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Installation Manual

Doc. No. S 223.855.en

Tank unit

SANDVIK CTHS430:02

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SANDVIK CTHS430:02
Tank unit
© Copyright 2012 Sandvik SRP AB. All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints. Document number: S 223.855.en Original instructions Issue: 20120827 Version: 01 Document type: Installation Manual (IM)

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

IM Sandvik CTHS430:02 Tank unit

1. Introduction
1.1 Equipment information.......................................................... 8 1.1.1 Document information............................................ 10 1.2 Operating principles............................................................ 11 1.2.1 Lubrication system ................................................. 11 1.2.2 Description ............................................................. 11

2. Safety precautions
2.1 Hazard information ............................................................. 2.1.1 Warning signs ....................................................... 2.1.2 Risk levels.............................................................. 2.1.3 Prohibition signs..................................................... 2.1.4 Mandatory signs..................................................... 2.1.5 Personnel............................................................... 2.1.6 Personal protection ................................................ 2.2 General safety precautions................................................. 2.2.1 Machine safety guards........................................... 2.2.2 Machine access ..................................................... 2.2.3 Electrical safety...................................................... 2.2.4 Welding .................................................................. 2.2.5 Hydraulic system.................................................... 2.2.6 Lubrication system ................................................. 2.2.7 Lubricants and waste lubricants............................. 2.2.8 Diesel oil, white spirit and other cleaning agents ... 2.2.9 Lifting and moving loads ........................................ 2.3 Emissions ........................................................................... 14 14 15 15 15 16 17 18 19 19 20 20 21 22 23 23 24 24

© 2012 Sandvik SRP AB

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IM Sandvik CTHS430:02 Tank unit

3. Installation preparations
3.1 General ............................................................................... 3.2 Installation preparations check list ...................................... 3.3 Placement ........................................................................... 3.3.1 Electrical installation............................................... 3.3.2 Remote control system .......................................... 3.3.3 Guard ..................................................................... 3.4 Operating in low temperatures............................................ 3.4.1 Measures for easier starting and running in cold climate ........................................................ 3.4.2 Low temperature problems – symptoms and remedies ..................................... 3.4.3 Heater set - cold climate ........................................ 3.4.4 Diesel heating system ............................................ 3.4.5 Heating cables on oil lines ..................................... 3.4.6 Heating in the component section of the oil tank unit ................................................... 3.4.7 Synthetic oils .......................................................... 3.4.8 Mineral oil for the winter season ............................ 3.4.9 Blanking off the oil cooler radiator .......................... 3.4.10 Frequency converter .............................................. 3.4.11 Two-speed fan motor for oil cooler ......................... 3.4.12 Insulation of the oil tank ......................................... 3.4.13 Continuous running of the lubrication oil pump ...... 26 27 28 29 29 29 30 30 31 32 33 33 34 34 35 36 36 36 37 37

4. Transport handling
4.1 Goods data ......................................................................... 4.1.1 Contents ................................................................. 4.1.2 Loading and unloading goods signs....................... 4.2 Lifting equipment................................................................. 4.2.1 Overhead gantry or mobile crane........................... 4.2.2 Using a fork lift (only for goods on pallet) ............... 40 40 41 42 43 44

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.....3.....................................................................................................................4.............................. 6......1 M2 – Main lubrication pump.................2 Inspection of goods.....................................2 Air/oil cooler ........................................................6 Disposal/return of packaging material ...... Hoses and pipes – General ................3 Unloading the goods............................ 4.................................................... Foundation...............................3 5............................... 4........................ 6..................3...................................................... 6....................3 Motors and heating elements ..4.......................855.. 4........................................................ 5............. 6...3 M6 – Hydroset pump.....................1 Moving ......1 5...................................................IM Sandvik CTHS430:02 Tank unit 4.......................... 5.............3...........................................................en-01 5 .....................2 Overview......................4................ 6.....................5 Overpressure system...........3........... 4..4 Connection boxes ...5 Unpacking the goods ........................................................................ Electrical installation 6..........................................3....3 Water/oil cooler (option) ....................................................... 5..................... 5...........1 Unpacking area.........1 Oil tank unit ....... 6.4 E7 – Oil heaters ............2 5............... 4......................3............4.....................4 General requirements .................. 5..2 Storage.. 45 45 45 46 46 46 48 49 5.... Hydroset and lubrication systems. 6...............4................................................4 Moving and Storage................... 4. 62 62 63 63 63 63 63 63 64 © 2012 Sandvik SRP AB S 223.................. 52 53 53 54 54 56 57 58 60 6......5 M8 – Overpressure fan ............2 M3 – Oil cooler fan motor.............................. Mechanical installation and connections 5......6 Lubricants .1 General requirements ................. 4..... 6...........3......

...............en-01 © 2012 Sandvik SRP AB .....1.1 Moving and storage ..6 Documentation................................................................................1.....1 8.1 Lubrication system and Hydroset checks........ 9......855.....4 Start-up ..............4 General ..... storage and removal 9...................................... Supply value checks . 8..................................................5 Health and safety checks..... 66 66 66 67 68 68 8..IM Sandvik CTHS430:02 Tank unit 7...1 Preparation.. 7................................ Presence and correctness checks ...3 Disposal ...... 9............................................... 7.................................2 8............. 70 70 70 71 71 71 71 9...........................................2.. 9.................... 8........................................1 Installation and connection checks ..................... 8... 7...................3 Regular inspection during storage .................................2 Return to the manufacturer ................................. 74 74 75 76 76 77 6 S 223..................................3 8.... Final installation checks 7. 9....... Function checks .....1..... 9.......................................................1...............................2 Electrical checks .......................1 Check the pressure switch PS2 ....... Preparations for commissioning 8...................2 Long moves and long-term storage ......1 Short moves and short-term storage..................................................... Disassembly.................................................. 7............. 7....................................................................................3 Safety checks...........4...

Safety precautions before carrying out any work on the equipment or making any adjustments. IM Sandvik CTHS430:02 Tank unit 7 . Introduction To ensure maximum safety. always read section 2.1.

This crusher component has been exclusively designed for this application.1 Equipment information Purpose The purpose of this Sandvik equipment is to be an oil tank component in a crushing and screening unit or site within an aggregate or mining process. Introduction 1. Sandvik will not accept any liability for damage to equipment or injury to personnel caused by unauthorized or improper use or modification of this equipment.855. Manufacturer This Sandvik equipment has been manufactured by: Sandvik SRP AB SE-233 81 Svedala Sweden www.IM Sandvik CTHS430:02 Tank unit 1.com For maintenance Contact the nearest Sandvik company. It is not the responsibility of Sandvik secure the design and usage for the complete aggregate.en-01 © 2012 Sandvik SRP AB .sandvik. mining. 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 8 S 223. or recycling process. agent or representative.

Sandvik will not take responsibility for this compliance when customers modify any configuration of the oil tank unit. Introduction Identification The figure below shows the location and an example of the tank unit’s identification plate. V10 8 1 2 7 3 1 2 3 4 Machine type Serial number/PCR Local manufacturer number Mass (kg) 4 5 6 7 8 5 6 Order number Manufacturer Maximum operating speed Year of manufacture CE marking This equipment complies with the basic health.855. © 2012 Sandvik SRP AB S 223. environment and safety regulations of the European Union and European Economic Area. The identification plate contains data needed when contacting Sandvik concerning this specific equipment.IM Sandvik CTHS430:02 Tank unit 1.en-01 9 .

IM Sandvik CTHS430:02 Tank unit 1.1.Operator’s and Maintenance Manual • SPC .Spare Parts Catalog Read more about the document structure and accompanying work categories in section 2. Technical Publications Technical publications related to the installation of this equipment are: • IM .1 Document information Purpose of this Installation Manual The purpose of this manual is to provide the installation personnel with information on how to safely install this Sandvik equipment.srp@sandvik. Introduction 1.com 10 S 223.5 Personnel. 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.Installation Manual Appendix Technical publications related to the operation and maintenance of this equipment are: • OMM .1.Installation Manual • IMA .en-01 © 2012 Sandvik SRP AB . Feedback If you have comments on this manual or problems connected to the documentation. 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. send an e-mail to: manuals.855.

