightness of all bolts. Operator –
Check the play between the mainshaft sleeve and the spider bushing.
Operator 10.1, 10.3
Check the grease level in the spider bearing. Operator 7.5
Clean the air vent passages in the spider cap and topshell. Operator 10.1
Check the quality of the lubrication oil. Operator 7.2
Check the function of the return oil flow switch. Operator 8.2.9
Check the backlash in the pinion and eccentric gear. Service personnel See MM Check – using feeler gauges – between the headcentre and
the mantle and between the topshell and the concave ring.
Service personnel See MM Check the spider bearing grease seal for wear. Service personnel See MM
Action Responsible See section
Check the gas pressure in the accumulator. Operator 9.3
Clean out the oil tank. Operator 8.2.1, 8.3
Change the oil filter element and clean the dirt trap of the Hydroset system.
Operator 8.7.2, 8.7.3
6. Inspection and care
6.1.5 Yearly
These inspections should be carried out yearly or after every 2000 hours of operation. The crusher must be stopped.
Action Responsible See section
Check the topshell and bottomshell for wear. Service personnel See MM Check the chevron packing for wear. Service personnel See MM Check the tapered contact faces of the topshell and
bottom-shell.
Service personnel See MM Check the mainshaft sleeve for wear and pitting. Service personnel See MM Check the inner seal ring for wear. Service personnel See MM Check the play between the locating bar and the gear hub. Service personnel See MM Check the eccentric bushing for wear and scratches. Service personnel See MM Check the eccentric for wear and scratches. Service personnel See MM Check the eccentric wearing plate for wear. Service personnel See MM Check the bottomshell bushing for wear and scratches. Service personnel See MM Check the thickness of the step bearing assembly. Check for
wear and scratches.
Service personnel See MM
Check the gears for wear. Service personnel See MM
Check the Hydroset cylinder bushing for wear and scratches. Service personnel See MM Check the function of the temperature gauge. Operator 8.2.7
Check the function of the protective thermostat TG 1 and the thermostat for heat exchanger TG 2
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 442.7283-00 Eccentric bushing Lifting tool 442.7281-00 Bottomshell bushing Lowering rod with nut M24×600 843.1333-00 Piston
Nut M6M M24 845.0012-00 Lowering rod Lowering rod 442.7284-00 Mainshaft step Piston stop plate 442.9995-00 Holding piston Eye bolt 442.7282-01 Mainshaft step Eye bolt M48 899.0157-00 Mainshaft Eye bolt M20 899.0160-00 Spider bushing 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 Mainshaft sleeve
Ring spanner striking 65 mm 920.0110-00 Screw and nut M42 Ring spanner striking 36 mm 920.0151-00 Screw and nut M24 U-ring spanner 46 mm 920.0131-00 Screw and nut M30 U-ring spanner 36 mm 920.0135-00 Screw and nut M24 U-ring spanner 30 mm 920.0134-00 Screw and nut M20 U-ring spanner 24 mm 920.0022-00 Screw and nut M16 U-ring spanner 18 mm 920.0244-00 Screw and nut M12 U-ring spanner 13 mm 920.0186-00 Screw and nut M8 Allen key 17 mm 920.0041-00 Screw MC6S M20 Allen key 10 mm 920.0038-00 Screw MC6S M12 Allen key 8 mm 920.0037-00 Screw MC6S M10 Allen key 5 mm 920.0035-00 Air bleed screw Allen key 5/8" 920.0032-00 Spider cap plug Chunk of lead 442.0800-91 CSS check
6. Inspection and care
6.3 Bottomshell and mainshaft assembly
There are two inspection holes through the bottomshell through which the dust seal ring and dust collar can be inspected and checks can be made on liner condition and oil leakage.
PROHIBITION!
Do not remove covers/guards
Do not open the covers while the machine is crushing. Never put hands inside while the crusher is running.
1
1 Cover / inspection hole6.3.1 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.
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
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.
mm/(inches) 1.5/(0.060)
5
4
3
2
2 Retaining ring 3 Dust seal ring 4 Dust collar 5 Scraper
6. Inspection and care
6.4 V-belts
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.
PROHIBITION!
Do not remove fixed guards
Never operate the cone crusher unless the fixed guards around its moving parts are mounted.
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
)
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, 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) 2 3 4 5 14 6 12 10 8 6 2 W F D F
1
2
1 F-scale 2 D-scale D = deflection W = belt span F = deflection load6. Inspection and care
6.5 Topshell assembly
For further information about inspection and care of the topshell assembly, see section 10. Topshell assembly.
6.6 Hydroset and lubrication system
For further information about inspection and care of the Hydroset and lubrication system, see section 8. Hydroset and lubrication system.
