04.CH660-03 Operators Instructions S223.1079-02 en

Original instructions
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Operator's Instructions
CH660:03
This publication is copyright of Sandvik – © Sandvik 2014.
It must not be copied*, reproduced or otherwise made available in full or in part to any third party
without Sandvik's prior written consent.
All rights reserved.
* The maintenance checklists in the Maintenance Instructions and Operator's Instructions may be
copied solely for maintenance purposes of Sandvik equipment.
Document number: S 223.1079

Version: 2
Language: en-US
Issue: 06/02/2015
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
WARNING
IGNORING INSTRUCTIONS HAZARD
Lack of knowledge can lead to risky situations.
Read and understand the information in the manual. If anything is

unclear, please contact Sandvik. Keep this publication for future
reference.
Copyright © Sandvik
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Table of contents
1. Operating instructions
1.1. Starting and stopping the crusher..................................................8
1.1.1. Starting the crusher............................................................8
1.1.1.1. Starting the crusher in low ambient temperatures...
8
1.1.2. Stopping the crusher.......................................................... 9
1.2. Adjusting the CSS..........................................................................9
1.3. Clearing out the crushing chamber................................................9
1.4. Opening the tank covers..............................................................10
1.5. Closing the tank covers............................................................... 10
2. Operator's inspection and care

2.1. Determining inspection and maintenance intervals..................... 14
2.2. Daily inspection and care.............................................................14
2.3. Weekly inspection and care.........................................................15
2.4. Monthly inspection and care........................................................ 16
2.5. Checks before starting the pumps............................................... 16
2.5.1. Checking the guards and dust sealing components for
defects........................................................................................16
2.5.2. Checking the electrical cables and connectors................ 16
2.5.3. Checking the crushing chamber for wear.........................16
2.5.3.1. Checking the crushing chamber for uneven wear...
16
2.5.3.2. Checking the mantle and concave.......................17
2.5.3.3. Checking the A-dimension...................................17
2.5.4. Checking the movement between the flanges of the
topshell and the bottomshell...................................................... 18
2.5.5. Checking the oil level in the main lubrication tank before
starting the pump....................................................................... 18
2.5.6. Checking the shut-off valves between the tanks and the
pumps........................................................................................ 19
2.5.7. Checking the crusher for jammed material...................... 19
2.5.8. Cleaning the air/oil cooler.................................................20
2.6. Checks after starting the pumps.................................................. 20
2.6.1. Checking the oil level in the main lubrication tank after
starting the pump....................................................................... 20
2.6.2. Checking the condition of the lubrication oil.....................21
2.6.3. Checking the oil hoses, pipes, valves, connections and
fittings for leaks.......................................................................... 21
2.7. Checks when idling......................................................................22
2.7.1. Checking the overpressure dust sealing system..............22
2.7.1.1. Overpressure fan................................................. 22
2.7.1.2. Regulator for compressed air.............................. 22
2.7.2. Checking the pressure of the main lubrication system.....23
2.7.3. Checking the return oil temperature.................................23
2.7.4. Checking the CSS with lead.............................................24
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Table of contents
2.7.5. Listening for abnormal noise............................................ 24

2.7.6. Checking the function of the return oil flow switch........... 24
2.8. Checks while crushing................................................................. 25
2.8.1. Checking the Hydroset pressure......................................25
2.8.2. Checking the temperature of the pinionshaft housing......26
2.8.3. Checking if bolts have come loose...................................26
2.8.4. Checking the pressure of the main lubrication system.....26
2.8.5. Checking the return oil temperature.................................27
2.8.6. Checking the oil level in the Hydroset tank...................... 27
2.9. Checks during stop...................................................................... 28
2.9.1. Cleaning the return oil screen.......................................... 28
2.9.2. Cleaning the dirt trap........................................................29
2.9.3. Checking the wear and tension of the V-belt....................30
2.9.4. Checking the dust seal ring for wear................................31
2.9.5. Checking the condition of the scraper above the dust collar
................................................................................................... 32
2.9.6. Checking the grease level in the spider bearing.............. 33
2.9.7. Checking the air vent filter................................................34
3. Operator's troubleshooting
3.1. Possible causes and corrective actions.......................................36
3.2. The crusher does not start...........................................................36
3.3. The crusher stops........................................................................ 36
3.4. The lubrication oil temperature is too high...................................37
3.5. The CSS varies or the product is oversized................................ 37
3.6. The pinionshaft does not operate correctly................................. 38
3.7. The crusher sounds different....................................................... 38
3.8. The crusher's capacity drops.......................................................38
3.9. A bearing in the crusher fails....................................................... 38
3.10. The oil is contaminated..............................................................39
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1.1. Starting and stopping the crusher

