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CH420:01

4. Installation preparations

To ensure maximum safety, always read

section 2. Safety precautions

before

doing any work on the equipment or making any adjustments.

Summary of Contents for CH420:01

Page 1: ...installation manual Doc no S 223 510 SANDVIK CH420 01 ...

Page 2: ...duced 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 223 510 en Issue 20070220 Version 1 Sandvik SRP AB Stationsplan SE 233 81 Svedala Sweden Tel 46 0 40 40 90 00 Fax 46 0 40 40 92 60 www sandvik com ...

Page 3: ...s 2 1 Hazard information 20 2 1 1 Warning signs 20 2 1 2 Risk levels 20 2 1 3 Prohibition signs 20 2 1 4 Mandatory signs 20 2 2 Personnel 21 2 2 1 Personal protection 22 2 3 General safety precautions 22 2 3 1 Machine safety guards 23 2 3 2 Electrical safety 24 2 3 3 Welding 24 2 3 4 Hydraulic system 25 2 3 5 Lifting and moving loads 25 2 3 6 Feed and jams 26 2 4 Emissions 26 2 4 1 Dust 26 2 4 2 N...

Page 4: ... Locking fluid for threaded fasteners 39 4 Installation preparations 4 1 General 42 4 2 Crusher capacity and performance 43 4 3 Installation preparations check list 44 4 3 1 Placement 45 4 3 2 Foundation for a cone crusher 46 4 3 3 Electrical installation 47 4 3 4 Remote control system 47 4 3 5 Process material 47 4 3 6 Dust protection 47 4 3 7 Feed arrangement 48 4 3 8 Discharge arrangement 52 4 ...

Page 5: ...for oil cooler 60 4 4 13 Modified return oil flow switch interlock 61 4 4 14 Insulation of the oil tank 62 4 4 15 Continuous running of the lubrication oil pump 62 4 4 16 A heater in the Hydroset tank 62 5 Transport handling 5 1 Goods data 64 5 1 1 Contents 64 5 1 2 Loading and unloading goods signs 65 5 2 Lifting equipment 65 5 2 1 Overhead gantry or mobile crane 66 5 2 2 Fork lift 67 5 3 Unloadi...

Page 6: ...nk unit 82 6 5 2 Water oil heat exchanger 83 6 5 3 Air oil heat exchanger 84 6 6 Over pressure system 85 6 7 Guards platforms and covers 87 6 7 1 Guards and covers 87 6 7 2 Platforms 87 6 8 Lubricants 87 7 Electrical installation 7 1 General requirements 90 7 2 Overview 90 7 3 Motors and heating elements 91 7 3 1 M1 Crusher motor 91 7 3 2 M2 Lubrication pump 91 7 3 3 M3 Heat exchangers 92 7 3 4 M6...

Page 7: ... checks 99 9 6 Documentation 99 10 Disassembly storage and removal 10 1 Moving and storage 102 10 1 1 Short moves and short term storage 102 10 1 2 Long moves and long term storage 103 10 1 3 Regular inspection during storage 103 10 2 Return to the manufacturer 103 10 3 Disposal 104 Appendix A Installation drawings A 1 General A 2 A 1 1 Mechanical drawings A 2 A 1 2 Electrical drawings A 2 A 1 3 M...

Page 8: ...Table of contents 6 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 ...

Page 9: ...7 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 1 Introduction To ensure maximum safety always read section 2 Safety precautions before doing any work on the equipment or making any adjustments ...

Page 10: ...of Sandvik SRP AB to secure the design and usage for the complete aggregate mining or recycling 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 SE 233 81 Svedala Sweden www sandvik com For maintenanc...

Page 11: ... Sandvik concerning this specific equipment The type number is a designation system that describes the product 1 2 3 4 5 6 7 8 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 9 10 12 13 14 11 CH430 M B M 36 29 32 34 1 Type description 9 Type and size of crusher 10 Crushing chamber concave ring 11 Mantle 12 Filler rin...

Page 12: ...andvik 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 will not take responsibility for this compliance when customers modify any configuration of the cone crusher 21 22 15 16 17 18 19 20 15 Machine type 16 Part number 17 Serial number 18 Mass Kg 19 Order number 2...

