CTHS430-02_OMM_S223.857.en-01

(1)

&

Operator’s & Maintenance Manual

Doc. No. S 223.857.en

SANDVIK CTHS430:02

Tank unit

(2)

Serial No. / Machine No. Signature

SANDVIK CTHS430:02

Tank unit

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 223.857.en

Issue: 20120710 Version: 01

Document type: Operator’s & Maintenance Manual (OMM)

Sandvik

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

(3)

1. Introduction

1.1 Equipment information... 10 1.1.1 Document information... 12 1.2 Operating principles... 13

1.2.1 Main lubrication system ... 13

1.2.2 Pinionshaft lubrication... 13

1.2.3 Hydroset system for setting adjustment... 13

1.2.4 Description ... 13

2. Safety precautions

2.1 Hazard information ... 16 2.1.1 Warning signs ... 16 2.1.2 Risk levels... 17 2.1.3 Prohibition signs... 17 2.1.4 Mandatory signs... 17 2.1.5 Personnel... 18 2.1.6 Personal protection ... 19

2.2 General safety precautions... 20

2.2.1 Machine safety guards... 21

2.2.2 Machine access ... 21

2.2.3 Electrical safety... 22

2.2.4 Welding ... 22

2.2.5 Hydraulic system... 23

2.2.6 Lubrication system ... 24

2.2.7 Lubricants and waste lubricants... 25

2.2.8 Diesel oil, white spirit and other cleaning agents ... 25

2.2.9 Lifting and moving loads ... 26

(4)

3. Lubrication systems

3.1 General ... 28

3.2 Overview ... 29

3.2.1 Tank unit... 29

3.2.2 Cabinet... 30

3.3 Main lubrication components ... 32

3.3.1 Main lubrication components - designation ... 33

3.4 Hydroset components ... 34

3.4.1 Hydroset components - designation... 35

3.4.2 CH-crusher’s accumulator... 36

3.5 Connections and drainage ... 37

3.5.1 Connections and drainage - designation... 37

3.6 Pinionshaft lubrication... 38

3.7 Overpressure components... 39

3.7.1 Overpressure fan ... 39

3.7.2 Overpressure fan components - designation ... 39

3.7.3 Overpressure air regulator ... 40

3.7.4 Overpressure air regulator components - designation... 40

4. Starting up the tank

4.1 General ... 42

4.2 Running-in... 42

4.2.1 Starting the main oil pump... 43

(5)

5

5. Using the tank unit

5.1 Starting and stopping ... 46

5.1.1 Start... 46

5.1.2 Normal operation ... 47

5.1.3 Stop... 47

5.2 Changing oil... 48

5.2.1 Normal operating conditions ... 49

5.2.2 Operation at elevated temperatures ... 50

5.2.3 Operation in low temperatures... 51

6. Inspection and care

6.1 Routine inspection and care ... 54

6.1.1 Daily ... 54

6.1.2 Weekly ... 55

6.1.3 Monthly ... 55

6.1.4 Twice a year... 56

6.1.5 Yearly ... 56

6.2 Overpressure dust sealing... 57

6.2.1 Overpressure parts ... 58

6.2.2 Air flow ... 59

6.2.3 Fan... 59

6.2.4 Regulator assembly for compressed air ... 60

7. Lubricants

7.1 Lubricant requirements ... 62

7.1.1 Miscibility... 62

7.1.2 Low temperatures ... 62

7.1.3 High temperatures ... 63

7.2 Oil for lubrication system ... 63

7.3 Oil for Hydroset system ... 66

(6)

8. Maintenance

8.1 Main lubrication system ... 70

8.1.1 Cleaning the tank ... 71

8.1.2 Condensation water, draining... 71

8.1.3 Dirt trap, main lubrication ... 72

8.1.4 Main lubrication oil filter... 73

8.1.5 Oil pump... 74

8.1.6 Pressure indicator ... 75

8.1.7 Pressure switch... 76

8.1.8 Temperature indicator ... 77

8.1.9 By-pass valves on coolers... 78

8.1.10 Return oil flow switch ... 79

8.1.11 Return oil screen ... 80

8.1.12 Temperature switches ... 81

8.1.13 Oil heating control ... 83

8.2 Main lubrication oil exchange... 84

8.2.1 Draining the main lubrication system. ... 84

8.2.2 Tank with air/oil cooler... 85

8.2.3 Tank with water/oil cooler (option)... 86

8.2.4 Dirt trap cleaning, main lubrication... 87

8.2.5 Filter exchange, main lubrication ... 88

8.2.6 Return oil screen and oil tank cleaning ... 89

8.2.7 Cleaning out oil remnants, air/oil cooler ... 90

8.2.8 Cleaning out oil remnants, water/oil cooler (option) 91 8.2.9 Refilling the main lubrication system... 92

8.3 Air/oil cooler ... 94

8.4 Water/oil cooler (option) ... 95

8.4.1 Dirt trap water/oil cooler, cleaning ... 95

8.4.2 Blocked water channels in water/oil cooler, cleaning and deliming ... 96

8.5 Hydroset system ... 98

8.5.1 General ... 98

8.5.2 Hydroset pump... 100

8.5.3 Hydroset pressure indicator ... 100

8.5.4 Pressure relieve - Hydroset... 101

8.5.5 Oil filter ... 101

(7)

7

9. Troubleshooting

9.1 Faults and suggested corrective actions ... 106

10. Technical specifications

10.1 General data ... 112

10.2 Lubrication systems ... 112

10.2.1 Main lubrication system ... 112

10.2.2 Pinionshaft lubrication system ... 113

10.3 Hydroset system ... 113

10.4 Oil cooling systems... 114

10.4.1 Air/oil cooler ... 114

10.4.2 Water/oil cooler (option) ... 114

10.5 Overpressure dust exclusion system... 115

10.5.1 General ... 115

10.5.2 Fan motor... 115

10.6 Tightening threaded fasteners ... 116

(8)

(9)

9

OMM Sandvik CTHS430:02 Tank unit

To ensure maximum safety, always read section 2. Safety precautions before

(10)

1.1 Equipment information

Purpose

The purpose of this Sandvik equipment is to supply the crusher with oil for lubrication and for operating the hydraulic setting system. This tank unit has been exclusively designed for this application.