855. Moving the Hydroset piston up and down will change the discharge setting and the size of the crushed material.2 Description The following figure shows an overview of the oil tank unit’s nomenclature and components.2. Setting adjustment To control fragment size and to compensate for wear the crusher has a setting control system. Introduction 1. The main lubrication system is described in Operator’s and Maintenance Manual for the tank unit.en-01 11 . It basically consists of a robust hydraulic jack which supports the mainshaft and adjusts its position. 1.1 Lubrication system There are two separate lubrication systems – the circulatory main lubrication system and the pinionshaft oil bath lubrication. The pinionshaft lubrication is described in the Operator’s manual for the crusher.IM Sandvik CTHS430:02 Tank unit 1.2.2 Operating principles 1. 3 2 1 4 5 1 2 3 Oil tank unit Overpressure fan Overpressure air regulator (option) 4 5 Air/oil cooler Water/oil cooler (option) © 2012 Sandvik SRP AB S 223. called the Hydroset system.

Introduction This page is intentionally left blank 12 S 223.855.en-01 © 2012 Sandvik SRP AB .IM Sandvik CTHS430:02 Tank unit 1.

Safety precautions To ensure maximum safety. always read this section carefully before operating. IM Sandvik CTHS430:02 Tank unit 13 .2. carrying out any work on the equipment or making any adjustments.

855.1.1 Hazard information 2.en-01 © 2012 Sandvik SRP AB .IM Sandvik CTHS430:02 Tank unit 2. Safety precautions 2.1 Warning signs General danger Dangerous voltage Risk of crushing Hanging load Skid risk Flying fragments Rotating fan Irritant Hot surface 14 S 223.

en-01 15 . risk levels are indicated with “DANGER”.1. see section 2. Safety precautions 2.4 Mandatory signs Disconnect current Read the manual © 2012 Sandvik SRP AB S 223.855.1.2 Risk levels Throughout the manual. or destruction of. “WARNING” or “CAUTION”.IM Sandvik CTHS430:02 Tank unit 2. Failure to observe information marked “DANGER!” can result in lifethreatening injuries! DANGER! Failure to observe information marked “WARNING!” can result in personal injury and/or serious damage to.1. The “DANGER” and “WARNING” levels are accompanied by a warning sign.1.1 Warning signs.3 Prohibition signs Do not remove guards 2. equipment! WARNING! CAUTION! Failure to observe information marked “CAUTION!” can result in minor personal injury and/or damage to equipment! 2.

16 S 223.IM Sandvik CTHS430:02 Tank unit 2. 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.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. contact Sandvik SRP AB for further information. Safety precautions 2. 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.en-01 © 2012 Sandvik SRP AB .1.855. 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.

Sandvik SRP AB strongly recommends to use a safety harness when working above. Safety precautions 2.6 Personal protection Sandvik SRP AB strongly recommends that personal protective equipment is always worn when working in the vicinity of the equipment.855. The Sandvik SRP AB recommendation for personal protective equipment includes: Ear protection Safety helmet Eye protection Protective gloves Safety boots Mask or respirator © 2012 Sandvik SRP AB S 223.IM Sandvik CTHS430:02 Tank unit 2.1.en-01 17 . inside or under the equipment.

CAUTION! Sharp edges can appear on the equipment due to wear. Also ensure that it is not possible for anyone else to switch the power on while maintenance work is carried out.855. Avoid staying on the equipment. to prevent stones from falling down. please consider sharp edges when handling worn parts. 18 S 223. Remove any sharp edges. Safety precautions 2.en-01 © 2012 Sandvik SRP AB .2 General safety precautions Falling stones Clear the feed arrangement and the crusher thoroughly from process material before any maintenance work is carried out inside or below the crusher. unless necessary for maintenance work.IM Sandvik CTHS430:02 Tank unit 2. WARNING! Always switch the power off and lock out the equipment (so that it cannot inadvertently be switched on) before any maintenance work is started.

stairs and ladders must be designed in accordance with applicable regulations. contact Sandvik SRP AB. 2. Sandvik SRP AB also recommends additional protection. WARNING! Make sure all defective guards are checked. Provide adequate guards and warning signs at appropriate places around the danger zone.2 Machine access Every machine requires access for personnel who carry out inspections and/ or maintenance work. Only operate the equipment when all PROHIBITION! guards are mounted. repaired and replaced before starting the equipment.IM Sandvik CTHS430:02 Tank unit 2. fans etc.en-01 19 . to prevent exposure to rotating parts. Rotating parts Exposure to rotating parts (pumps.2. WARNING! Flying fragments Ejected fragments can fall down in the vicinity of the equipment. Safety precautions 2. © 2012 Sandvik SRP AB S 223.855. Walkways. For advice. These parts are not included in the tank unit’s standard specification.) must be prevented by guards.1 Machine safety guards Do not remove guards Make sure that all guards are in place and functioning. Suitable access platforms and guard rails must be installed. Always attach the guards after maintenance work.2.

2. Dangerous voltage Personnel must regard all electrical equipment as live until it is proven dead by proper testing procedures. DANGER! 20 S 223. Risk of fire and explosion Due to the risk of leakage.IM Sandvik CTHS430:02 Tank unit 2.en-01 © 2012 Sandvik SRP AB .4 Welding CAUTION! Never weld the tank unit or parts attached to it. Safety precautions 2. DANGER! Make sure all broken or damaged electrical cables and connectors are checked.855.3 Electrical safety CAUTION! Only personnel working according to European Standard EN 50110 or equivalent are permitted to perform electrical operations on the equipment. 2. 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.2. repaired and replaced before starting the equipment. Control cabinets must be lockable.

IM Sandvik CTHS430:02 Tank unit 2. WARNING! Skid risk When filling. Allow the oil to cool before working on the hydraulic system. Always wear protective gloves. WARNING! Hot surface Equipment and hoses/pipes containing hydraulic oil can have hot surfaces. Make sure all defective hoses. Hot oil Hydraulic oil can become very hot during operation. Never adjust pressure relief valves beyond the recommended values.2.855. Safety precautions 2. valves or fittings are checked.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). controlling or changing oil there is a risk of spillage that can cause a slippery surface. repaired and replaced before starting the equipment. Always remove oil spillage and stains to avoid skid risk. WARNING! CAUTION! WARNING! CAUTION! © 2012 Sandvik SRP AB S 223. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system. Oil pressure Pressurized oil is dangerous if released incorrectly.en-01 21 .

valves or fittings are checked. Safety precautions 2.2. Oil pressure Pressurized oil is dangerous if released incorrectly. Always wear protective gloves.855. repaired and replaced before starting the equipment. WARNING! WARNING! CAUTION! 22 S 223. WARNING! Hot surface Equipment and hoses/pipes containing lubrication oil can have hot surfaces. Make sure all defective hoses. Hot oil Lubrication oil can become very hot during operation. WARNING! Skid risk When filling. Always remove oil spillage and stains to avoid skid risk. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system. controlling or changing oil there is a risk of spillage that can cause a slippery surface.6 Lubrication system When changing from mineral oil to synthetic oil.IM Sandvik CTHS430:02 Tank unit 2. Allow the oil to cool before working on the lubrication system.en-01 © 2012 Sandvik SRP AB . Contact Sandvik SRP AB for further instructions. or if the oil has coked. the tank unit must be thoroughly cleaned.

Always remove oil spillage and stains to avoid skid risk. Collect waste lubricants in suitable containers and dispose as recommended in the MSDS and according to local regulations. Collect the waste in suitable containers and dispose as recommended in the MSDS and according to local regulations. Health hazard Before you use a cleaning agent.2. wipe it off carefully and allow it to evaporate before pouring oil into the cleaned compartments. controlling or changing oil there is a risk of spillage that can cause a slippery surface. Use protective gloves and goggles.IM Sandvik CTHS430:02 Tank unit 2. read the supplier’s Material Safety Data Sheet (MSDS) and follow the instructions carefully. respiratory system etc. Safety precautions 2. Risk of serious injuries to eyes.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. Use white spirit only if it is necessary. Skid risk When filling. white spirit and other cleaning agents It is recommended to clean the tank and the tank unit’s parts with diesel oil. WARNING! CAUTION! © 2012 Sandvik SRP AB S 223. Toxic substances Read the supplier’s Material Safety Data Sheet (MSDS). Used and contaminated oil can be a health hazard. skin. Use personal protection and other safety measures as recommended in the MSDS. Handle all cleaning agents and their waste with care and according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. WARNING! WARNING! 2.en-01 23 .855.2.8 Diesel oil. CAUTION! If white spirit is used for cleaning.