Page 13: ...ng technical publications always specify the language and quote the identity and manufacturing numbers from the identification plate Technical publications related to the installation and operation of this equipment are Installation manual IM Wear parts catalog WPC Operator s manual OM Technical publications related to the maintenance of this equipment are Maintenance manual MM Spare parts catalog...

Page 14: ...r 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 6 is the spider bearing 1 that acts as the pivot point for this gyrating motion The mantle 4 is fixed to the mainshaft 6 and the concave ring 3 is fixed to the topshell 2 The gyr...

Page 15: ...raulic 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 Read more in section 9 Preparations for commissioning Auxiliary systems The cone crusher has a circulatory system for lubrication of the main shaft The lubrication system is described in OM section 8 2 setting decrease small...

Page 16: ... crusher intersected view 1 2 4 5 3 6 8 7 10 12 11 13 16 17 18 19 20 15 14 9 1 Spider cap 2 Spider bushing 3 Head nut 4 Mantle 5 Concave ring 6 Mainshaft with head centre 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...

Page 17: ...1 Introduction 15 CH420 01 Sandvik SRP AB Doc no S 223 510 en Ver 1 Cone crusher side view 23 21 22 24 21 Hole for level indicator 22 Inspection door 23 Feed hopper 24 Inspection hatch ...

Page 18: ...Doc no S 223 510 en Ver 1 CH420 01 Tank and auxiliary equipment 25 26 27 28 29 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 30 ...

Page 19: ...1 Introduction 17 CH420 01 Sandvik SRP AB Doc no S 223 510 en Ver 1 This page is intentionally left blank ...

Page 20: ...1 Introduction 18 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 ...

Page 21: ... Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 2 Safety precautions To ensure maximum safety always read this section carefully before carrying out any work on the equipment or making any adjustments ...

Page 22: ...serve 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...

Page 23: ...rk roles are Installation Operation Maintenance Sandvik 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 can provide adequate training for all three work roles and can carry out authorization of trained personnel The technical documentation from Sandvik covers only wo...

Page 24: ... 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 fr...

Page 25: ...ving 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...

Page 26: ...al Sandvik 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 Person...

Page 27: ...ty 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 ke...

Page 28: ...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 bea...

Page 29: ...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 ...

Page 30: ...2 Safety precautions 28 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 This page is intentionally left blank ...

Page 31: ...29 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 3 Technical data ...

Page 32: ...b Material Steel plate Thickness 6 mm 0 24 Height 1000 mm 39 Inner diameter Ø 980 mm 38 Capacity B D 1600 kg m3 100 lb ft3 380 kg 840 lb Topshell Mass 1400 kg 3100 lb Diameter at lower flange Ø 1280 mm 50 Material Cast steel Spider bushing lubrication Grease Spider cap Mass 65 kg 140 lb Securing method Bolts seal with O ring Bottomshell Mass 2360 kg 5200 lb Inner diameter at discharge opening Ø 11...

Page 33: ...c contact Mass of heaviest concave ring 360 kg 800 lb Mainshaft Mainshaft position sensing No Mass 1180 kg 2600 lb Length 1305 mm 51 Eccentric Alternative throws Yes Standard eccentric throws 13 16 18 20 22 25 28 Eccentric speed 395 rpm Balancing Yes Eccentric assembly mass 255 kg 560 lb Eccentric bushing mass 40 kg 88 lb Pinionshaft assembly Pinion mass 10 kg 22 lb Pinionshaft assembly mass 145 k...

Page 34: ...Manufacturer WEG Type HGF Squirrel cage Voltage 220 380 240 420V 50 Hz 250 440 280 480V 60 Hz Phases 3 Frequency 50 60 Hz Power 55 90 kW Speed 1475 rpm 50 Hz 1770 rpm 60 Hz Typical full load efficiency 95 Enclosure TEFC Insulation F Protection IP55 Frame IEC 315 S M Bearing type Anti friction regreasable Lubrication method Grease Mass 800 1000 kg 1760 2200 lb depending on motor size ...