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 equipment has been manufactured by: Sandvik SRP AB

SE-233 81 Svedala Sweden

www.sandvik.com

For maintenance

Contact the nearest Sandvik company, agent or representative, or contact the factory directly: Sandvik SRP AB Service department SE-233 81 Svedala Sweden Telephone +46 (0)40 40 90 00 Telefax +46 (0)40 40 92 60 (Continued)

(11)

11

Tank unit identification

The figure below shows an example of the tank units’s identification plate. The identification plate contains data needed when contacting

Sandvik SRP AB concerning this specific equipment.

Please enter the serial number of the associated machine in the intended field on the first page of this manual (the copyright page).

CE marking

This equipment complies with the basic health, environment and safety regulations of the European Union and European Economic Area. Sandvik will not take responsibility for this compliance when customers modify any configuration of the oil tank unit.

V10 6 5 4 3 8 7 1 2 1 Machine type 2 Serial number/PCR

3 Local manufacturer number 4 Mass (kg)

5 Order number 6 Manufacturer

7 Maximum operating speed 8 Year of manufacture

(12)

1.1.1 Document information

Purpose of this Operator’s and Maintenance Manual

The purpose of this manual is to provide the operator with information on how to handle and operate this Sandvik equipment and to provide

maintenance personnel with:

• information on all scheduled maintenance procedures listed in the checklists

• information for unscheduled maintenance such as: – additional maintenance procedures.

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

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 AB manufacturing plant.

Technical Publications

Technical publications related to the installation of this equipment are: • IM - Installation Manual

• IMA - Installation Manual Appendix

Technical publications related to the operation and maintenance of this equipment are:

• OMM - Operator’s and Maintenance Manual • SPC - Spare Part Catalog

Read more about the document structure and accompanying work roles in

section 2.1.5 Personnel.

Feedback

If you have comments on this manual or problems connected to the documentation, send an e-mail to: [email protected]

(13)

13

1.2 Operating principles

There are two separate lubrication systems on the crusher – the circulatory main lubrication system connected to the tank unit and the closed pinionshaft oil bath lubrication.

The hydraulic setting system for the crusher has most of its vital parts and an oil tank in the tank unit.

1.2.1 Main lubrication system

The main lubrication system is connected to the tank unit.

1.2.2 Pinionshaft lubrication

The pinionshaft is lubricated by a separate oil bath in the pinionshaft housing and has no connection to the main lubrication system. The pinionshaft lubrication is described in the Operator’s manual for the crusher.

1.2.3 Hydroset system for setting adjustment

To control fragment size and to compensate for wear the crusher has a setting control system, called the Hydroset system. It basically consists of a robust hydraulic jack which supports the mainshaft and adjusts its position. Moving the Hydroset piston up and down will change the discharge setting and the size of the crushed material.

1.2.4 Description

The following figure shows an overview of the oil tank unit’s components and nomenclature.

1 2

3 4 5

1 Oil tank unit 2 Overpressure fan

3 Overpressure air regulator (option)

4 Air/oil cooler

(14)

(15)

15

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

(16)

2.1 Hazard information

2.1.1 Warning signs

General danger Dangerous voltage Risk of crushing

Hanging load Skid risk Flying fragments

(17)

17

2.1.2 Risk levels

Throughout the manual, risk levels are indicated with “DANGER”,

“WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels are accompanied by a warning sign, see section 2.1.1 Warning signs.

CAUTION! Failure to observe information marked “CAUTION!” can result in minor personal injury and/or damage to equipment!

2.1.3 Prohibition signs

2.1.4 Mandatory signs

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

(18)

2.1.5 Personnel

All work on the equipment must be carried out by trained personnel.

– “Trained” means that the person in question has been given practical instructions by Sandvik SRP AB personnel on how the various tasks are carried out.

All expected work tasks on this production equipment have been defined by Sandvik SRP AB as belonging to one of three categories:

• Installation • Operation • Maintenance

Sandvik SRP AB provides technical documentation appropriate to the categories:

• Installation Manual and Installation Manual Appendix • Operator’s and Maintenance Manual

• Spare Parts Catalog

Adequate training can be provided, contact Sandvik SRP AB for further information.

The technical documentation from Sandvik SRP AB only covers 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.

(19)

19

2.1.6 Personal protection

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

Sandvik SRP AB strongly recommends to use a safety harness when working above, inside or under the equipment.

The Sandvik SRP AB recommendation for personal protective equipment includes:

Ear protection Safety helmet Eye protection

(20)

2.2 General safety precautions

Always switch the power off and lock out the equipment (so that it cannot inadvertently 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 carried out.

Avoid staying on the equipment, unless necessary for maintenance work. CAUTION! Sharp edges can appear on the equipment due to wear, please consider

sharp edges when handling worn parts. Remove any sharp edges. WARNING!