Normally, the crusher´s control system restricts the ways in which the
crusher can be started. Read complementary information from the
manufacturer of the control system. Nevertheless, make sure that the
control system follows the start and stop procedures below.
Follow the Checks before starting the pumps on page 16 and
procedures on the maintenance card Daily inspection and care on page
14 before starting the crusher.
NOTE! The oil heating should run for 24 hours a day.
1.1.1. Starting the crusher

a) Start the main lubrication oil pump.
b) When the “Ready for start” signal is received, start the crusher’s
drive motor. The pinionshaft lubrication pump also starts when the
drive motor is started.
c) Start the feeder. The crusher should be choke fed without
segregation.
1.1.1.1. Starting the crusher in low ambient temperatures
NOTE! In low ambient temperatures the oil is more viscous, and this can
cause the warning lamp H10 to light up. The electrical signal is
automatically reset when the working temperature has been
reached, but the mechanical signal (the red pop-up button) must
be reset manually. If the button pops up immediately, contact
maintenance personnel.
H10 PS2 1
1 Pop-up button
H10 Warning lamp, main lubrication filter
PS2 Pressure switch, main lubrication
In low ambient temperatures, before normal operating temperature is

reached, the lubrication oil can overflow the dust collar when the main
lubrication pump is started. Refer to section Operating in low
temperatures in the Installation instructions for further information.
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a) Start and stop the oil pump repeatedly at 30 second intervals until
the “Ready for start” signal is received. Then start the crusher and
allow it to idle. Look through the inspection glass on the tank and
make sure that the oil flow is normal.
1.1.2. Stopping the crusher

a) Stop the feeder, and let the crusher run until the crushing chamber
is empty.
b) Stop the crusher’s drive motor. The pinionshaft lubrication pump
also stops when the drive motor is stopped.
c) After the crusher has stopped completely, stop the main lubrication
pump.
1.2. Adjusting the CSS

Use the push button box L1 to increase or decrease the CSS.
a) Stop the crusher, see section Stopping the crusher on page 9.
b) Make sure the crusher is empty.
c) Press (1) to raise the mainshaft and decrease the CSS.
d) Press (2) to lower the mainshaft and increase the CSS.
1 Decrease the CSS

2 Increase the CSS
1.3. Clearing out the crushing chamber

Risk of equipment or property damage.
Do not start the crusher if it has stalled because of
uncrushable material (metal, wood etc.). Empty the
NOTICE crusher manually or unbolt the topshell so that all
material can leave the crushing chamber, refer to the
Maintenance Instructions.
Risk of equipment or property damage.

NOTICE Never start the crusher with a loose topshell.
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If the crusher stalls with the crushing chamber full of material, clear it
out as follows:
a) Make sure that the crusher’s feeding arrangement is switched off.
b) If there is material in the discharge chute beneath the crusher,
remove the material.
NOTE! If there is an ASRi system, switch it off. The ASRi system
must be disconnected to prevent an automatic raising or
lowering of the mainshaft.
c) Use the L1 push button box to lower the mainshaft, keeping an eye
on the Hydroset pressure.
d) If the Hydroset pressure drops below 0.3 MPa, then raise the
mainshaft again until the pressure gauge displays at least
0.5 MPa.
e) Start the crusher.
NOTE! Check for material build-up on the bottomshell arms. If
damp, wet feed is causing packing, operate at a larger
setting.
NOTE! Check the interlocking between the feeding arrangement
and discharge system. There must be room beneath the
crusher for material in the crushing chamber and feed
hopper, in case the discharge system stops.
1.4. Opening the tank covers