Page 35: ...20 01 Drive belts Manufacturer Rexnord Size 8V SPC Banded belts No No Number of belts 4 4 Standard distance between pulleys c c 1103 mm 43 in 1086 mm 43 50Hz 1027 mm 40 60 Hz Sheave locking devices Taper lock bushing Motor pulley Pulley PCD 18 335 mm Crusher pulley Pulley PCD 16 375 mm 50 Hz 450 mm 60 Hz ...

Page 36: ...ps 1 Lubrication pump motor Type Squirrel cage Power 1 1 kW 50Hz 1 3 kW 60 Hz Speed 700 rpm 50 Hz 840 rpm 60 Hz Voltage 220 380 240 420V 50 Hz 250 440 280 480V 60 Hz Phases 3 Frequency 50 60 Hz Service factor 1 00 Enclosure TEFC Insulation F Protection IP55 Frame IEC 132 Main oil filter Number of oil filters 1 Blocked filter sensor Differential pressure sensor Oil heater Type Electrical immersion ...

Page 37: ...1088 psi Hydroset pump Type Reversible gear pump Number of pumps 1 Capacity 4 3 l min 50Hz 5 1 l min 60Hz Hydroset pump motor Type Squirrel cage Motor power 1 1 kW 50 Hz 1 3 kW 60 Hz Motor speed 950 rpm 50 Hz 1175 rpm 60 Hz Voltage 220 380 240 420V 50 Hz 250 440 280 480V 60 Hz Phases 3 Frequency 50 60 Hz Service factor 1 00 Enclosure TEFC Insulation F Protection IP55 Frame IEC 71 Oil filter Number...

Page 38: ... Oil temperature detector Yes Oil pressure drop 0 29 MPa 42 psi Oil flow 33 l min Water flow 25 35 l min Water temperature 30 C 86 F Max water feed pressure 3 0 MPa 435 psi Characteristics CH420 01 Number of oil air heat exchangers 1 Material Aluminium Oil pressure drop 0 31 kPa 4 5 psi Motor power 1 5 kW 50 Hz 1 7 kW 60 Hz Motor speed 950 rpm 50Hz 1175 rpm 60 Hz Max air flow 4650 m3 h 2700 ft3 mi...

Page 39: ...er pressure blower or compressed air system Air quality Filtered Air flow 0 3 m3 h 0 18 ft3 min Air pressure 0 6 1 kPa 0 09 0 15 psi Characteristics CH420 01 Motor power 0 37 kW 50 Hz 0 43 kW 60 Hz Voltage 220 380 240 420V 50 Hz 250 440 280 480V 60 Hz Phases 3 Frequency 50 60 Hz Speed 2800 rpm 50 Hz 3350 rpm 60 Hz Enclosure TEFC Insulation F Protection IP55 Frame size IEC 71 ...

Page 40: ...sher s setting and the feed material s bulk density crushability size analysis moisture content etc Consult Sandvik regarding application of the crusher Characteristics CH420 01 Primer Type Zinc phosphate Procedure Spray painting Thickness 40 µm Second coating Type Alkyd enamel Procedure Spray painting Thickness 40 µm Characteristics CH420 01 Maximum feed size 18 130 mm 0 7 5 1 Closed Side Setting...

Page 41: ...l come across the recommendation to use locking fluid Unless otherwise stated this normally means using Loctite 243 or an equivalent Use Loctite 577 or an equivalent to seal pipe threads in the lubrication system where no other sealing is used For pipes up to 3 4 in size and in the Hydroset system use Loctite 543 or an equivalent When a previously used screw is to be reinstalled it is important to...

Page 42: ...3 Technical data 40 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 This page is intentionally left blank ...

Page 43: ...ndvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 4 Installation preparations To ensure maximum safety always read section 2 Safety precautions before doing any work on the equipment or making any adjustments ...

Page 44: ... the cone crusher meets the local legislation demands In case of doubt consult the local authorities or local authorized personnel Prepare the installation site as much as possible by installing electricity and water supply foundation etc before starting the main installation Use the check list in section 4 3 Installation preparations check list as a guide when carrying out and documenting the ins...