6.7 Over-pressure dust sealing
The crusher has a dust seal ring (4305-0) to keep out dust, but air must be introduced into the crusher at a small over-pressure. This is because a slight under-pressure can otherwise occur inside the crusher when aerated
lubricating oil runs back to the tank. The resultant under-pressure will draw dust into the crusher and a film of dust will collect on the inside of the dust collar (1400-0).
The lubricating oil will transport these dirt and dust around the lubrication system. This will result in rapid blockage of the filters, accelerated wear of step bearing components and sedimentation in the oil tank. Other
components inside the crusher will also be subjected to unnecessarily heavy wear.
The over-pressure air (white arrows) can be provided by a blower (as described in section 6.7.2 Blower) or from a compressed air system (as described in section 6.7.3 Regulator assembly for compressed air).
1400-0 Dust collar
1450-0 Inner dust seal ring 4305-0 Dust seal ring 4350-0 Retaining ring 4355-1 Scraper 1 Dust
1400-0
1450-0
4305-0
4350-0
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.
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.)
NOTE! The covers on the tank unit must be air tight. Adjust or replace the sealing strips if necessary.
2 4 5
2 T-connector4 Blower 5 Sleeve
6. Inspection and care
6.7.2 Blower
The blower capacity at a pressure of 600 Pa (60 mm w.g.) must be at least 0.3 m3/min.
Check
The blower (4) has an air filter (6) with a replaceable paper element. Inspect the filter element at regular intervals and change it when necessary.
6.7.3 Regulator assembly for compressed air
The regulator assembly includes a pressure gauge (3) which measures the over-pressure at the entry to the crusher.
4
6
4 Blower 6 Filter3 7 8 9
3 Pressure gauge 7 Air regulator 8 Filter7. Lubrication
This section describes the requirements that must be put on the lubricants used in the cone crusher.
To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
7.1 Lubricant requirements
If the crusher is to be utilized optimally, stringent demands must be made on the lubricants that are used.
Check
A change in oil colour may indicate the presence of water or dirt. Change the oil.
7.1.1 Miscibility
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.
NOTE! Lubricants which do not meet Sandvik Rock Processing’s requirements must not be used during the warranty period.
WARNING!
Risk of fire and toxic gases
Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier’s instructions and safety directions when handling oils and greases.
NOTE! Changing the oil is described in section 5.3 Changing oil.
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.
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
(Continued)
Operating condition Normal Operation at elevated
tempera-tures Operation in low temperatures Ambient air temperature Max. 32°C (89.6°F) Max. 40°C (104°F) Below 0°C (32°F)
Oil viscosity ISO VG 150 ISO VG 220 ISO VG 100 Specification DIN 51 517-CLP 150 DIN 51 517-CLP 220 DIN 51 517-CLP 100 Properties Test method Requirement Requirement Requirement Base oil viscosity at 40°C
(104°F) in mm2/s (cSt)
DIN 51 519 150 220 100
Viscosity index DIN ISO 2909 ≥ 100 ≥ 100 ≥ 100
FZG DIN 51 354 ≥ 12 ≥ 12 ≥ 12
Lowest pour point DIN ISO 3016 ≤ –9°C (15.8°F) ≤ –6°C (21.2°F) ≤ –12°C (10.4°F)
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:
BP Energol GR-XP 220 Molub-Alloy Tribol 1100/220 ESSO Spartan EP 220 Shell Omala 220
Klüber Klüberoil GEM 1-220 Statoil LoadWay EP 220 Mobil Mobilgear 630 Texaco Meropa 220 For operation in low temperatures:
BP Energol GR-XP 100 Molub-Alloy Tribol 1100/100 ESSO Spartan EP 100 Shell Omala 100
Klüber Klüberoil GEM 1-100 Statoil LoadWay EP 100 Mobil Mobilgear 627 Texaco Meropa 100
Biologically degradable oil
If a biologically degradable oil is to be used, Sandvik Rock Processing recommends that only a 100 % synthetic oil of ester type is selected. Due to the higher viscosity index of this type of oil, an ISO VG 150 grade can normally be used all year round.
If the ambient air temperature is over 32°C (90°F), it may still be necessary to reset thermostats TG 1 and TG 2 for “Operation at elevated temperatures” since TG 1 could otherwise trip because of excessively high oil temperature and thus stop the crusher, see section 8.2.11 Thermostats.
7. Lubrication
Oil quantity
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
Requirement specification
The oil used in the Hydroset system must be miscible with the lubricating oil and comply with the same requirements. However, the viscosity must be according to ISO VG 68.
The oil must comply with DIN 51 517-CLP 68.
(Continued)
Capacity