Falling stones

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

(21)

21

2.2.1 Machine safety guards

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

2.2.2 Machine access

Every machine requires access for personnel who carry out inspections and/ or maintenance work. Suitable access platforms and guard rails must be installed. Walkways, stairs and ladders must be designed in accordance with applicable regulations.

These parts are not included in thetank unit’s standard specification. For advice, contact Sandvik SRP AB.

PROHIBITION!

Do not remove guards

Make sure that all guards are in place and functioning, to prevent exposure to rotating parts. Only operate the equipment when all guards are mounted.

WARNING!

Rotating parts

Exposure to rotating parts (pumps, fans etc.)must be prevented by guards. Always attach the guards after maintenance work.

WARNING!

Flying fragments

Ejected fragments can fall down in the vicinity of the equipment. Provide adequate guards and warning signs at appropriate places around the danger zone.

(22)

2.2.3 Electrical safety

CAUTION! Only personnel working according to European Standard EN 50110 or equivalent are permitted to perform electrical operations on the equipment.

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

Control cabinets must be lockable.

2.2.4 Welding

CAUTION! Never weld the tank unit or parts attached to it. DANGER!

Dangerous voltage

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

DANGER!

Risk of fire and explosion

Due to the risk of leakage, open flames and hot surfaces (>200 °C/ >390 °F) must be kept at a safe distance from the tank unit and the lubrication pipe work.

(23)

23

2.2.5 Hydraulic system

CAUTION! Only personnel certified in hydraulics are permitted to perform maintenance on the hydraulic system (except bleeding air from the Hydroset system).

CAUTION! Never adjust pressure relief valves beyond the recommended values.

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

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!

Hot oil

Hydraulic oil can become very hot during operation. Allow the oil to cool before working on the hydraulic system.

WARNING!

Hot surface

Equipment and hoses/pipes containing hydraulic oil can have hot surfaces. Always wear protective gloves.

WARNING!

Skid risk

When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.

(24)

2.2.6 Lubrication system

When changing from mineral oil to synthetic oil, or if the oil has coked, the tank unit must be thoroughly cleaned. Contact Sandvik SRP AB for further instructions.

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

WARNING!

Oil pressure

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

WARNING!

Hot oil

Lubrication oil can become very hot during operation. Allow the oil to cool before working on the lubrication system.

WARNING!

Hot surface

Equipment and hoses/pipes containing lubrication oil can have hot surfaces. Always wear protective gloves.

WARNING!

Skid risk

When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.

(25)

25

2.2.7 Lubricants and waste lubricants

CAUTION! Handle all lubricants and waste lubricants with care and according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Collect waste lubricants in suitable containers and dispose as

recommended in the MSDS and according to local regulations.

2.2.8 Diesel oil, white spirit and other cleaning agents

It is recommended to clean the tank and the tank unit’s parts with diesel oil. Use white spirit only if it is necessary.

CAUTION! If white spirit is used for cleaning, wipe it off carefully and allow it to evaporate before pouring oil into the cleaned compartments.

CAUTION! Handle all cleaning agents and their waste with care and according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Collect the waste in suitable containers and dispose as recommended in the MSDS and according to local regulations.

WARNING!

Toxic substances

Read the supplier’s Material Safety Data Sheet (MSDS). Used and contaminated oil can be a health hazard. Use protective gloves and goggles.

WARNING!

Skid risk

When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.

WARNING!

Health hazard

Before you use a cleaning agent, read the supplier’s Material Safety Data Sheet (MSDS) and follow the instructions carefully. Risk of serious injuries to eyes, skin, respiratory system etc. Use personal protection and other safety measures as recommended in the MSDS.

(26)

2.2.9 Lifting and moving loads

CAUTION! Only personnel with adequate lifting training are permitted to perform lifting operations.

Make sure that the capacity of the lifting equipment (Working Load Limit,

WLL) is adequate and that the lifting equipment is in good working order.

If lifting tackle has to be made up by joining separate components, make sure that the joints are secure and have the same lifting capacity (Working Load

Limit, WLL) 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. Never 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 quickly and safely lower the load to the ground in case of an emergency.

When depositing loads, keep the lifting equipment in place until it has been made sure that the load is stable.

2.3 Emissions

For emissions such as dust, noise and radioactivity in the tank units environment, see section 2. Safety precautions in the crusher’s manuals. DANGER!

Hanging load

Never work or stand underneath a crane that is lifting material. Keep a safe distance to hanging loads.

(27)

27

(28)

3.1 General

The lubrication tank unit is supplied as a complete module with the oil tank and the various components mounted in a cabinet.

The tank is equipped with an oil cooler. Two versions are available either the standard version an air/oil cooler or the optional version a water/oil heat exchanger, in this set of manuals are both called coolers.

To prevent dust from entering the main lubrication tank and the crusher an overpressure blower is connected to the tank unit and the crusher.

The standard version is an overpressure fan and the optional version is a regulator with filter connected to the sites compressed air system.

The tank components designation (bold) used in the text that follows are those that are used in the Installation manual and on the Piping and

Instrumentation Diagram (PID) in the Installation Manual Appendix for the tank unit.

(29)

29

3.2 Overview

3.2.1 Tank unit

The tank unit consists of a cabinet (4) with two tanks, one for the main lubrication and one for the Hydroset oil, both protected with covers (1 and 5) on the cabinet’s top. The covers are used for inspection, cleaning and to pour oil into the tanks.

Two pair of outlets are placed underneath the cabinet, one pair for the main lubrication tank and one for the Hydroset tank. Each pair has one outlet for oil and one for condensation water.