24 S 223. Safety precautions 2. Keep a safe distance to hanging loads. 2. Make sure that the route and the destination are free from obstacles before moving a suspended load. NOTE! Always use lifting tackle certified in accordance with local conditions. DANGER! Make sure that the capacity of the lifting equipment (Working Load Limit. Use ropes or poles to steady and maneuver loads.2.9 Lifting and moving loads CAUTION! Only personnel with adequate lifting training are permitted to perform lifting operations. When depositing loads. see section 2. WLL) as the rest of the tackle.en-01 © 2012 Sandvik SRP AB . noise and radioactivity in the tank units environment. make sure that the joints are secure and have the same lifting capacity (Working Load Limit. Never use hands or feet. If lifting tackle has to be made up by joining separate components.3 Emissions For emissions such as dust. Hanging load Never work or stand underneath a crane that is lifting material. WLL) is adequate and that the lifting equipment is in good working order.855. keep the lifting equipment in place until it has been made sure that the load is stable. It must be possible to quickly and safely lower the load to the ground in case of an emergency. Always engage the safety clips on lifting hooks to prevent the tackle from slipping off. Safety precautions in the crusher’s manuals.IM Sandvik CTHS430:02 Tank unit 2.

Safety precautions before carrying out any work on the equipment or making any adjustments.3. always read section 2. IM Sandvik CTHS430:02 Tank unit 25 . Installation preparations To ensure maximum safety.

IM Sandvik CTHS430:02 Tank unit 3. please contact Sandvik SRP AB for guidance and customizing. In case of doubt. and that the installation area is accessible for spare and wear part delivery. before starting the main installation. If the site does not meet the specifications. foundation etc. NOTE! Make sure that the required service area at the site matches the requirements in the installation drawings.855. 26 S 223. Use the check list in section 3.en-01 © 2012 Sandvik SRP AB . please consult local authorities or local authorized personnel. Prepare the installation site as much as possible by installing electricity and water supply.1 General Check that the dimensions of the installation site and the positions of the connections comply with the installation drawings in the Installation Manual Appendix and with any site-specific installation drawings.2 Installation preparations check list as a guide and for documenting the installation procedure. Installation preparations 3. Check that the oil tank unit meets the local legislation demands.

IM Sandvik CTHS430:02 Tank unit 3.en-01 27 .855. Installation preparations 3.2 Installation preparations check list System Placement Checks Site access checked for oil tank unit dimensions? Smallest area that the oil tank unit components must pass through? (W × H) Available service area? (L × W × H) Available lifting device on site? Length of oil hoses and pipes? Foundation (if needed) Electrical system Foundation constructed according to drawings? All necessary cables arranged to the oil tank unit? Cable lengths? All necessary switchgear installed? All necessary connections to plant control system arranged? Electrical power available? Guards Platforms and guard rails Need for additional guards? Comply with local regulations? Designed so they do not interfere with crusher’s or tank unit’s function? Remarks Date/sign × × Type: × © 2012 Sandvik SRP AB S 223.

This to prevent oil from running into the overpressure system. Place the overpressure fan or air regulator for compressed air above the connection to the pinionshaft housing. Return oil must run back to the oil tank unit and be pumped to the cone crusher. See section 5. Installation preparations 3.en-01 © 2012 Sandvik SRP AB .4.5 Overpressure system and installation drawings in the Installation Manual Appendix.3 Placement Place the tank unit as close to the cone crusher as possible. Excessively long oil lines as well as many or sharp bends will increase the flow friction and lower the performance. (Continued) 28 S 223. 1 3 4 2 1 Crusher 2 Oil tank unit 3 Overpressure fan or regulator for compressed air 4 Pinionshaft Place the tank unit below the level of the cone crusher.855.1 Oil tank unit and installation drawings in the Installation Manual Appendix.IM Sandvik CTHS430:02 Tank unit 3. See section 5.

3. External cables. © 2012 Sandvik SRP AB S 223.3 Guard The oil tank unit have two moving parts covered with guards.en-01 29 .3. disconnecting switches and fuses must be ordered before installation. 3. Make sure that all requirements for the service area are met as shown in the installation drawings in the Installation Manual Appendix. Note the dimensions of the actual service area in the check list. switches and fuses. Electrical installation and the electrical drawings in the Installation Manual Appendix. the pump P1 connected to the motor M2 and the fan connected to the motor M3 on the air/ oil cooler.1 Electrical installation Make sure that all local and site-specific requirements for electrical installations are fulfilled. Make sure that the control system is prepared for the addition of the tank. mark the limits of the service area with paint.IM Sandvik CTHS430:02 Tank unit 3.3. 3. Transport handling. Note the available type of lifting device in the check list. If possible. Contact Sandvik for further information about cables. Installation preparations Place the oil tank unit so that it is easily accessible for operation.855.3. See section 6. Make sure that there is sufficient room to drain out all oil. Make sure that there is access to a lifting device meeting the requirements in section 4.2 Remote control system At most sites a main control system is used to control the process. service and maintenance but protected against damage and unauthorized access.

IM Sandvik CTHS430:02 Tank unit 3. The accompanying flow chart (section 3. contact Sandvik for further assistance. A combination of several methods may be necessary. 3.2 Low temperature problems – symptoms and remedies) can be used to determine which method to use.855. Part numbers for ordering the modification kits are listed under the respective methods. Installation preparations 3.en-01 © 2012 Sandvik SRP AB .4. NOTE! If it is difficult to start the crusher even when the appropriate recommendations have been followed. The order in which these methods are applied should be judged in each individual case.1 Measures for easier starting and running in cold climate The following methods will increase the oil flow at low temperatures.4.4 Operating in low temperatures The following section describes recommended methods for reliable operation in low temperature. – Heating cables on oil lines – Additional oil heaters – Diesel heating system – 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 for oil cooler or a frequency converter – Insulation of the oil tank – Continuous running of the lubrication oil pump A cone crusher that is fitted with “low temperature equipment” will normally be equipped with: – Additional oil heaters – Insulated bottom in the component section of the oil tank unit 30 S 223.

en-01 31 .IM Sandvik CTHS430:02 Tank unit 3. use an ISO VG 100 oil. Stop the oil pump. Wait 3. Alternatively. Does oil flow back to the tank? Alternatively. Does oil flow back to the tank? Sometimes it can be advisable to run the lubrication oil pump continuously to minimize starting problems © 2012 Sandvik SRP AB S 223. Has oil run back through the oil line to the return oil flow switch? Does the crusher stop due to interruptions in return oil flow? Has oil overflowed over the dust collar? There is a blockage in the return oil line.855. If necessary. the lubrication oil pump should be run continuously. The ambient air temperature is too low. Does the “Crusher ready for start” signal appear within 40 s? Has the crusher started and continued to run normally? Start crushing when the crusher has warmed up. In addition.) Does oil flow back to the tank? During long periods with very low temperatures. Start with 50% blanked off. (Heating in component section and insulated tank bottom. but not in sufficient quantity. Position a fan heater beneath the crusher and cover the feed opening. install a frequency converter or a two-speed motor to the cooling fan. Does the oil flow back to the tank? Install low temperature equipment in the tank. Install heating cables on the oil lines. The oil is slowed down and blocks the passages in the radiator coil! Blank off the radiator completely or partially. Change to synthetic oil.2 Low temperature problems – symptoms and remedies Start Start the oil pump.5 min. No Yes Oil returns to the tank.4. Clean out the blockage. to drain the crusher and then make a new attempt to start up. Does oil flow back to the tank? Under very low temperatures the radiator coil can be “thawed out” with a fan heater. install heating cables on the return oil line. the crusher should be heated during the night to avoid excessive cooling. Insulate the oil tank. Installation preparations 3. which makes the oil cooler too effective.