Page 45: ... of crushing chamber Choice of eccentric throw Feed size distribution and particle top size Feed rate Discharge system capacity Screening capacity Automation controls The following factors will lower capacity and performance Adhesive or moist process material in feed Excessive amount of fines in feed 20 of process material smaller than CSS value Very tough process materials Uneven distribution in ...

Page 46: ...drive belts Foundation Foundation constructed according to drawings Electrical system All necessary cables to the cone crusher arranged Length of cables All necessary switchgear installed All necessary connections to plant control system arranged Electrical power available Process material Process material tested by Sandvik Dust protection Dust protection complies with local regulations Feed arran...

Page 47: ...cess to a lifting device meeting the requirements in section 5 Transport handling Note the available type of lifting device in the check list Consider additional clearance for the feed and discharge arrangements See section 4 3 7 Feed arrangement and section 4 3 8 Discharge arrangement Make sure that the drive motor can be correctly positioned and aligned Lubrication and Hydroset system Place the ...

Page 48: ...tall the crusher on anti vibration compression mountings For more information on the foundation see section 6 2 Foundation Steel supporting structure A steel supporting structure or transportable frame must be level and resting on a firm foundation or it will vibrate and be subjected to abnormal stresses WARNING Risk of crushing There is a risk of crushing when the machine is running especially wh...

Page 49: ... system At most sites a main control system is used to control the process Make sure that the control system is prepared for the addition of the cone crusher 4 3 5 Process material Process material wears the cone crusher and adjacent equipment in varying ways Sandvik recommends the prior testing of the quality of the material that is to be processed Sandvik can assist with such testing 4 3 6 Dust ...

Page 50: ...n ultrasonic level monitor in the feed hopper to stop the feed if the material is too high or too low Another method is to use a variable speed drive to maintain a constant material level in the feed hopper install a screen ahead of the cone crusher to remove fine material before crushing This increases the performance and capacity of the crusher install a magnet ahead of the cone crusher to remov...

Page 51: ...gles to the feeder or conveyor If a splitter is not used it is important to optimize the feed arrangement as far as possible This can be accomplished with a feed box above the feed hopper as shown below The feed box must be designed in such a way that it can be moved longitudinally to correctly guide the material Feed hopper with cone Feed hopper with distributor splitter Feed from a belt conveyor...

Page 52: ...evenly around the crushing chamber For installation dimensions of the splitter and the feed hopper see the installation drawing in appendix A Installation drawings The material must be led into the splitter through the area outlined by a red dashed line in the drawing below This area can be adjusted by slackening off the screws between the distributors and the supporting angle profile across the f...

Page 53: ...height and speed of the material particularly important with EC or C crushing chambers that are fed with relatively coarse material The feed box also reduces segregation With an EC or C crushing chamber the mass and dimensions of the larger feed lumps will be greater than with finer crushing chambers Design the feed box accordingly When processing coarse material keep the level of material in the ...

Page 54: ... a discharge conveyor stops the feed arrangement must also stop to allow the process material to pass out from the crusher The discharge arrangement must have an inspection door for cleaning and inspection The Hydroset cylinder must be easily accessible A ledge or shelf inside the discharge compartment will absorb the impact of the material falling onto the discharge conveyor Chutes should have a ...

Page 55: ...and maintenance The supply from Sandvik does not include platforms and guard rails The floor of the platform should be solid not wire mesh to avoid the risk of tools or equipment falling from the platform Use kicking boards and wire mesh on the sides under the handrails for the same reason Platforms must not be attached to the cone crusher because of its constant vibration and movement WARNING Fly...

Page 56: ...ry Part numbers for ordering the modification kits are listed under the respective methods Heating cables on oil lines Additional oil heaters Diesel heating system Thermostatic valve to bypass the oil cooler Heater in the Hydroset oil tank Heating in the component section of the oil tank unit Synthetic oils Mineral oil for the winter season Blanking off the oil cooler radiator Two speed fan motor ...