An electrical cabinet (3) is placed on the same side as the connections to and from the crusher as well as from the overpressure system.

1 2

3

4 5

1 Main lubrication tank cover 2 Lifting eye

3 Electrical cabinet 4 Cabinet

(30)

3.2.2 Cabinet

The cabinet contains components of the main lubrication system and Hydroset system such as pumps, filters, valves, indicatorsetc.

In the figures below, the tank unit and the interior of the cabinet is divided into different views:

Main lubrication system with air/oil cooler (standard)

(31)

31

For further information about the pinionshaft oil bath lubrication, see the

Operator’s or the Maintenance Manual for the crusher.

(32)

3.3 Main lubrication components

(Continued) FU1 HA1 V10 HA1 B A - A A A B B - B

TI1 PI2 H10 PS2 FU1 TS4

TS1 TS2 TI1 FS1 FU4 LV1

TS3 TS2 TS1

E7.1 E7.2 LI1 E7.3 TS3 V1 E7.4 V1 M2 CV4 M3 TS4 FU7 CV5

(33)

33

3.3.1 Main lubrication components - designation

The tank component’s designations on the drawing above and in the table below are those that are used in the Installation manual and on the Piping and Instrumentation Diagram (PID) in the Installation Manual Appendix for the tank unit. Component designation, alphabetical order Description Note

CV4 By-pass valve Check valve on air/oil cooler

CV5 By-pass valve Check valve on water/oil cooler (option) E7.1 Oil heater element Oil in tank, cold climate option

E7.2 Oil heater element Oil in tank

E7.3 Oil heater element Oil in tank

E7.4 Oil heater element Oil in tank, cold climate option

FS1 Flow switch Monitoring the return oil flow (not shown)

FU1 Filter unit with cartridge Oil, main lubrication FU4 Filter unit with dirt trap Oil, main lubrication

FU7 Filter unit with dirt trap Water to water/oil cooler, option H10 Warning lamp, red Too high oil pressure across filter FU1 LI1 Level indicator Oil level in main lubrication tank LV1 Logic element valve with drain Main lubrication system

M2 Pump and motor Main lubrication system

M3 Fan motor Air/oil cooler

OS1 Return oil screen In return oil chamber (not shown) PI2 Pressure indicator Shows oil pressure across filter FU1

PS2 Pressure switch Oil pressure across filter FU1

TI1 Temperature indicator Oil temperature in return oil chamber

TS1 Temperature switch Return oil chamber.

Stops the crusher if the temperature exceeds the limit of the setting

TS2 Temperature switch Oil in main lubrication tank.

Starts the air/oil cooler when return oil tem-perature exceeds the limit of the setting TS3 Temperature switch Controls the heater elements in the main

lubrication tank

TS4 Temperature switch Controls the inlet water to the water/oil cooler (option), adjustable

V1 Ball valve Main lubrication system

(34)

3.4 Hydroset components

B A - A A A B B - B HA1 L1 C - C PI1 HA1 LI2 V10 V5 V4 C C M6 MP1 MP2 MP3 CV3”1A” CV3”1B” CV1 C RV4 RV3 RV2 FV8 FU3 PI1 V10 R B T A V10

(35)

35

3.4.1 Hydroset components - designation

The tank component’s designation on the drawing above and in the table below are those that are used in the Installation manual and on the Piping and Instrumentation Diagram (PID) in the Installation Manual Appendix.

HA1

Raising the mainshaft to increase the setting.

The pump sucks the oil via port T through check valve CV3”1A” and port A. The oil is pumped via port B to the pilot operated check valve CV1 and then to the crusher via port C.

When the pump stops, the pilot operated check valve CV1 will close to prevent oil from draining to the tank.

Lowering the mainshaft to decrease the setting.

The pump works in reversed direction and sucks the oil from port T via check valve CV3”1B” and port B to port A.

From port A the oil is pumped via the pressure relief valve RV3 and further on to port R to raise the pressure until the pilot operated check valve CV1 opens. By then it is possible to suck the oil via port C.

Component designation, alphabetical order

Description Note

A, B, C, R and T Ports See VB1 below

CV1 Check valve Pilot operated

CV3”1A” Check valve Mainshaft raising

CV3”1B” Check valve Mainshaft lowering

FU3 Filter unit with cartridge Return oil filter

FV8 Needle flow valve Relieves system pressure

HA1 Hydraulic assembly See below

L1 Push button box ASRi-L1, for Close Side Setting (CSS) LI2 Level indicator Oil level in Hydroset tank, min.-max.

M6 Pump and motor Hydroset

MP1 Measuring nipple Pressure in port B MP2 Measuring nipple Pressure in port A MP3 Measuring nipple Pressure in port C

PI1 Manometer Activated by V5

RV2 Pressure relief valve Raises the pressure to open CV1 RV3 Pressure relief valve Pressure limit for pump RV4 Pressure relief valve Pressure limit for system

V4 Ball valve Pump drainage line, closed position on drawing V5 Ball valve Valve block VB1 suction line, closed position on drawing V10 Shut-off valve Activates and protects pressure indicator PI1

(36)

3.4.2 CH-crusher’s accumulator

The CH-crushers has an accumulator connected to the Hydroset and mounted on the crusher.