4.5370-901 Description Heaters and insulation for a cold climate Voltage (V) Rating (W) Connection diagram Position number 1 (2 ×) 2 3 Heater element 265/460 240/415 220/400 2×2190 2×1785 2×1500 3. The component section of the oil tank unit is normally open at the bottom to provide good ventilation and cooling of the oil pumps. Installation preparations 3.cold climate 32 S 223. In a cold climate it might be necessary to insulate the tank to keep the oil at working temperature and prevent pressure drop. 1 1 Heater element . but extra heaters can also be fitted in the tanks of older crushers.cold climate (not visible) Modification kit Modification kit 452.cold climate In order to heat the oil to the correct temperature. it can be necessary to install extra heaters.855.en-01 © 2012 Sandvik SRP AB .cold climate 2 Bottom plate insulated 2 3 1 3 Cable set .IM Sandvik CTHS430:02 Tank unit 3. Installation is easiest if this equipment is ordered together with a new crusher.0191 Insulation Cable set .194.3 Heater set .

5 Heating cables on oil lines See installation drawings in the Installation Manual Appendix. This problem can be minimized by insulating the oil lines and installing heating cables. The tank unit is prepared for diesel heating.en-01 33 . the oil in the lines between the tank unit and the crusher can solidify and block the lines. a timer-controlled diesel heating system can be used.5388-901 3. increase the slope of the return oil line before installing heating cables. It is preferable to use a heating cable of the self-regulating type which needs no thermostat. If the oil lines are >50 mm (2") in diameter.4. If possible.4.IM Sandvik CTHS430:02 Tank unit 3. the heating cable can be led backwards and forwards on the same line. The system starts heating the oil up to three hours before electrical power is available. At low temperatures. Modification kit 452.855. © 2012 Sandvik SRP AB S 223. or if the oil need be heated to a temperature 50 ºC (122 ºF) above the ambient temperature. The heating cable should have a rating of 8–10 W/m and 40 mm (1.4 Diesel heating system In plants without 24-hour electrical power.6") insulation. Heating cable is normally supplied for 230 V. The heating cable can be purchased from a local supplier who can usually also install it. Installation preparations 3. Install the heating cable on the underside of the oil line and use insulating tape to keep the cable in place. The diesel heating system uses a 12 V DC supply. Heating cables are in many countries considered as high voltage equipment and must therefore be installed by an authorized electrician.

3.IM Sandvik CTHS430:02 Tank unit 3. CAUTION! Position the fan heater so that oil cannot drip onto it. controlling or changing oil there is a risk of spillage that can cause a slippery surface.855. Always remove oil spillage and stains to avoid skid risk. See the text and the table for mineral oil in the Operator’s and Maintenance Manual for the oil tank unit.7 Synthetic oils Skid risk When filling.6 Heating in the component section of the oil tank unit Extra heating in the tank unit can be provided by a standard fan heater with a rating of about 600 W.en-01 © 2012 Sandvik SRP AB .4. and are in all respects superior to mineral-based oils: • Longer change intervals due to high stability • Easier starting at low temperature • Lower energy consumption due to lower friction • Wider temperature range • No oxidation and “coking” The synthetic oil shall meet the same requirements as for mineral oil. Sandvik does not supply modification kits with fan heaters. Synthetic oils will allow for trouble-free starting at about 10ºC lower temperature than a mineral-based oil. Installation preparations 3. The fan heater must have a thermostat which prevents overheating. Select a suitable fan heater from any supplier. (Continued) 34 S 223.4.

4. The following synthetic oils are recommended by Sandvik for the Hydroset system. Other brands can be used after consulting the supplier. Brand Mobil oil Type SHC 626 Minimum pour point -51 °C Viscosity (cSt) at 40 °C 68 3. Collect the waste in suitable containers and dispose as recommended in the MSDS and according to local regulations. but should be diluted as little as possible. For further information. A grade with a viscosity down to 30 cSt at 40 °C can be selected for the Hydroset system. To reduce the risk of dilution of a synthetic lubricating oil. Other brands can be used after consulting the supplier. see the Operator’s and Maintenance Manual for the tank unit. Empty the crusher and oil tank carefully before refilling with synthetic oil.IM Sandvik CTHS430:02 Tank unit 3. the Hydroset oil should also be synthetic. CAUTION! Handle all oil and waste oil with care and according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Installation preparations The following synthetic oils are recommended by Sandvik for the lubricating system.en-01 35 .855. Brand Mobil oil Type SHC XMP 150 Minimum pour point -48 °C Viscosity (cSt) at 40 °C 150 The recommended synthetic oils can be mixed with mineral-based oils. CAUTION! It must be possible to mix the lubricating and Hydroset oils used in the crusher. an ISO VG 100 oil can be used. © 2012 Sandvik SRP AB S 223.8 Mineral oil for the winter season In ambient temperatures below 0 ºC (32 °F). Consult the oil supplier if in doubt.

855.10 Frequency converter To reduce the air flow through the radiator. a frequency converter for the oil cooling fan can be used. please contact Sandvik 3.11 Two-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.4. The speed of the cooling fan is determined by the oil temperature in the return line.4. For further information about the frequency converter. The easiest way to avoid this is to blank off the radiator so that less air passes through the radiator matrix. The oil is then not cooled at all and can overheat. Installation preparations 3. The degree of blanking depends on the ambient temperature and must be determined by trial-and-error. Examples of switching points with ISO VG 150 oil: Return oil temperature Rising oil temperature 43 °C (109 °F) 43–46 °C (109-115 °F) Over 46 °C (115 °F) Falling oil temperature Over 43 °C (109 °F) 43–40 °C (109-104 °F) 40 °C (104 °F) Cooling fan The fan starts at low speed Runs at low speed Runs at high speed Runs at high speed Runs at low speed The fan stops 36 S 223. the pressure drop across the cooler will cause the by-pass valve CV4 on the cooler to open. 3.9 Blanking off the oil cooler radiator If the cooling fan on the air/oil cooler is started at low ambient temperature.en-01 © 2012 Sandvik SRP AB .4.IM Sandvik CTHS430:02 Tank unit 3.

Cover the crusher’s feed opening to prevent excessive cooling by cold air passing through the crusher chamber. as it will otherwise lose its insulating properties. A suitable material is PAROC Pro Slab 35.IM Sandvik CTHS430:02 Tank unit 3. Insulation kits are not supplied by Sandvik.13 Continuous running of the lubrication oil pump Running the oil pump continuously while the cone crusher is stopped will prevent the oil from solidifying in the lines and crusher.4.en-01 37 . Leave the oil tank heaters switched on. The insulation material must be protected from moisture. 50 mm (2") thick. 3. © 2012 Sandvik SRP AB S 223.4.855. In warmer weather the insulation should be removed to prevent overheating. Installation preparations 3. Insulation can easily be installed by the plant personnel.12 Insulation of the oil tank Insulating the oil tank will reduce the overnight drop in oil temperature at low ambient temperatures.

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4. always read section 2. Safety precautions before carrying out any work on the equipment or making any adjustments. Transport handling To ensure maximum safety. IM Sandvik CTHS430:02 Tank unit 39 .

1 Goods data The oil tank unit is delivered as a complete assembled unit.9 × 27.855. Auxiliary and optional equipment is delivered in separate packages. Some basic measurements are given in the table below to indicate the space required by the equipment during transportation. If the tank is delivered by Sandvik either to a harbour or to the work site.IM Sandvik CTHS430:02 Tank unit 4.6) 4.6 × 23.6) 300 × 300 × 700 (20 × 11.1. 40 S 223. check immediately after arrival that the equipment corresponds with the items in the “Package Inventory List”. check before transport that the equipment corresponds with the items in the “Package Inventory List”.1 Contents A “Package Inventory List” is attached to one of the packages in the delivery. NOTE! If the tank is collected from the factory. Part name Tank unit Air/oil cooler Water/oil cooler (option) Mass kg (lbs) 400 (800) 150(330) 100 (220) Measurements L × W × H mm (") 1350 × 950 × 900 (53.en-01 © 2012 Sandvik SRP AB .5) 1000 × 800 × 700 (40 × 27. Transport handling 4. The number of packages delivered may vary depending on the oil tank variant and equipment.4 × 35.2 × 37.