Page 57: ...tor core Blank off the radiator completely or partially Start with 50 blanked off Alternatively fit a 2 speed motor to the cooling fan Has oil overflowed over the dust collar During long periods with very low temperatures the crusher should be heated during the night to avoid excessive cool ing Position a fan heater beneath the crusher and cover the feed opening In addition the lubrica tion oil pu...

Page 58: ...all extra heaters Installation is easiest if this equipment is ordered together with a new crusher but extra heaters can also be fitted in the tanks of older crushers 4 4 5 Diesel heating system In plants without 24 hour electrical power a timer controlled diesel heating system can be used The system starts heating the oil up to three hours before electrical power is available The tank unit is pre...

Page 59: ... line before installing heating cables If the oil lines are 50 mm in diameter or if the oil should be heated to a temperature 50ºC above the ambient temperature the heating cable can be led backwards and forwards on the same line Heating cables are in many countries considered as high voltage equipment and must therefore be installed by an authorized electrician The heating cable can be purchased ...

Page 60: ...e Empty the crusher and oil tank carefully before refilling with synthetic oil To reduce the risk of dilution of a synthetic lubricating oil the Hydroset oil should also be synthetic A grade with a viscosity down to 30 cSt at 40 C can be selected for the Hydroset system CAUTION It must be possible to mix the lubricating and Hydroset oils used in the crusher Consult the oil supplier if in doubt The...

Page 61: ...hanger completely At oil temperatures 35ºC oil flow is gradually shifted from port 2 to port 3 which is connected to the heat exchanger s inlet manifold At oil temperature 45ºC port 2 and the bypass line are closed and the oil flows only through port 3 and the heat exchanger Thermostat and mounting kit The thermostatic valve is mounted on the air oil heat exchanger NOTE through At low temperature ...

Page 62: ... of blanking depends on the ambient temperature and must be determined by trial and error 4 4 12 2 speed fan motor for oil cooler Another way to reduce the air flow through the radiator is to use a two speed motor on the cooling fan The speed of the cooling fan is determined by the oil temperature in the return line Examples of switching points with ISO VG 150 oil Return oil temperature Cooling fa...

Page 63: ...switch OG1 is now bypassed and the crusher can be started even if no oil is detected in the return line c When Timer 2 expires the by pass is removed If oil has reached the return oil flow switch the crusher drive motor will continue to run Otherwise the drive motor will stop The components needed for interlock bypass can be obtained from Sandvik Installation can be carried out by a local electric...

Page 64: ... will prevent the oil from solidifying in the lines and crusher Leave the oil tank heaters switched on Cover the crusher s feed opening to prevent excessive cooling by cold air passing through the crusher chamber 4 4 16 A heater in the Hydroset tank The Hydroset oil is normally heated indirectly by the lubricating oil At very low ambient temperatures it may be necessary to also install a heating e...

Page 65: ...3 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 5 Transport handling To ensure maximum safety always read section 2 Safety precautions before doing any work on the equipment or making any adjustments ...

Page 66: ...tents A packing list is attached to one of the packages in the delivery Part name Mass kg lb Measurements L W H mm inch Cone crusher 5600 12300 2100 1550 2150 83 61 85 Tank unit 450 990 1450 1050 1070 57 41 42 Feed hopper 160 350 1200 1200 700 47 47 27 Tool box 400 880 1170 1170 920 46 46 36 NOTE If the crusher is collected from the factory check before transport that the equipment corresponds wit...

Page 67: ... crane fork lift Equipment specifications Make sure that the lifting capacities of the equipment and tackle meet the requirements in the following table Use the forks here Overhead lifting point Center of gravity Lifting point for chain NOTE The lifting capacity of a mobile crane varies with the lifting radius Make sure that the lifting capacity is sufficient at the appropriate lifting radius Equi...

Page 68: ...n 5 1 2 Loading and unloading goods signs f Check that the load lies against the saddles of the hooks Never put load on the tip of a hook g Slowly take up the slack in the lifting chains Make sure that the hooks are secure in the lifting eyes of the component If necessary adjust the chains to distribute the load evenly h Check that the chains can straighten out correctly Never lift with a twisted ...