Accumulator components

Accumulator components - designation

For further information, see the Operator’s and Maintenance Manuals for the crusher. Component designation, alphabetical order Description Note AC Accumulator On CH-crusher

CV6 Check valve On CH-crusher

MP5 Measuring point (nipple) On CH-crusher

AC

MP5 CV6

(37)

37

3.5 Connections and drainage

3.5.1 Connections and drainage - designation

Connections

and drainage

1 Water drain plug Condensation water from main lubrication tank

2 Oil drain plug Oil from main lubrication tank

3 Oil drain plug Oil from Hydroset tank

4 Water drain plug Condensation water from Hydroset tank

J Water to cooler Water/oil cooler option

L Oil from crusher Main lubrication tank

M Oil pipe/hose to crusher From connection V

N Oil to and from crusher Hydroset tank

O Water from cooler Water/oil cooler option

P Overpressure air To tank via T-connection on pinionshaft housing U Oil from tank Air/oil cooler and water/oil cooler option V Oil to crusher Air/oil cooler and water/oil cooler option

U P L N D D V U V J U O 1 2 3 4

(38)

3.6 Pinionshaft lubrication

The pinionshaft is lubricated in an oil bath in the pinionshaft housing. For main part of the information about checking and changing the oil in the pinionshaft housing: See Maintenance Manual for the crusher.

For information about lubricants for the pinionshaft, see section 7.4 Oil for pinionshaft lubrication in this manual.

(39)

39

3.7 Overpressure components

3.7.1 Overpressure fan

3.7.2 Overpressure fan components - designation

Component

designation, alphabetical order

C Coupling to the pinionshaft housing Overpressure fan/compressed air regulator

FU5 Air filter Overpressure fan

M8 Motor to fan Overpressure fan

P Coupling to the main lubrication tank Overpressure fan/compressed air regulator

PF Fan Overpressure fan

C

P M8

PF FU5

(40)

3.7.3 Overpressure air regulator

3.7.4 Overpressure air regulator components -

designation

C P PI4 FV6 FU6 Component designation, alphabetical order Description Note

C Coupling to the pinionshaft housing Overpressure fan/compressed air regulator

FU6 Air filter unit Compressed air regulator

P Coupling to the main lubrication tank Overpressure fan/compressed air regulator PI4 Pressure indicator, manometer Compressed air regulator

(41)

41

The complete instruction for running-in the crusher and the tank unit is collected in the Operator’s Manual for the crusher.

This section is mainly a list of references for more information about measures to be taken on the tank unit during running-in of the crusher. To ensure maximum safety, always read section 2. Safety precautions before

(42)

4.1 General

Each tank unit delivered by Sandvik SRP AB has been assembled, test run and checked in our factory before shipping. The test run is carried out without connection to the crusher to discover any mechanical faults.

4.2 Running-in

For complete step-by step instructions for running-in the crusher and the tank unit, see the Operator’s Manual for the crusher.

List of references for more information

• Valves V1, V4 and V5 are open, see drawing in section 5.1.1 Start

• Level indicator LI1 for oil in the main lubrication tank, see drawing in

section 4.2.1 Starting the main oil pump.

• Temperature indicator TI1 in the return oil chamber, see section 8.1.8 Temperature indicator.

• Temperature switch TS2 for oil cooling control, see section

8.1.12 Temperature switches and section 8.1.13 Oil heating control. • Return oil screen OS1 in the return oil chamber, see section 8.2.6 Return

oil screen and oil tank cleaning.

• Hydroset push button V10 and pressure indicator PI1, see drawing in

section 3.4 Hydroset components. For pressure limits, see section 10. Technical specifications.

• Pressure indicator PI2 for pressure drop across filter FU1, see section 8.1.6 Pressure indicator.

(43)

43

4.2.1 Starting the main oil pump

Before the main oil pump is started check the oil level LI1 (for main lubrication tank’s volume, see section 10.2.1 Main lubrication system). When the pump is started, the oil tank must be full (MAX. or a little less) of oil so that the pump does not operate dry. When the pump is operating the oil level should be slightly above the holder (1) on the level indicator LI1. For more information about the oil requirements, see section 7.2 Oil for lubrication system.

4.2.2 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, see section 8.1.10 Return oil flow switch.

• For more information about avoiding problems when operating in low temperature, see the Installation Manual for the tank unit.

(44)

(45)

45

This section describes basic procedures when using the tank.

(46)

5.1 Starting and stopping

For further information about running-in, after repair work or fitting of new parts, see the Operator’s Manual for the crusher.

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.

For starting the tank unit and the crusher in extremely low temperatures, see

section 4.2.2 Starting a crusher in extremely low temperatures and the

Installation Manual for the tank unit.

5.1.1 Start

a) Start the main lubrication oil pump M2.

b) When the signal “Ready for start” lights up, start the crusher’s drive motor M1.

(Continued) The crusher and the tank unit are normally 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! The oil heating should run for 24 hours a day. The heating elements are automatically controlled by the oil heating temperature switch TS3.

V5 TS3 V4 V1 M2 H10 PS2 M6

(47)

47

c) When the oil has reached operating temperature reset the red pop up button on the pressure switch PS2.

If the button pop up immediately or the red warning lamp H10 is lit, stop the crusher and the pump to exchange the filter cartridge at once. See

section 8.2.5 Filter exchange, main lubrication.

For starting the crusher, see the Operator’s Manual for the crusher.

5.1.2 Normal operation

During normal operation: • The pump M2 is active.

• The pump M6 is active when the crusher’s setting is being adjusted. • The valves V1, V4 and V5 are open.

If the oil flow is inconsistent or too low check the pumps, see section 6. Inspection and care and section 9. Troubleshooting.

5.1.3 Stop

a) Stop the feeder, but let the crusher run until the crushing chamber is free of process material.

b) Stop the crusher’s drive motor M1. c) Stop the main lubrication oil pump M2.