© 2012 Sandvik SRP AB S 223.855.1.IM Sandvik CTHS430:02 Tank unit 4.en-01 41 .0260-00 Use the forks here Overhead lifting point 885.2 Loading and unloading goods signs Make sure that the handling personnel understand and follow the mandatory and warning symbols used on the packages.0250-00 Center of gravity Lifting point for chain NOTE! Maximum load for both lifting eyes and lifting angles are shown in the installation drawings in the Installation Manual Appendix. Transport handling 4. 885.

Equipment or tackle Overhead gantry Mobile crane Lifting chains. Equipment specifications Make sure that the lifting capacities of the equipment and tackle comply with the minimum values given in the following table. ropes or slings Fork lift (only for goods on pallet/platform) Lifting capacity kg (lbs) 500 (1200) 500 (1200) 500 (1200) 500 (1200) 42 S 223.2 Lifting equipment Different types of lifting equipment The following types of equipment can be used to lift and move the goods: • • • NOTE! overhead gantry mobile crane fork lift (use only for goods on pallet/platform) Lifting with fork lift without a pallet or a platform may damage the goods.855. Transport handling 4. cables.en-01 © 2012 Sandvik SRP AB . NOTE! The lifting capacity of a mobile crane varies with the lifting radius.IM Sandvik CTHS430:02 Tank unit 4. Make sure that the lifting capacity is sufficient at the appropriate lifting radius.

i) Make sure that the destination is clear and able to support the weight before lifting. DANGER! The following instructions apply to this oil tank unit. h) Check that the chains can straighten out correctly. a) Make sure that the lifting chains. g) Slowly take up the slack in the lifting chains. Never lift with a twisted chain. hooks and other equipment are in a good state. See section 2. Avoid twitches and jerks. and attended to according to instructions from the manufacturer. e) Place the lifting equipment according to the symbols found in section 4. c) Make sure that the lifting equipment has a sufficient WLL (Working Load Limit) for the weight to be lifted and for the method of lifting. Make sure that the hooks are secure in the lifting eyes of the component. Safety precautions. Transport handling 4. © 2012 Sandvik SRP AB S 223.IM Sandvik CTHS430:02 Tank unit 4. Keep clear of the load. Check the gross weight of the components to be lifted and make sure the WLL (Working Load Limit) of the lifting equipment is sufficient for the weight to be lifted. adjust the chains to distribute the load evenly. b) Make sure that the lifting chains have the correct lengths for the angle from the vertical in which they are to be used. k) Never use hands or feet to guide the load.1 Overhead gantry or mobile crane Hanging load Keep clear of hanging loads.en-01 43 . If necessary.2. d) Follow the applicable lifting standard for the equipment used. j) Lift. move and lower the load carefully and calmly.2 Loading and unloading goods signs f) Check that the load lies against the saddles of the hooks.855. Never put load on the tip of a hook.1.

f) Lift and move the load carefully and calmly.2 Using a fork lift (only for goods on pallet) Hanging load Keep clear of hanging loads. g) Lower the load gently to the floor. Check the gross weight of the components to be lifted and make sure the WLL (Working Load Limit) of the lifting equipment is sufficient for the weight to be lifted. manoeuvre the forks inside these to lift the component.855. b) Set the lifting forks to the correct width for lifting the load from the side. The oil tank unit must be placed on a pallet/platform when lifted with a fork lift. See section 2. CAUTION! Always use the lifting eyes mounted on the top of the oil tank unit and a suitable lifting sling or similar when lifting the oil tank unit without pallet/platform.IM Sandvik CTHS430:02 Tank unit 4. see the installation drawings in the Installation Manual Appendix. d) If the transport platform of the component is fitted with fork tubes. Safety precautions. a) Make sure that the forks are of the correct length and lifting capacity for the oil tank unit on its transport pallet/platform.en-01 © 2012 Sandvik SRP AB . 44 S 223. Transport handling 4.2. e) Make sure that the destination is clear and able to support the weight before lifting. c) Make sure that the load is firmly attached to the transport pallet/ platform. DANGER! The following instructions apply to this oil tank unit.

5 m (5 ft) of free space around and above the tank. NOTE! If damage has occurred during transport.1 Unpacking area The unpacking area should have approximately 1.3 Unloading the goods 4.2 Inspection of goods Inspect the outside and wrapping of the packages before unloading.en-01 45 . document the damage with a camera.3.2 ft) 4.2 × 8. The address is found on the”Package Inventory List”.855.3.5 m (10 × 8. Transport handling 4.5 × 2. If the damage is severe enough to prevent installation. report this immediately also to the Sandvik shipping department.IM Sandvik CTHS430:02 Tank unit 4. If possible. Minimum recommended unpacking area L × W × H CTHS430 3 × 2. Report any damage immediately to the person responsible for the installation. submit a damage claim to the transport company without delay. © 2012 Sandvik SRP AB S 223.

IM Sandvik CTHS430:02 Tank unit 4. Sandvik recommends storing the oil tank unit indoors.4. make sure that the storage area meets the requirements in section 4. d) Make sure that the component remains stable on the lifting equipment. Position the packages on the installation site so that the oil tank unit can be lifted out and installed without being turned around.4 Moving and Storage Important notes If the oil tank must be stored before installation. Move the load into position.2 Storage. place the oil tank unit at the installation site before unpacking. See section 2.en-01 © 2012 Sandvik SRP AB . Check the gross weight of the components to be lifted and make sure that the WLL (Working Load Limit) of the lifting equipment is sufficient for the weight to be lifted. 4.855.4. When lifting. Check the gross weight of the components to be lifted and make sure that the WLL (Working Load Limit) of the lifting equipment is sufficient for the weight to be lifted. Remove the lifting equipment. 4.2 Storage Hanging load Keep clear of hanging loads. Safety precautions. WARNING! CAUTION! 46 S 223. Transport handling 4. Safety precautions. Make sure that the component is firmly supported. Leave enough room for access to all sides. Long-term exposure to moisture or very high or low temperatures may damage the tank. follow the instructions in section 4. If possible.2 Lifting equipment and the drawings in the Installation Manual Appendix. Do not unpack the components until immediately before starting installation.2 Lifting equipment. See section 2. Lower it gently to the floor.1 Moving Hanging load Keep clear of hanging loads. e) f) g) h) i) Check that the transport platform has come loose from the oil tank unit.4. c) Lift the component only enough to clear the floor. b) Remove any screws holding the transport platform to the component. WARNING! a) Attach the lifting equipment according to the instructions in section 4.

Transport handling a) Prepare a storage area large enough to store the components with at least 1. © 2012 Sandvik SRP AB S 223. d) Make sure that the components are stable before removing the lifting equipment.5 m (5 ft) of free space around and above for access and ventilation. b) Make sure that the storage area environment meets the conditions in the table below: Characteristic Min–max temperatures Max relative humidity Value 5–40 °C (41–104 °F) 80% Notes Non-condensing c) Lift the components into position according to the instructions in section 4.4.en-01 47 . the oil tank unit is wrapped with rust preventative materials sufficient for approximately one year of storage.855. If the ground/floor is uneven.IM Sandvik CTHS430:02 Tank unit 4.1 Moving. NOTE! Before delivery from the factory. place blocks or plates under the components to provide a steady support.