a) Loosen the two screws (1). Make sure that the screws (1) are
removed from the threaded part on tank roof.
b) Open the tank cover (2) until it is upright.
c) Lift off the tank cover (2).
1
2
1 Screw
2 Tank cover
1.5. Closing the tank covers

a) Hold the tank cover upright and fit the hinges (3) together.
b) Close the tank cover (2).
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c) Refit the screws (1) and tighten them.
1
2
3
1 Screw
2 Tank cover
3 Hinge
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2. Operator's inspection and

care
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2.1. Determining inspection and

maintenance intervals
Every equipment must be subjected to regular systematic checks. This
will result in fewer and smaller repairs, less downtime and thus lower
overall running costs.
NOTE! New equipment must be inspected often during the initial operating
period. The intervals between inspections can then be increased until a
suitable frequency is found.
Keep a written log including the crusher’s and tank unit's operating
conditions and loads, important data and details of adjustments made
and any repairs carried out.
Since equipment operate under widely differing conditions, it is
impossible to recommend an inspection and care schedule applicable to
all equipment. However, regular inspections are necessary.
2.2. Daily inspection and care
Operation hours - Daily or every 8 hours of operation

Maintenance procedure Notes
CHECKS BEFORE STARTING
THE PUMPS
Check the guards and dust sealing
16
components for defects
Check the electrical cables and
16
connectors
Check the oil level in the main lubrication
18
tank before starting the pump
Check the shut-off valves between the
19
tanks and the pumps
Check the crusher for jammed material 19
CHECKS AFTER STARTING
THE PUMPS
Check the oil level in the main lubrication
20
tank after starting the pump
Check the oil hoses, pipes, valves,
21
connections and fittings for leaks
CHECKS WHEN IDLING
Check the pressure of the main
23
lubrication system
Check the return oil temperature 23
Check the CSS with lead 24
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Operation hours - Daily or every 8 hours of operation

Listen for abnormal noise 24
CHECKS WHILE CRUSHING
Check the Hydroset pressure (N/A for
25
crushers with ASRi)
Check the temperature of the pinionshaft
26
housing
Check if bolts have come loose 26
Check the pressure of the main
26
lubrication system
Check the return oil temperature 27
Check the oil level in the Hydroset tank 27
When completed:
Date ............................................................... Operation hours .................................................
Approved .......................................................
2.3. Weekly inspection and care
Operation hours - Weekly or every 40 hours of operation

CHECKS BEFORE STARTING
THE PUMPS
Check the crushing chamber for wear 16
Check the movement between the
flanges of the topshell and the 18
bottomshell
Clean the air/oil cooler 20
CHECKS AFTER STARTING

THE PUMPS
Check the condition of the lubrication oil 21
CHECKS WHEN IDLING
Check the overpressure dust sealing
22
system
CHECKS DURING STOP
Clean the dirt trap 29
If applicable: Check the wear and
30
tension of the V-belt
When completed:
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Approved .......................................................
2.4. Monthly inspection and care
Operation hours - Monthly or every 160 hours of operation

CHECKS WHEN IDLING
Check the function of the return oil flow
24
switch
CHECKS DURING STOP
Clean the return oil screen 28
Check the dust seal ring for wear 31

Check the condition of the scraper above
32
the dust collar
Check the grease level in the spider
33
bearing
Check the air vent filter 34
When completed:
Approved .......................................................
2.5. Checks before starting the pumps
2.5.1. Checking the guards and dust sealing

components for defects
a) Visually check all guards and dust sealing components for defects.
b) If any defects are detected, contact maintenance personnel.
2.5.2. Checking the electrical cables and connectors

a) Visually check all electrical cables and connectors.
b) If any damage is detected, contact maintenance personnel.
2.5.3. Checking the crushing chamber for wear