If any service or maintenance is to be performed during the stop:

Wait a few minutes to let oil from the crusher and hoses return to the tank. WARNING!

Hot surface

Equipment and hoses/pipes containing oil can have hot surfaces. Always wear protective gloves.

NOTE! Never close any of the valves before the pumps have stopped.

WARNING!

Hot oil

Lubrication and hydraulic oil can become very hot during operation. Allow the oil to cool before working on the systems.

NOTE! The oil heating should run for 24 hours a day. The heating elements are automatically controlled by the oil heating temperature switch TS3.

(48)

5.2 Changing oil

Normally the old lubricant must be flushed out very carefully before a change is made, see section 8.2 Main lubrication oil exchange.

The lubricant manufacturer(s) can provide information on whether mixing can take place or not .

(Continued)

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 the instructions and safety directions in the Material Safety Data Sheet (MSDS) from the lubricant supplier when handling oils and greases.

NOTE! Never mix different brands or types of lubricants. A bad mixture may cause precipitation and loss of its lubricating characteristics.

Consult the lubricant supplier.

Designation Description Note

(E7.1) Oil heater element Oil in main lubrication tank, cold climate option E7.2 Oil heater element Oil in main lubrication tank, standard installation E7.3 Oil heater element Oil in main lubrication tank, standard installation (E7.4) Oil heater element Oil in main lubrication tank, cold climate option TS1 Temperature switch Return oil to main lubrication tank

Stops the crusher if the temperature exceeds the maximum limit. This to avoid damage to the crusher parts

TS2 Temperature switch Starts the air/oil cooler when return oil temperature exceeds the settings

TS3 Temperature switch Controls the temperature of the oil in the main lubrication tank

E7.2

(E7.1) E7.3 (E7.4)

TS1 TS2 TS1 TS2 TS3

TS3

(49)

49

5.2.1 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 8.2 Main

lubrication oil exchange. Also change the filter cartridge FU1 and clean the dirt trap FU4, return oil screen OS1, tank and cooler. See from

section 8.2.4 Dirt trap cleaning, main lubrication to section 8.2.8 Cleaning out oil remnants, water/oil cooler (option).

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 cartridge FU3, see section 8.5.5 Oil filter.

d) Exchange the oil in the pinionshaft housing. Always use the same oil as in the main lubrication system, see section 7.2 Oil for lubrication system

e) If temperature switches TS1, TS2 and TS3 are not already set for normal operating conditions, reset them according to section 8.1.12 Temperature switches and section 8.1.13 Oil heating control.

Normal operating conditions

Ambient air temperature ±0 to +32 °C (+32 to +90 °F)

FU1

FU4

FU3 TS1 TS2 TS1 TS2 TS3

(50)

5.2.2 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 SRP AB. 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.

lubrication oil exchange. Also change the filter cartridge FU1 and clean the dirt trap FU4, return oil screen OS1, tank and cooler. See from

section 8.2.4 Dirt trap cleaning, main lubrication to section 8.2.8 Cleaning out oil remnants, water/oil cooler (option).

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 cartridge FU3, see section 8.5.5 Oil filter.

d) Exchange the oil in the pinionshaft housing. Always use the same oil as in the main lubrication system, see section 7.2 Oil for lubrication system

e) If temperature switches TS1, TS2 and TS3 are not already set for normal operating conditions, reset them according to section 8.1.12 Temperature switches and section 8.1.13 Oil heating control.

Operation at elevated temperatures

Ambient air temperature +32 to +40 °C (+90 to +104 °F)

FU1

FU4

(51)

51

5.2.3 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 for the tank unit and consult Sandvik SRP AB. 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.

lubrication oil exchange. Also change the filter cartridge FU1 and clean the dirt trap FU4, the return oil screen OS1, tank and air/oil or water/oil heat cooler. See from section 8.2.4 Dirt trap cleaning, main lubrication

to section 8.2.8 Cleaning out oil remnants, water/oil cooler (option). 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

cartridge FU3, see section 8.5.5 Oil filter. 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 SRP AB.

(Continued)

Operation in low temperatures

Ambient air temperature -30 to ±0 °C (-22 to +32 °F)

FU1

FU4

(52)

d) Exchange the oil in the pinionshaft housing. Always use the same oil as in the main lubrication system, see section 7.2 Oil for lubrication system.

e) For operation under extreme ambient temperatures, consult the lubricant supplier regarding grease for spider bearing lubrication, see the

Operator’s Manual for the crusher.

f) If temperature switches TS1, TS2 and TS3 are not already set for operation in low temperatures, reset them according to section 8.1.12 Temperature switches and section 8.1.13 Oil heating control.

(53)

53

This section describes the routine inspection and care instructions for the tank.

(54)

6.1 Routine inspection and care

Every tank unit 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 tank unit’s operating conditions and pressure, important data and details of adjustments made and any repairs carried out. An example of such a record sheet can be found behind the tab

Inspection list in the binder.

Since crushers and tank units 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

The operator is responsible for these inspections daily or after every 8 hours of operation.

(Continued)

NOTE! A new tank unit 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 8.5

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

Before starting the pumps and crusher

5.1.1

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

After starting the lubrication pump

8.1.11

Check that the oil lines do not leak. After starting the pumps – Listen for abnormal noises in the lubrication pump. While crushing and before –

Check the return oil temperature. While crushing 8.1.8

Check the Hydroset pressure. While crushing 8.5.3

Check the oil pressure of the main lubrication system at nor-mal operating temperature.