1 Equipment information.855. See section 2. See also section 4. WARNING! a) Remove any loose boxes and packages before unpacking the main components. e) Locate the “Package Inventory List”. send a transport damage report to Sandvik. See section 1.6 Disposal/return of packaging material.en-01 © 2012 Sandvik SRP AB .5 Unpacking the goods Hanging load Keep clear of hanging loads. In case of damage. b) Unpack and check each item against the “Package Inventory List”.IM Sandvik CTHS430:02 Tank unit 4.3.2 Inspection of goods. 48 S 223. Check the gross weight of the components to be lifted and make sure that the WLL (Working Load Limit) of the lifting equipment is sufficient for the weight to be lifted. Transport handling 4. c) Check the unpacked components and accessories for damage. d) Open the crushers tool box and take out the documentation. h) Dispose of the packaging material according to the instructions in section 4. f) Check that the data on the oil tank unit identification plate corresponds with the “Package Inventory List”. Safety precautions. g) Move spare and wear parts to the spare part store.

transport racks and any other returnable packaging. wrapping. If the packaging is not to be returned or recycled. Dispose of pollutant waste (bubble wrapping. • • • • • Check if there is a special agreement for the return of the packaging to the manufacturer. prepare an area to store pallets.855. Packaging is normally not returned to the manufacturer. expanded polystyrene.en-01 49 . etc. crates. Check if there is a special arrangement for recycling packaging material. © 2012 Sandvik SRP AB S 223. check with the local authorities how to separate and dispose of packaging material.IM Sandvik CTHS430:02 Tank unit 4.6 Disposal/return of packaging material The packaging material includes all pallets. boxes and other protective material that are not part of the equipment.) in accordance with local regulations. plastic bags. If the packaging must be returned. Transport handling 4.

Transport handling This page is intentionally left blank 50 S 223.en-01 © 2012 Sandvik SRP AB .855.IM Sandvik CTHS430:02 Tank unit 4.

Mechanical installation and connections To ensure maximum safety. IM Sandvik CTHS430:02 Tank unit 51 . Safety precautions before carrying out any work on the equipment or making any adjustments.5. always read section 2.

IM Sandvik CTHS430:02 Tank unit

5. Mechanical installation and connections

5.1 General requirements
Personnel Only qualified installation personnel are authorized to install the oil tank unit. See section 2. Safety precautions for a definition of installation personnel. The installation area a) Clear the installation site. If necessary, clean the ground before starting the installation. b) Make sure that there is sufficient room to move safely around the installation, for further information, see the Installation Manual Appendix. If any adjacent machines on the site cannot be stopped, take measures to prevent accidental contact. c) Make sure that 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 components can also be used for unpacking and installing the oil tank unit. See section 4.2 Lifting equipment. Packing Leave wrapping and ties on the parts until they are ready for use. Leave the plastic plugs in the oil line openings until they are ready to be connected, but do not forget to remove them before connecting the pipes.

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5. Mechanical installation and connections

5.2 Foundation
The oil tank unit might need an adequately dimensioned foundation. Sandvik recommends a steel supporting structure or a concrete foundation. A steel supporting structure or a transportable frame must be mounted horizontally and rest on a firm ground. If the oil tank unit is not sufficiently stable the supporting structure will vibrate and be subjected to stresses.
NOTE!

The oil tank unit can be installed on either side of the crusher. This is important to decide before the foundation is designed. For further information, see the Installation Manual Appendix. For general information on placement, see section 3.3 Placement.

5.3 Hydroset and lubrication systems
Oil is supplied to the crusher through two lines – one two-way line from the Hydroset cylinder and one to the main lubrication system. The pinionshaft is lubricated in an oil bath in the pinionshaft housing. The oil returns to the oil tank unit through two lines – the Hydroset two-way line and the main lubrication return oil line. For general information on placement, see section 3.3 Placement.

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IM Sandvik CTHS430:02 Tank unit

5. Mechanical installation and connections

5.4 Hoses and pipes – General
NOTE!

Pipes are not supplied by Sandvik. Route all pipes and/or hoses to and from the crusher along the same path. All pipes and/or hoses to and from the crusher must be carefully sealed and tightened to avoid leakage and prevent the pipes/hoses to come loose from the connections. The inclination of return lines is critical. See section 5.4.1 Oil tank unit. For a description of hoses, pipes and connections on the tank unit and crusher, see the Installation Manual Appendix.

NOTE!

When starting the pumps the first time, make sure there are no leakages. If there are leakages, use a suitable compound to seal.

5.4.1 Oil tank unit
Hanging load Keep clear of hanging loads. See section 2. Safety precautions. The oil tank unit without cooler weighs approx. 310 kg (700 lbs). Make sure that the WLL (Working Load Limit) of the lifting equipment is sufficient for the load.

WARNING!

a) Install the tank unit in a suitable location. See also section 3.3 Placement and section 4. Transport handling.

L

L Return oil hose

NOTE!

The tank unit must be placed below the level of the cone crusher. (Continued)

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5. Mechanical installation and connections

Distance tank – crusher

Inclination of return oil hose

< 3 m (10 ft) > 3 m (10 ft)

5° 10°

b) Connect the oil lines to the tank unit, see the Installation Manual Appendix.
NOTE!

The connections are already fitted to the crusher. Pipes and pipe fittings are not supplied by Sandvik. – Make sure that there are no kinks in the return oil hoses/pipes. – Avoid pipe elbows. Use large-radius pipe bends instead to reduce resistance in the piping. – Run the piping so that it is protected against falling stones. – Make sure that the piping is securely supported to avoid vibration. – Make sure 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. c) Inspect and clean the lubrication oil tank. Hydroset connections a) Connect the Hydroset oil line to the oil tank unit with high-pressure piping or hoses. Minimum pressure rating: 8 MPa (1160 psi). – Make sure that there are no kinks in the oil hoses/pipes. – If pipes are used, avoid pipe elbows. Use large-radius pipe bends instead to reduce resistance in the piping. – Run the piping so that it is protected against falling stones. – Make sure that the piping is securely supported to avoid vibration. – Make sure that the piping is free from burrs, metal shavings and dirt before it is connected to the crusher and tank unit. b) Inspect and clean the Hydroset tank.

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4. Piping and hoses can be used to connect to the tank unit. c) Connect piping or hoses to the tank unit. 56 S 223. it is advisable to lead fresh air to the cooler through a duct from a dust-free place. see the Installation Manual Appendix. and it must not be rigidly connected to the air/oil cooler.855.en-01 © 2012 Sandvik SRP AB . A by-pass valve CV4 is fitted on the air/oil cooler. If the ambient air contains a lot of dust. CAUTION! NOTE! If the crusher is installed at high altitude and/or extremely high or low ambient air temperature. To reduce the amount of dust which settles in the radiator matrix. The duct must be correctly dimensioned so that air flow is not restricted. Mechanical installation and connections 5.pass valve NOTE! Pipes and pipe fittings are not supplied by Sandvik. a) Install the air/oil cooler on or close to the tank unit. Its duty is to limit the pressure over the pump and coolers if the crusher is started at low temperatures. CV4 Air flow CV4 By. b) Connect the hoses to the cooler. Hoses must always be fitted to the cooler. the air/oil cooler is best placed so that the fan blows towards the crusher.2 Air/oil cooler For further information. a special cooling system is required. The air/oil cooler can be installed directly on the oil tank unit or in a suitable place close to it. The cooler and the piping must be shielded from direct sunlight.IM Sandvik CTHS430:02 Tank unit 5.

For further information about temperature switches.3 Water/oil cooler (option) J Water in O Water out U Oil from tank V Oil to crusher TS2 Temperature switch. see the Operator’s and Maintenance Manual for the tank unit. If only contaminated water is available. This must be arranged at the site to suit local conditions.4. NOTE! Use clean fresh water. contact Sandvik first! b) Set the temperature switch TS2 to the correct value. The supply of cooling water is controlled by temperature switch TS4.IM Sandvik CTHS430:02 Tank unit 5. the temperature switches should be set at the values for “Normal Operating Conditions” regardless of the ambient temperature.en-01 57 . water pump and pipe fittings are not supplied by Sandvik. see the Operator’s and Maintenance Manual for the tank unit.return oil TS4 Temperature switch AVTA 25 See also the drawing in the Installation Manual Appendix. For further information. Mechanical installation and connections 5. TS2 TS4 TS4 V J O NOTE! U Pipes. NOTE! When a water/oil cooler is used.855. The values on its scale correspond to the following oil temperatures: Value on scale 1 2 3 4 5 Oil temperature 25 °C (77 °F) 32 °C (90 °F) 43 °C (109 °F) 57 °C (135 °F) 65 °C (149 °F) c) Set the temperature switch TS4 to “3” on the scale to keep the oil at 43 °C (109 °F). a) Connect water piping or hoses to the cooler. © 2012 Sandvik SRP AB S 223.