Page 69: ...rmly attached to the transport platform d If the transport platform is fitted with fork tubes manoeuvre the forks inside these to lift the component e Before lifting make sure that the destination is clear and able to support the load f Lift move and lower the load carefully and calmly WARNING Hanging load Keep clear of hanging loads See section 2 Safety precautions Make sure that the SWL Safe Wor...

Page 70: ...kages before unloading Report any damage immediately to the person responsible for the installation If the damage is severe enough to prevent installation submit a damage claim to the transport company without delay If possible document the damage with a camera Minimum recommended unpacking area L W H CH420 3 3 3 m 10 10 12 ft NOTE If damage has occurred during transport report this immediately al...

Page 71: ...und When lifting follow the instructions in section 5 2 Lifting equipment 5 4 1 Moving a Attach the lifting equipment according to the instructions in section 5 2 Lifting equipment b Lift the component only enough to clear the floor c Make sure that the component remains stable on the lifting equipment d Move the load into position and lower it gently to the floor Leave enough room for access to a...

Page 72: ... If the ground floor is uneven place blocks or plates under the components to provide a steady support d Make sure that the components are stable before removing the lifting equipment WARNING Hanging load Keep clear of hanging loads See section 2 Safety precautions Make sure that the SWL Safe Work Load of the lifting equipment is sufficient for the weight to be lifted Characteristic Value Notes Mi...

Page 73: ...of goods d Open the tool box and remove the documentation e Locate the packing list f Check that the data on the cone crusher and tank unit identification plates correspond with the packing list See section 1 1 Equipment information g Move spare and wear parts to the spare part store h Dispose of the packaging material according to the instructions in section 5 6 Disposal return of packaging mater...

Page 74: ... is a special agreement for the return of the packaging to the manufacturer If the packaging must be returned prepare an area to store pallets transport racks and any other returnable packaging Check if there is a special arrangement for recycling packaging material If the packaging is not to be returned or recycled check with the local authorities how to separate and dispose of packaging material...

Page 75: ...RP AB Doc no S 223 510 en Ver 1 CH420 01 6 Mechanical installation and connections To ensure maximum safety always read section 2 Safety precautions before doing any work on the equipment or making any adjustments ...

Page 76: ...see appendix A Installation drawings If any adjacent machines on the site cannot be stopped take measures to prevent accidental contact c Make sure that the lighting on the installation site is adequate Use additional portable lights if necessary Lifting equipment tools and materials The equipment used for lifting and moving the crusher components can also be used for unpacking and installing the ...

Page 77: ...on is not sufficiently stable the supporting structure will vibrate and be subjected to abnormal stresses See also section 4 3 2 Foundation for a cone crusher and section 4 3 8 Discharge arrangement For general information on placement see section 4 3 1 Placement NOTE Make sure that the crusher s mounting points are level Maximum deviation at load application point should be 1 mm NOTE The drive mo...

Page 78: ...there is enough room for the crusher s horizontal movement See appendix A Installation drawings NOTE The crusher can be mounted directly on the foundation with foundation bolts Dynamic loads will then be much higher Foundation bolts are not supplied by Sandvik 1 2 3 9 6 8 7 6 5 4 7 5 6 4 5 6 1 Locking nut 2 Washer 3 Upper fixing plate 4 Rubber compression mounting 5 Screw 6 Washer 7 Lower fixing p...

Page 79: ... 1 thick b Make sure that the mounting points are level and properly grouted Use shims to level Max deviation at load application point 1 mm c Carefully clean any dust and oil from the area beneath the crusher d Install the rubber dampers on the crusher s feet Make sure that the lower fixing plates 7 are attached to the dampers Continued WARNING Hanging load Keep clear of hanging loads See section...

Page 80: ...s g Remove the screws 5 and washers 6 from the upper fixing plates 3 h Lift the crusher away from the rubber dampers i Weld all around the lower fixing plates 7 to the anchor plates See drawing in appendix A Installation drawings j Lower the crusher onto the rubber dampers k Fit the washers 6 and screws 5 NOTE Make sure that the crusher is centered over the discharge opening and that the pinionsha...