While crushing 8.1.6

Check that there is no oil leakage. While crushing –

Check that the oil heaters are working. With crusher stopped 8.1.13

Check that there is no contamination increase or change on the return oil screen, e.g. an abnormal amount of metal parti-cles.

With crusher and lubrication pump stopped

(55)

55

6.1.2 Weekly

The operator is responsible for these inspections weekly or after every 40 hours of operation.

6.1.3 Monthly

The operator is responsible for these inspections that should be carried out monthly or after every 160 hours of operation. The crusher must be stopped.

(Continued)

Action When See section

Inspect the oil filter (check if the red button on the pressure switch PS2 protrudes).

8.1.4, 8.2.5

Clean the dirt trap and inspect the oil tank of the main lubrica-tion system.

8.1.1, 8.1.3,

8.2

Check the pumps for abnormal noise and wear. While crushing. 8.1.5, 8.5.2

Check the oil level in the pinionshaft housing. With crusher stopped Operator’s manual for

the crusher

Check the cooler core of the air/oil cooler. With crusher and lubrication pump stopped

8.3

Check the air pressure (fan running or regulator working) of the overpressure dust sealing.

Running idle 6.2.1

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

With crusher stopped 6.2.1

Action See section

Clean the air vent nipple on the pinionshaft housing. Operator’s manual

for the crusher

Check the tightness of all bolts. –

Check the quality of the lubrication oil. 7.2

(56)

6.1.4 Twice a year

The operator is responsible for these inspections that should be carried out twice a year or after every 1000 hours of operation. The crusher must be stopped.

6.1.5 Yearly

The operator is responsible for these inspections that should be carried out yearly or after every 2000 hours of operation. The crusher must be stopped.

Clean out the oil tank. 8.1.1, 8.2

Change the oil filter cartridge of the Hydroset system. 8.5.5,

Change oil in the pinionshaft housing. Operator’s

manual for

the crusher

Check the function of the temperature indicator. 8.1.8

Check the function of the protective temperature switch TS1 and the temperature switch for the cooler TS2

(57)

57

6.2 Overpressure dust sealing

The crusher and the tank shares a system to keep out dust. Air is introduced into the main lubrication oil tank and the crusher at a small overpressure. A slight negative pressure may otherwise occur when the lubricating oil is circulating. The resultant negative pressure will draw dust into the tank and the crusher and contaminate the oil.

Dirt and dust in the lubricant will result in rapid blockage of the filters, accelerated wear of the step bearing components and sedimentation in the oil tank. Other components inside the crusher will also be subjected to

(58)

6.2.1 Overpressure parts

The overpressure air can be provided by an fan PF as described in section 6.2.3 Fan or from a compressed air system with regulator FV6 as described in section 6.2.4 Regulator assembly for compressed air.

Hoses are connected from the overpressure unit to the crusher and the tank unit to accomplish pressure equalization.

One hose is connected from the overpressure fan or the compressed air regulator to the T-connector C mounted on the crusher, above the pinionshaft housing.

The other hose is connected from C to the sleeve P welded on the tank unit shell and placed above the oil level in the main lubrication tank.

When the crusher and the tank are operating, measure the air pressure at the entry to the crusher and check that it is within the limits shown in the table below. C PF M8 FU5 2 2 1 1 2 2 FV6 FU6 P P14

F5 Filter to overpressure fan PF Fan

M8 Fan motor

FV6 Compressed air regulator FU6 Filter unit to air regulator

P14 Manometer

1 Air supply coupling 2 Hoses

P Coupling to the oil tank unit

C Coupling to the pinionshaft housing

NOTE! The covers on the tank unit must be airtight. Adjust or replace the sealing strips if necessary.

Unit Pa psi

Air pressure in the tank during operation

(59)

59

6.2.2 Air flow

6.2.3 Fan

Check

The fan PF has an air filter FU5 with a replaceable pleated paper element. Inspect the filter element at regular intervals and change it when necessary.

m3/min foot3/min Minimum capacity for air flow at

600 Pa (0.087 psi) pressure 0.3 10.6 C P M8 PF FU5

C Coupling to the pinionshaft housing FU5 Filter

PF Fan M8 Fan motor

(60)

6.2.4 Regulator assembly for compressed air

The regulator assembly includes pressure indicator PI4, a manometer showing the overpressure measured at the entry to the crusher.

Check

The overpressure regulator has an air filter FU6 with a replaceable element. Inspect the filter element at regular intervals and change it when necessary.

C

P PI4 FV6

FU6

C Coupling to the pinionshaft housing FU6 Filter

FV6 Pressure regulator P Coupling to the tank unit PI4 Manometer

(61)

61

This section describes the requirements that must be put on the lubricants used in the crusher and the tank unit.

(62)

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 color 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, see section 8.2 Main lubrication oil exchange. 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 for the tank unit and consult Sandvik SRP AB.

Nevertheless, in extremely low temperatures it can sometimes be advisable to change to a less viscous oil. See section 5.2.3 Operation in low

temperatures.

(Continued)

NOTE! Lubricants which do not meet Sandvik SRP AB’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 Material Safety Data Sheet (MSDS) instructions and safety directions when handling oils and greases.

NOTE! Changing the oil is described in section 5.2 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.

(63)

63

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 SRP AB. At the same time, a change must be made to a lubricating oil with higher viscosity. See section 5.2.2 Operation at elevated temperatures.

7.2 Oil for lubrication system

The oil Sandvik SRP AB recommends must have mild EP additives and must comply with the requirements specified in the table below.