145psi) 0. Mechanical installation and connections 5. pipes and pipe fittings are not supplied by Sandvik.en-01 © 2012 Sandvik SRP AB . A correctly functioning overpressure system is important for the performance of the crusher.5 Overpressure system Minimum and maximum length of hoses Minimum and maximum pressure Minimum blower capacity at 600 Pa 2–15 m (7–50 ft) 600–1000 Pa (0.855.087–0.IM Sandvik CTHS430:02 Tank unit 5./min) The cone crusher and the tank unit are equipped with a common overpressure system to prevent dust from entering the cone crusher or the oil tank and contaminating the oil. FU5 PF M8 2 1 2 FU6 FV6 1 C C C C C 1 P P 1 Hoses 2 Coupling to the air supplier FU5 Air filter PF Fan M8 Motor to fan FV6 Compressed air regulator FU6 Filter to air regulator P Coupling to the oil tank unit C Coupling to the pinionshaft housing 1 P NOTE! Hoses. (Continued) 58 S 223.3 m3/min (793 US gall.

check that the direction of rotation is the same as shown by the arrow on the fan housing. • NOTE! The regulator FV6 with filter FU6 must be mounted horizontally and if it is possible. the output of the fan will be insufficient. © 2012 Sandvik SRP AB S 223. c) Cut the appropriate lengths from the hose coil supplied with the oil tank unit. see the Installation Manual Appendix. For detailed drawings.en-01 59 . Install the fan or the regulator at least 0.855.5 m (20") above the tank and the pinionshaft to prevent oil from running into them. b) Measure the hose length between the air supplier’s coupling (2) and the T-connection C on the pinionshaft. a) Install the fan or the regulator with filter • The fan can be mounted horizontally or vertically. d) Connect one hose (1) between the air supplier’s coupling (2) and the Tconnection C on the pinionshaft housing. When the fan motor is connected. The length of the hoses depends on the position of the air supplier and the tank. Use hose clamps. Measure the hose length between the T-connection C on the pinionshaft and the tank overpressure coupling P. If the rotation isn’t correct. Dust will damage the blower and result in malfunction of the cone crusher. The hoses are joined in a T-connector on the pinionshaft housing. NOTE! Air introduced into the crusher and the tank must be free from moisture and dust. they should be installed in a heated space. The air supplier is a fan or a regulator with filter connected to a compressed air system. e) Connect the other hose (1) between the tank overpressure coupling P and the T-coupling C on the pinionshaft housing.IM Sandvik CTHS430:02 Tank unit 5. Use hose clamps. Mechanical installation and connections Normally the system consists of two hoses and an air supplier. CAUTION! It is important to install the fan in a dust free environment.

en-01 © 2012 Sandvik SRP AB . 60 S 223.855. see the Operator’s and Maintenance Manual. Keep some extra oil within easy reach. For further information about lubricants and lubrication.IM Sandvik CTHS430:02 Tank unit 5. Mechanical installation and connections 5. It may be necessary to add some after start-up due to the length of the hoses.6 Lubricants Fill the required amount of oil into the tanks.

Electrical installation To ensure maximum safety. Safety precautions before carrying out any work on the equipment or making any adjustments.6. IM Sandvik CTHS430:02 Tank unit 61 . always read section 2.

The air/oil cooler fan and overpressure air fan motors are connected directly. see section 2.2 Overview Electrical drawings are included in the Installation Manual Appendix. testing and operation of the electrical equipment. and knowledge of local safety regulations regarding power and automation circuits. Safety precautions.855. Work with electrical equipment must be performed only by skilled or instructed technicians. 62 S 223.IM Sandvik CTHS430:02 Tank unit 6. The purpose of the electrical system is to power the cone crusher with its auxiliary systems and to control the operation. 6. Connections for pump motors and other equipment are routed through connection box L9 on the oil tank unit.en-01 © 2012 Sandvik SRP AB . If in any doubt about the connection. please contact Sandvik SRP AB. Electrical installation 6. proven skills in reading and working from drawings and cable lists. For further information.1 General requirements Electricians Electricians should be certified according to local regulations and have experience of similar types of installations.

Electrical installation 6. relays. The delivered electrical cabinet L3 contains fuses.3. relay and motor protection built into an appropriate switch gear cabinet.4 E7 – Oil heaters The power supply to the oil heaters must incorporate the necessary fuse. relay and motor protection built into an appropriate switch gear cabinet.3. so it is only possible to run the crusher when the lubrication pump M2 is in operation. With a water/oil cooler it can be convenient to open/close the cooling water supply with a magnetic valve. 6.3. © 2012 Sandvik SRP AB S 223. The temperature is controlled by a temperature switch TS3. 6. The temperature is controlled by a temperature switch TS2.3 M6 – Hydroset pump Starting and control equipment for the Hydroset pump is normally delivered by Sandvik.3. The power supply to each air/oil cooler motor must incorporate the necessary fuse.1 M2 – Main lubrication pump The power supply to the motor must incorporate the necessary fuse. relay and motor protection built into an appropriate switch gear cabinet.en-01 63 . 6. 6.IM Sandvik CTHS430:02 Tank unit 6. Starting and stopping can be made possible either by buttons or via software. see the Operator’s and Maintenance Manual for the tank unit.855.2 M3 – Oil cooler fan motor Every crusher has an air/oil or water/oil (option) cooler in the lubrication system. Fuses. relay and motor protector. motor protectors and control units must be installed in the appropriate switch gear cabinets. 6. all installed in an electrical cabinet. NOTE! The crusher drive motor’s M1 relay must be interlocked with the main lubrication pump motor M2.5 M8 – Overpressure fan The power supply to the overpressure fan must incorporate the necessary fuse.3. For further information about temperature switches. relays and motor protection for operation of the Hydroset pump.3 Motors and heating elements Starting equipment for the oil tank pumps/motors and heating elements are normally not part of the supply from Sandvik.

4 Connection boxes ASRiCBT L9 L9 Connection box.IM Sandvik CTHS430:02 Tank unit 6. motor power ASRi-CBT ASRi connection box 64 S 223. Electrical installation 6.855.en-01 © 2012 Sandvik SRP AB .

7. Final installation checks To ensure maximum safety. always read section 2. Safety precautions before carrying out any work on the equipment or making any adjustments. IM Sandvik CTHS430:02 Tank unit 65 .

en-01 © 2012 Sandvik SRP AB . Mechanical installation and connections for further details on the following checks.1. Checks Done 1 2 3 4 5 Brand name and type of oil and grease are recorded. Checks Done 1 2 All electric cables are correctly connected.1 Installation and connection checks See section 5. 7. Air/oil or water/oil (option) cooler is installed properly. No. 7.IM Sandvik CTHS430:02 Tank unit 7. The Hydroset and lubrication systems are correctly installed.855. (Continued) 66 S 223. Final installation checks 7. All motors have the correct rotation direction.2 Electrical checks See section 5.1 Lubrication system and Hydroset checks No. Piping and hosing has been installed according to the recommendations in this manual. Mechanical installation and connections for further details on the following checks. The oil tank unit is placed in relation to cone crusher according to instruction and is properly installed.

en-01 67 . e) Fit the clip (1) on top of the pressure switch PS2. WARNING! H10 PS2 1 1 PS2 FU1 H10 Clip Pressure switch . the need for oil filter exchange. Always wear protective gloves.main lubrication Filter unit . b) Remove the clip (1) on top of the pressure switch. The pressure drop warning lamp H10 on the front panel will light up if the pressure switch works. © 2012 Sandvik SRP AB S 223.IM Sandvik CTHS430:02 Tank unit 7. Final installation checks 7. This means that if the pressure switch malfunction it will not indicate. Allow the oil to cool before working on the lubrication system.2. d) Turn the pressure switch PS2 upside down and position the pressure switch back on the tube. Hot oil Lubrication oil can become very hot during operation.main lubrication Pressure drop warning lamp main lubrication FU1 a) Locate the pressure switch PS2.855.1 Check the pressure switch PS2 The pressure switch PS2 is of normally open (NO) type. Perform this check with the power on but pumps and crusher off.Turn the pressure switch PS2 back to its normal position. c) Remove the pressure switch PS2 by pulling it straight up from the oil filter assembly FU1.