Page 81: ...pers d Lower the crusher until the lower fixing plates 7 are resting on the supporting structure e Center the crusher over the discharge opening f Spot weld the lower fixing plates 7 to the supporting structure g Remove the screws 5 and washers 6 from the upper fixing plates 3 h Lift the crusher away from the rubber dampers i Weld all around the lower fixing plates 7 to the supporting structure Se...

Page 82: ...the screws 2 washers 4 5 and nuts 3 When installing a feed hopper with cone the spider arms must be aligned with the feeder or conveyor When installing a feed hopper with distributor splitter the spider arms must be at right angles to the feeder or conveyor 1 2 3 4 5 Feed hopper on topshell 1 Feed hopper 2 Screw 3 Nut 4 Washer 5 Washer Feed hopper with cone Feed hopper with distributor splitter ...

Page 83: ...ame path The inclination of return lines is critical See section 6 5 1 Oil tank unit For a description of hoses pipes and connections on the tank unit and crusher see appendix A 1 3 Mechanical connections NOTE Hoses and pipes are not supplied by Sandvik NOTE When starting the crusher for the first time make sure there are no leakages If there are leakages use a suitable compound to seal ...

Page 84: ...re that the piping is free from burrs metal shavings and dirt before it is connected to the crusher and tank unit Use normal water piping and hoses for lubrication oil lines Use high pressure piping and hoses for Hydroset oil lines WARNING Hanging load Keep clear of hanging loads See section 2 Safety precautions The oil tank unit weighs approximately 310 kg 680 lb Make sure that the SWL Safe Work ...

Page 85: ...uit local conditions c Connect the piping or hoses to the tank unit d Set the thermostatic valve TG2 to 3 on the scale initially NOTE Pipes and pipe fittings are not supplied by Sandvik NOTE Use clean fresh water If only contaminated water is available contact Sandvik first NOTE If a water oil heat exchanger is used thermostats should be set at the values for Normal Operating Conditions regardless...

Page 86: ...exchanger If the ambient air contains a lot of dust it is advisable to lead fresh air to the heat exchanger through a duct from a dust free place The duct must be correctly dimensioned so that air flow is not restricted and it must not be rigidly connected to the heat exchanger To reduce the amount of dust which settles in the radiator matrix the air oil heat exchanger is best placed so that the f...

Page 87: ...e crusher a The blower 1 can be mounted horizontally or vertically If a regulator assembly 2 is used it must be installed horizontally b When connecting the blower motor make sure that the direction of rotation corresponds to the arrow on the blower housing If the direction of rotation is incorrect the output of the blower will be insufficient c Measure the hose lengths required and cut the approp...

Page 88: ...6 Mechanical installation and connections 86 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 4 1 3 5 2 6 1 Blower 2 Regulator 3 Hose 4 T connection on crusher 5 Hose 6 Over pressure coupling on tank ...

Page 89: ... guards and covers to protect the personnel See section 4 3 9 Guards for further information 6 7 2 Platforms Sandvik recommends installing platforms at least 50 mm away from the crusher When the crusher is mounted on rubber compression mountings there is a risk of pinching between the oscillating parts of the crusher and the stationary structure See section 4 3 10 Platforms and guard rails for fur...

Page 90: ...6 Mechanical installation and connections 88 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 This page is intentionally left blank ...

Page 91: ...andvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 7 Electrical installation To ensure maximum safety always read section 2 Safety precautions before doing any work on the equipment or making any adjustments ...

Page 92: ...om drawings and cable lists and knowledge of local safety regulations regarding power and automation circuits Work with electrical equipment must be performed only by skilled or instructed technicians See section 2 2 Personnel for further information 7 2 Overview The purpose of the electrical system is to power the crusher with its auxiliary systems and to control the operation of the cone crusher...

Page 93: ...iate switchgear cabinet The main drive motor of the crusher can be started in several different ways depending on the power supply available Direct on line starter Electronic soft starter Starting and stopping can be made possible either by buttons or via software 7 3 2 M2 Lubrication pump The power supply to the motor must incorporate the necessary fuse relay and motor protector all installed in ...