If the crusher capacity is reduced, this can indicate that the mantle
and/or concave is worn out.
2.5.3.1. Checking the crushing chamber for uneven wear
Regular inspection of the crushing chamber is recommended for good
total economy and to make sure that it has not been worn unevenly or
that it has become oval. Check the crushing chamber as often as
necessary.
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a) Visually inspect the crushing chamber through the inspection

hatches. Look for any localized wear or other damage in the
crushing chamber.
b) If any uneven wear is detected, contact maintenance personnel.
2.5.3.2. Checking the mantle and concave
If a large proportion of the feed is close to the maximum material size,
crushing is concentrated to the upper part of the chamber. This can
cause an annular groove (B) around the top of the entire crushing
chamber. With a large proportion of fine material in the feed, crushing is
concentrated to the lower part of the chamber, which can cause a
similar groove (C) in the lower part of the chamber.
NOTE! The mantle and concave are worn out when they have been worn
down to about ⅓ of the original thickness.
a) Visually inspect the mantle and concave through the inspection
hatches. Look for any indentations, cracks or other damage to
them.
b) If any indentations, cracks or other damage is detected, contact
B
C
A A-dimension
B Groove
C Groove
2.5.3.3. Checking the A-dimension

Check the A‑dimension as often as necessary.
NOTE! This check is unnecessary if your crusher is equipped with ASRi.
Refer to the ASRi's Installation and Operator's Manual for
instructions about how to check the A‑dimension.
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NOTE! The concave and/or mantle can be completely worn out before
the minimum A‑dimension is reached, especially if the CSS and
the eccentric throw are small.
NOTE! If the mainshaft is raised further than the minimum A‑dimension, it
can damage the spider bearing.
a) Measure the A‑dimension between the head nut (1) and the
underside of the wear ring (2).
b) If the A‑dimension is less than 15 mm (0.59"), the concave and/or
mantle is worn out and must be replaced. Contact maintenance
personnel.
A A‑dimension
1 Head nut
2 Wear ring
2.5.4. Checking the movement between the flanges of

the topshell and the bottomshell
a) Use a feeler gauge to check if there is play between the flanges of
the topshell and the bottomshell.
b) If any play is detected, contact maintenance personnel.
2.5.5. Checking the oil level in the main lubrication

tank before starting the pump
a) Check the oil level on the level indicator LI1.
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b) The oil level must be at max. If necessary, top up with oil.
LI1
LI1 Level indicator for main and pinionshaft lubrication tank
2.5.6. Checking the shut-off valves between the tanks

and the pumps
a) Check that the shut-off valves V1, V3, V4, V5, V11 are fully open.
V1 V11 V3 V5 V4
V1 Shut-off valve, main lubrication system

V3 Shut-off valve, pinionshaft lubrication system
V4 Shut-off valve, Hydroset pump drainage line
V5 Shut-off valve, Hydroset suction line
V11 Shut-off valve, cooler system
NOTE! All valves are in closed position in the illustration above.
2.5.7. Checking the crusher for jammed material

NOTE! Remove any jammed material from the top of the crusher.
a) Check the feed hopper and the distributor for any jammed material,
that may be blocking the feed opening.
b) Check that no material has built up on the bottomshell arms.
c) Remove any jammed material.
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2.5.8. Cleaning the air/oil cooler

Keep the cooling efficiency as high as possible by cleaning the air/oil
cooler matrix with compressed air as often as necessary. If necessary,
also clean the outside of the coil with compressed air. If vibration occurs
in the fan, it should be cleaned or replaced, to avoid damage to the
air/oil cooler.
To provide maximum cooling effect, the air must be sucked through the
coolers matrix.
a) Clean the air/oil cooler with compressed air. Be careful not to
damage the cooler.
Air flow direction
2.6. Checks after starting the pumps
2.6.1. Checking the oil level in the main lubrication

tank after starting the pump
a) Check the oil level. It must be above min. on the level indicator L1.
b) If the oil level is near or below the minimum level, stop the crusher.
Wait for the oil to return to the tank, then top up with oil to the
maximum level.
LI1
L1 Level indicator for main lubrication tank
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2.6.2. Checking the condition of the lubrication oil