See the Operator’s and Maintenance Manual for further details. Checks Done 1 Prepare the oil tank unit for production.3 Safety checks No. 7.en-01 © 2012 Sandvik SRP AB .IM Sandvik CTHS430:02 Tank unit 7. 68 S 223. Checks Done 1 All threaded fasteners have been tightened to the correct torque.855. Final installation checks 7.4 Start-up No.

8. always read section 2. IM Sandvik CTHS430:02 Tank unit 69 . Safety precautions before carrying out any work on the equipment or making any adjustments. Preparations for commissioning To ensure maximum safety.

8. 1 2 3 Checks The data on the oil tank unit identification plate corresponds with the machine specification document.Fuse rating Done 2 70 S 223.1 General Perform the following checks even if an actual commissioning test is not required.Factory acceptance test report (if relevant) .Lubricants of the correct types are available Electrical power supply: .2 Presence and correctness checks No.IM Sandvik CTHS430:02 Tank unit 8.Machine deviation report (if relevant) Sufficient process material is available for commissioning purposes. 1 Checks Hydroset and lubrication systems: . Done 4 8.Machine specification document (if relevant) .Systems have been thoroughly cleaned .Installation drawings (IMA) .en-01 © 2012 Sandvik SRP AB .3 Supply value checks No. NOTE! Commissioning covers only the functioning of the individual machine.Spare part catalog (SPC) .Operator’s and Maintenance Manual (OMM) .Voltage . Contact the local service organization about arrangements for a line performance test.855. A line performance test is still required to check the functioning of the oil tank unit as part of a complete production line. All the documents correspond to the specific oil tank unit: . The ordered wear and spare parts have been delivered and deposited in the spare part store.Max voltage fluctuation within limits . Preparations for commissioning 8.Frequency .

List all work.4 Function checks 8. 1 2 4 5 6 Checks No unusual noises which could indicate misaligned parts or faults. Technical Data Oil heating elements operate correctly.4.1 Preparation Start the oil tank unit according to the Operator’s and Maintenance Manual. Done 8. Done 2 3 8.IM Sandvik CTHS430:02 Tank unit 8. Preparations for commissioning 8. The installation work covered by this manual is now complete. Hydroset pressure within limits. Overpressure dust exclusion system functions correctly Return lubrication oil temperature within limits for the chosen oil.en-01 71 . besides the installation work. see the Operator’s and Maintenance Manual. No. that was performed to ensure correct functioning.855.5 Health and safety checks No. The oil tank unit stops after a short delay when the Stop button for the cone crusher is pressed.6 Documentation – Compile the Installation report. All necessary guards are in place. © 2012 Sandvik SRP AB S 223. 1 Checks The oil tank unit stops when an Emergency stop button (if applicable) is pressed. Test must be made with the cone crusher running.

IM Sandvik CTHS430:02 Tank unit 8. Preparations for commissioning This page is intentionally left blank 72 S 223.en-01 © 2012 Sandvik SRP AB .855.

78 IM Sandvik CTHS430:02 Tank unit 73 .9. always read section 2. Safety precautions before carrying out any work on the equipment or making any adjustments. storage and removal To ensure maximum safety. Disassembly.

Check the weight of the components to be lifted and make sure that the WLL (Working Load Limit) of the lifting equipment is sufficient for the weight to be lifted. See section 2. See the Operator’s and Maintenance Manual for the oil tank unit.1 Moving and storage 9. see the Operator’s and Maintenance Manual for the crusher.en-01 © 2012 Sandvik SRP AB . Make sure that no water remains in the water/oil cooler. WARNING! CAUTION! Sandvik recommends storing of the oil tank unit indoors. Disassembly. but leave the oil in the pump. See the Operator’s and Maintenance Manual for the oil tank unit e) If a water/oil cooler is used (option): Drain the water circuit at the lowest point. c) Drain the oil from the main lubricating system but leave the oil in the pump. the compressed air supplies and the cooling water if a water/oil cooler is used. d) Drain the oil from the Hydroset system. b) Shut off and disconnect the electrical power.1 Short moves and short-term storage Hanging load Keep clear of hanging loads. Collect waste lubricants in suitable containers and dispose as recommended in the MSDS and according to local regulations. (Continued) 74 S 223.1. WARNING! If the oil tank unit is to be taken out of operation and moved into storage. CAUTION! Handle all lubricants and waste lubricants with care and according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. carry out the following steps: a) Shut off the cone crusher. Safety precautions. storage and removal 9. Risk of electrocution High voltage. Long-term exposure to moisture or very high or low temperatures may damage the oil tank unit. Disconnect electrical power before disassembling the oil tank unit.IM Sandvik CTHS430:02 Tank unit 9.855.

the following steps should be carried out. b) Wrap any loose components in bubble wrap or other suitable wrapping to prevent damage.IM Sandvik CTHS430:02 Tank unit 9.4 Moving and Storage. l) Cover the oil tank unit with suitable covering if stored outdoors.en-01 75 . crates and transport platforms. h) Check that the main lubrication tank cover and the Hydroset tank cover are fit to the tank. k) Move the oil tank unit to the storage area according to the instructions in section 4.2 Long moves and long-term storage If the oil tank unit is to be moved into storage for more than 30 days. fill with oil to keep all surfaces inside lubricated. Use the original packing.855. crates and transport platforms if possible. closed and the locking handles are fastened. For further information on how to disassemble. i) Prepare a storage area large enough to store the components with at least 1.1. Make sure that all parts are adequately protected.5 m (5 ft) of free space around and above them for access and ventilation. g) Check that the doors to the cabinet are closed and locked with the handle. see the Operator’s and Maintenance Manual for the tank unit.1. © 2012 Sandvik SRP AB S 223. a) Carry out the steps in section 9. Make sure that the storage area environment meets the conditions in the table below: Characteristic Min–max temperatures Max relative humidity Value 5–40 °C (41–104 °F) 80% Notes Non-condensing Disassemble the oil tank unit to the extent necessary for the planned transport/storage. Disassembly. j) 9.1 Short moves and short-term storage. c) Pack the equipment using suitable packing. storage and removal f) Plug or protect any open connections on the oil tank unit. d) If there is no oil left in the pumps.

en-01 © 2012 Sandvik SRP AB . b) Contact the local service organization for further instructions on arranging transport. If the oil tank unit has not been in operation before being stored. storage and removal 9. Disassembly.1.855.IM Sandvik CTHS430:02 Tank unit 9.2 Return to the manufacturer a) Prepare the equipment for transport according to the instructions in section 9.3 Regular inspection during storage The following checks should be carried out regularly during the storage period: • • Inspect the oil tank unit for damage and make sure that it is protected from rust and contamination. check that the rust prevention packing is undamaged.1 Moving and storage. 9. and renew it if necessary. 76 S 223.

WARNING! a) Shut down and disconnect the oil tank unit according to the instructions in section 9. storage and removal 9. 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. Risk of fire and explosion Due to the risk of leakage. Provide good ventilation and use breathing apparatus.en-01 77 .855.3 Disposal CAUTION! If the oil tank unit is to be permanently disposed of. Recycle or dispose all material and components in compliance with the Material Safety Data Sheet (MSDS) if any and/or local regulations.IM Sandvik CTHS430:02 Tank unit 9. follow the sequence given below. DANGER! WARNING! Toxic gases When dismantling and scrapping the oil tank unit it can be necessary to cut the parts. (Continued) © 2012 Sandvik SRP AB S 223. Environmental hazard Disposed oil tank parts can leak toxic substances into the subsoil water and soil during long-term storage. Disassembly. This process can create toxic gases.1 Moving and storage.

IM Sandvik CTHS430:02 Tank unit 9.) – Cast manganese steel (mantle.en-01 © 2012 Sandvik SRP AB . etc. 78 S 223. storage and removal b) Disassemble the equipment as much as possible and separate the following parts and material: – Stainless steel – Cast steel (frame etc. concave ring.) – Bronze (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 all material and components in compliance with suitable Material Safety Data Sheets (MSDS) and local regulations. Disassembly.855.