Requirement specification

The oil shall meet the requirements in the table below. Furthermore, it shall contain anti-wear additives as well as additives to prevent oxidation and foaming. The oil must be harmless to copper alloys, as these are used in the crusher’s bearings.

Oil requirements for different operating conditions

Characteristics Operating conditions Testing method

Operation in low

temperatures Normal Operation temperaturesat elevated Operation at extreme temperatures Ambient air

temperature –30 to 0 °C(–22 to 32 °F) –10 to 32 °C(14 to 90 °F) 25 to 40 °C(77 to 104 °F) 35 to 50 °C

a

(95 to 122 °F)

a. With oil that meets these specifications, the crusher may be run in ambient temperatures from +40 to +50 °C, if these temperatures are temporary and exceptional. Also refer to section 5.2.2 Operation at elevated temperatures

Tank temperature (oil to crusher) From 25 °C (From 77 °F) From 35 °C (From 95 °F) From 42 °C (From 131 °F) From 49 °C (From 131 °F) Base oil viscosity at

(cSt) at 40 °C(104 °F) 100 150 220 320 ASTM D-445,DIN EN ISO 3104

Base oil type mineral or PAO

Viscosity index base

oil natural ≥ 95 ASTM D-2270,DIN ISO 2909

Base oil specified weight

kgm3_{at 15 °C (59 °F)}

≥ 870 ≥ 870 ≥ 870 ≥ 880 ASTM D-1298 DIN 51 376

Flash point COC ≥ 200 °C (392 °F) ASTM D-92,

DIN ISO 3016 Lowest pour point ≤ –20 °C (-4 °F) ≤ –15 °C (5 °F) ≤ –10 °C (14 °F) ≤ –5 °C (23 °F) ASTM D-97

Greasability FZG, step ≤ 12 DIN 51 354

Copper corrosion 1A ASTM D-130,

DIN 51 811

Rust test Approved ASTM D-665

Oxidation resistance

(64)

Examples of lubricants

The examples listed below are lubricants which – according to the respective manufacturer – comply with Sandvik SRP AB’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 600XP 150 Texaco Meropa 150 For operation at elevated temperatures:

Klüber Klüberoil GEM 1-220 Statoil LoadWay EP 220 Mobil Mobilgear 600XP 220 Texaco Meropa 220 For operation in low temperatures:

Klüber Klüberoil GEM 1-100 Statoil LoadWay EP 100 Mobil Mobilgear 600XP 100 Texaco Meropa 100

Biologically degradable oil

If a biologically degradable oil is to be used, Sandvik SRP AB recommends that only a 100 % synthetic oil of ester type is selected. If the ambient air temperature is over 32 °C (90 °F), it may still be necessary to reset

temperature switches TS1 and TS2 for “Operation at elevated temperatures” since TS1 could otherwise trip because of excessively high oil temperature and thus stop the crusher, see section 8.1.12 Temperature switches.

Example: Tribol Bio Top 1418/150 (VI > 170)

(65)

65

Oil quantity

When the crusher is running, the oil level must be above the minimum level mark. See the oil level indicator LI1 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 screen 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 temperature switch TS3 are always covered with oil during operation. This is to avoid overheating in the heating elements.

Oil changes

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

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

Capacity

(66)

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 or DIN 51 517-CLP 68.

Requirements for the Hydroset oil

(Continued)

Properties Requirement Test method

Viscosity grade 68 DIN 51 519

Type of base oil mineral or PAO Viscosity - nominal, cSt@

40 °C 68 DIN EN ISO 3104, ASTM D-445

Viscosity index - natural ≥ 95 DIN ISO 2909,

ASTM D-2270 Specific gravity,

kg/m3_{@ 15 °C} ≥ 870

DIN 51 757, ASTM D-1298

Flash point COC, °C ≥ 200 DIN 51 376,

ASTM D-92

Pour point, °C ≤ - 25 DIN ISO 3016,

ASTM D-97

FZG test, load ≥ 12 DIN 51 354

Oxidation stability TOST,

hours ≥ 1 500 DIN EN ISO 4263, ASTM D-943

Corrosion copper 1A DIN 51 811,

ASTM D-130

Rust preventing Pass DIN 51 585,

(67)

67

Examples of oils for Hydroset system

The examples listed below are oils which – according to the respective manufacturer – comply with Sandvik SRP AB’s requirements.

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

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

Mineral oils

Klüber Klüberoil GEM 1-68 Statoil LoadWay EP 68 Mobil Mobilgear 600XP 68 Texaco Meropa 68

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 SRP AB 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

Oil quantity

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 5.2 Changing oil and section 7.2 Oil for lubrication system – Oil changes.

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

Capacity

(68)

7.4 Oil for pinionshaft lubrication

When the crusher is delivered from the factory, the pinionshaft housing is filled with Mobil Mobilgear 600XP 150 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 and Operator´s Manual for the crusher.

(69)

69

This section describes the maintenance and service procedures for the main lubrication and Hydroset systems of the tank unit.

(70)

8.1 Main lubrication system

In the main lubrication circuit, oil is pumped from the tank through the filter FU1 and oil cooler 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.

A - A A

A TI1 PI2 H10 PS2 FU1 L

FU4

LV1

V1 M2

M2 Main lubrication pump and motor

TI1 Temperature indicator, return oil chamber FU1 Main lubrication filter with cartridge PS2 Pressure switch, filter FU1

PI2 Pressure indicator for filter FU1

H10 Warning lamp, high pressure across filter FU1

LV1 Check valve, main lubrication oil to cooler V1 Ball valve, main lubrication oil from tank

(closed position on drawing) FU4 Dirt trap with filter screen