Page 94: ...c valve The temperature is controlled by a thermostatic valve TG2 See OM 8 4 Water oil heat exchanger 7 3 4 M6 Hydroset pump Starting and control equipment for the Hydroset pump is normally delivered by Sandvik The delivered electrical cabinet L3 contains fuses relays and motor protection for operation of the Hydroset pump 7 3 5 E7 Oil heaters The power supply to the oil heaters must incorporate t...

Page 95: ...ndvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 8 Final installation checks To ensure maximum safety always read section 2 Safety precautions before doing any work on the equipment or making any adjustments ...

Page 96: ...g structure 3 The discharge system is sufficient and connected positioned 4 The feed arrangement is connected positioned 5 The drive arrangement has been correctly installed 6 All transport and packing materials have been removed from the parts No Checks Done 1 The brand names and types of oil and grease are recorded 2 The oil tank unit is properly installed and correctly positioned in relation to...

Page 97: ...with the power on a Locate the pressure drop sensor PG2 2 b Remove the clip on top of the indicator 2 c Remove the indicator 2 by pulling straight up from the oil filter assembly 3 d Turn the indicator 2 upside down and position the indicator back on the tube The pressure drop lamp 1 on the panel will lit if the indicator works e Turn the indicator 2 back to its normal position f Fit the clip on t...

Page 98: ...8 4 Start up No Checks Done 1 All accessible moving parts are correctly protected by guards 2 All Emergency stop buttons engage and release correctly 3 All threaded fasteners have been tightened to the correct torque No Checks Done 1 Prepare the cone crusher for production See OM for further details ...

Page 99: ...vik SRP AB Doc no S 223 510 en Ver 1 CH420 01 9 Preparations for commissioning To ensure maximum safety always read section 2 Safety precautions before doing any work on the equipment or making any adjustments ...

Page 100: ... Checks Done 1 The data on the machine identification plate corresponds with the machine specification document 2 The ordered wear and spare parts have been delivered and deposited in the spare part store 3 All the documents correspond to the specific cone crusher Operator s manual Installation drawings Factory acceptance test report Machine specification document Machine deviation report if relev...

Page 101: ...ed by this manual is now complete No Checks Done 1 No unusual noises which could indicate misaligned parts or faults 2 Hydroset pressure within limits 4 Oil heating elements operate correctly 5 Return lubrication oil temperature within limits 6 Over pressure dust exclusion system functions correctly 7 No contact between oscillating crusher and stationary structure No Checks Done 1 The cone crusher...

Page 102: ...9 Preparations for commissioning 100 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 This page is intentionally left blank ...

Page 103: ... SRP AB Doc no S 223 510 en Ver 1 CH420 01 10 Disassembly storage and removal To ensure maximum safety always read section 2 Safety precautions before doing any work on the equipment or making any adjustments 106 ...

Page 104: ...ne crusher and on the oil tank unit f Prepare a storage area large enough to store the components with at least 1 m 3 ft of free space around and above them for access and ventilation Make sure that the storage area environment meets the conditions in the table below g Disassemble the cone crusher to the extent necessary for the planned transport storage See IM and MM for information on how to dis...

Page 105: ...g with grease to prevent condensation on bearing surfaces f Coat the exposed part of the mainshaft sleeve between the spider and the head nut with grease Make sure that this area is protected from contamination g Fill the oil pumps with oil 10 1 3 Regular inspection during storage The following checks should be carried out every two weeks during the storage period Inspect the cone crusher and oil ...

Page 106: ...onze bushings and bearing components Rubber Nylon and other plastics Lubrication and water hoses Electrical cables Electrical components Pumps and motors Oil filters Lubricants c Recycle or dispose of all material and components in compliance with local regulations WARNING Toxic gases When dismantling and scrapping the crusher it can be necessary to cut the parts This process can create toxic gase...

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Page 108: ...10 Disassembly storage and removal 106 Sandvik SRP AB Doc no S 223 510 en Ver 1 CH420 01 This page is intentionally left blank ...

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SANDVIK CH420:01, Installation Manual

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