If there is an increased amount of metal particles on the return oil
screen OS1, the cause should be investigated to prevent possible
damage.
a) Clean the inspection glass.
b) Check the color of the oil. The color darkens as the oil becomes
more contaminated.
A yellow shimmer indicates bronze deposits in the oil.
c) Check the return oil screen OS1.
• An increased amount of swarf indicates a bearing or bushing
failure inside the crusher. Contact maintenance personnel.
• Needle-like particles indicate a seizure or wear in bevel gears
inside the crusher. Contact maintenance personnel.
• Lead flakes indicate high temperature or localized overheating
and partial seizure in bushings or step bearing components.
Contact maintenance personnel.
• Bronze particles indicate a bearing or bushing failure inside
the crusher. Contact maintenance personnel.
• Dirt can indicate that the overpressure dust sealing system is
malfunctioning or that the dust seal ring is worn.
NOTE! Dirt can also enter the system when the liners are
changed.
d) If necessary, clean the return oil screen OS1, see section Cleaning
the return oil screen on page 28.
OS1
1 Return oil screen handle

OS1 Return oil screen
2.6.3. Checking the oil hoses, pipes, valves,

connections and fittings for leaks
a) Visually check all oil hoses, pipes, valves, connections and fittings
for leakage.
b) If any leak is detected, contact maintenance personnel.
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2.7. Checks when idling
2.7.1. Checking the overpressure dust sealing system

a) Check the covers on the tank unit. The covers on the tank unit
must be air tight.
b) If necessary, adjust or replace the sealing strips.
2.7.1.1. Overpressure fan
a) Visually check all the hoses (1) of the overpressure dust sealing
system.
b) Visually check the filter FU5.
FU5
1 Hoses
FU5 Filter, overpressure fan
2.7.1.2. Regulator for compressed air

a) Visually check all the hoses (1) of the overpressure dust sealing
system.
b) Visually check the filter FU6.
FU6
1 Hoses
FU6 Filter, pressure regulator
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2.7.2. Checking the pressure of the main lubrication

system
NOTE! When the fan of the air/oil cooler is running, the pressure in the oil
system generally rises. Avoid reading off the pressure at such
times.
Check the pressure and keep a record of the readings. If the pressure
rises, it usually means that the filter is clogging up. If the pressure is
low, the pump can be worn.
Normal pressure (tank installation dependent) 0.15 - 0.5 MPa (21.8 - 72.5 psi)
a) Check the pressure on the pressure indicator PI2.

b) Record the value.
c) If the value is below or above the normal pressure, or if the
warning lamp H10 is lit, contact maintenance personnel.
PI2 H10

PI2 Pressure indicator
2.7.3. Checking the return oil temperature

The return oil temperature is affected by the load on the crusher and the
ambient air temperature.
NOTE! The crusher is automatically stopped if the oil temperature is too
high. With TIMS, an A-alarm is initiated and the
“TT1 - High temperature” LED lights up on the TIMS box LC10.
a) Check the return oil temperature on the temperature indicator TI1.
Return oil temperature during normal conditions 35 to 50°C (95 to 122°F)
b) If the temperature deviates from the values in the table, contact

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2.7.4. Checking the CSS with lead

NOTE! This check is not necessary if your crusher is equipped with ASRi.
Refer to the ASRi's Installation and Operator's Manual for
instructions about how to check and calibrate the CSS.
a) Fasten a lump of lead to a steel wire. Make sure that the lead lump
is larger than the CSS.
Crushing hazard
If you fall into the crusher during operation you
are crushed.
DANGER! Avoid staying on the equipment, unless it is
necessary for inspections and maintenance
work.
b) Slowly lower the lead lump into the discharge area of the crushing
chamber.
c) Check the CSS at four points evenly spaced around the crushing chamber, in ord
The thickness of the squeezed lead lump corresponds to the CSS.
d) If any uneven wear is detected, contact maintenance personnel.
2.7.5. Listening for abnormal noise

a) Listen for any abnormal noise from the crusher.
b) Listen for any abnormal noise from the main lubrication pump and
the pinionshaft lubrication pump.
c) If you hear any abnormal noise, stop the crusher and contact
2.7.6. Checking the function of the return oil flow

switch
a) Check the oil level in the return oil chamber (4). When a sufficient
flow of oil is returning to the tank, the oil level in the return oil
chamber (4) should be 5 mm (0.20") above the spillway. With this
oil level in the return oil chamber (4), the float (1) is completely
immersed in oil but the oil’s lifting force pushes the float (1) up
against its upper stop.
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b) Check the level monitor by pushing the float (1) down about
5 mm (0.20") from its upper stop. The crusher’s drive motor must
then stop. If the oil flow decreases, the oil level will drop in the
return oil chamber (4). When the oil level has dropped about
15 mm (0.59"), the float (1) will sink about 5 mm (0.20") below the
upper stop. In this position the switch FS1 opens and stops the
crusher’s drive motor.
FS1
2
5 3
4 OS1
1 Float
2 Spillway
3 Adjustable lower outlet
4 Return oil chamber
FS1 Return oil flow switch
2.8. Checks while crushing
2.8.1. Checking the Hydroset pressure

NOTE! This check is not necessary if your crusher is equipped with ASRi.
The maximum pressure is then automatically regulated.
a) Push the button V10 to activate the pressure indicator PI1.
PI1 V10
PI1 Hydroset pressure indicator

V10 Button to activate the pressure indicator PI1
b) Check the pressure indicator for the current Hydroset pressure

measured at the hydraulic assembly HA1.
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c) Check that the maximum Hydroset pressure does not exceed

3.6 MPa (522 psi).
d) If the pressure exceeds, increase the CSS until the pressure falls
below the value, see section Adjusting the CSS on page 9.
2.8.2. Checking the temperature of the pinionshaft

housing
a) Use an infrared temperature sensor to measure the temperature.
Normal temperature 40 to 60 °C (104 to 140 °F)
b) If the housing is too hot, stop the crusher and contact maintenance
personnel.
2.8.3. Checking if bolts have come loose

a) Check if any bolts have come loose.
b) If there are loose bolts, contact maintenance personnel.
2.8.4. Checking the pressure of the main lubrication

system
NOTE! When the fan of the air/oil cooler is running, the pressure in the oil
system generally rises. Avoid reading off the pressure at such
times.
Check the pressure and keep a record of the readings. If the pressure
rises, it usually means that the filter is clogging up. If the pressure is
low, the pump can be worn.
Normal pressure (tank installation dependent) 0.15 - 0.5 MPa (21.8 - 72.5 psi)
a) Check the pressure on the pressure indicator PI2.

b) Record the value.
c) If the value is below or above the normal pressure, or if the
warning lamp H10 is lit, contact maintenance personnel.
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PI2 H10

PI2 Pressure indicator
2.8.5. Checking the return oil temperature

The return oil temperature is affected by the load on the crusher and the
ambient air temperature.
NOTE! The crusher is automatically stopped if the oil temperature is too
high. With TIMS, an A-alarm is initiated and the
“TT1 - High temperature” LED lights up on the TIMS box LC10.
a) Check the return oil temperature on the temperature indicator TI1.
Return oil temperature during normal conditions 35 to 50°C (95 to 122°F)
b) If the temperature deviates from the values in the table, contact

2.8.6. Checking the oil level in the Hydroset tank

a) Lower the mainshaft to its lowest position, see section Adjusting
the CSS on page 9.
b) Make sure the Hydroset pressure is 0, see section Checking the
Hydroset pressure on page 25.
c) Stop the crusher, see section Stopping the crusher on page 9.
d) Check the oil level on the level indicator LI2.
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e) The oil level must be at max. (1). If necessary, top up with oil.
1
LI2
1 Maximum level mark

LI2 Level indicator for oil in the Hydroset tank
2.9. Checks during stop
2.9.1. Cleaning the return oil screen

Health hazard
Oil can be a health hazard.
Handle waste oil with care and according to the
WARNING! supplier's Material Safety Data Sheets (MSDS) and
local regulations. Collect the waste oil in suitable
containers and dispose of it as recommended in the
MSDS and according to local regulations.
a) Open and remove the lubrication oil tank covers, see section
Opening the tank covers on page 10.
b) Use the handle (1) and lift out the return oil screen OS1.
c) NOTE! Use white spirit only if diesel oil does not dissolve the
residues.
Rinse contamination from the return oil screen with diesel oil or
white spirit.
d) Blow the return oil screen clean with compressed air.
Risk of equipment or property damage
If white spirit is used for cleaning, wipe it off
NOTICE carefully and allow it to evaporate before filling
the tank with oil.
e) If the return oil screen is damaged, replace it.

f) Put the return oil screen back into place in the tank.
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g) Close the lubrication oil tank covers, see section Closing the tank
covers on page 10.
1
OS1

2.9.2. Cleaning the dirt trap

Burn hazard
Oil can become hot during operation. Equipment and
hoses/pipes that contain oil can have hot surfaces.
WARNING! Allow the oil, the equipment and hoses/pipes to cool
down before working in the tank unit or on the
hydraulic or lubrication systems.

The gauze element (1) must not, under any
NOTICE circumstances, be left out or replaced by another
with a different mesh
If the dirt trap FU4 is allowed to clog, cavitation occurs in the pump,
which can result in pump breakdown. The gauze element (1) must not,
under any circumstances, be left out or replaced by another with a
different mesh.
a) Close the shut-off valve V1 ahead of the filter unit with dirt
trap FU4.
b) Put a suitable container underneath the dirt trap FU4 to collect the
oil that runs out.
c) Unscrew the plug (2).
d) Remove and clean the gauze element (1).
e) Install the gauze element (1) and screw back the plug (2).
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f) Open the shut-off valve V1.
FU4 V1
1
FU4 Dirt trap

V1 Shut-off valve (closed position on drawing)
1 Gauze element
2 Plug

Check that the shut-off valve V1 is fully open
NOTICE before the main lubrication pump is started. The
pump and the hoses will be seriously damaged if
the valve is closed.
NOTE! During the running-in period, and when the tank has been
cleaned, check the dirt trap FU4 daily.
2.9.3. Checking the wear and tension of the V-belt

During the first few days of operation, the belt tension must be checked
frequently since new belts stretch. If the belts are not tensioned
sufficiently, slipping can occur and belt life will be reduced considerably.
Proper belt tension can be determined with the help of the deflection
load. Check the deflection load with a spring balance, a tensiometer or
similar.
Recommended deflection load (F)
F/belt
Belt profile Normal Max. (newly fitted belts)
Unit kp N lbf kp N lbf
SPC 7 69 15.4 12 117.7 26.5
8V 9 88 19.8 14 137.3 30.9
a) Measure the belt span (W) in meters, as shown below.

b) Multiply the span by 1.5, to give the belt deflection (D) in cm.
c) Set the top side of the lower O-ring to the correct deflection in cm
on the meter’s lower scale.
d) Push the upper O-ring up against the lower edge of the outer
sleeve.
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e) Press the meter against the belt in the middle of the span and
press sufficiently hard to bring the top side of the lower O-ring level
with the belt alongside.
f) Remove the meter and read off the load (F) in kp (lbf) at the top
side of the upper O-ring. The correct load is obtained from the
table above, which should be reproduced on the meter.
2
1
6
6 14 12 10 8
W
5
F
4
2
32
D
1
1 F-scale
2 D-scale
D = deflection
W = belt span
F = deflection load
2.9.4. Checking the dust seal ring for wear

You measure the play between the dust seal ring and the dust collar
through one of the inspection hatches.
a) Open one of the inspection hatches.
b) Use feeler gauges to measure the play between the dust seal
ring (1) and the dust collar (2). The play must not exceed
1.9 mm (0.075").
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c) If the play is larger, contact maintenance personnel.
1 Dust seal ring

2 Dust collar
3 Measure the play here
d) Close the inspection hatch.
2.9.5. Checking the condition of the scraper above the

dust collar
a) Check the condition of the scraper (5) at regular intervals. The
scraper (5) should scrape against the dust collar (4).
b) If necessary, clean out the area around the dust collar (4) and the
bottomshell arms.
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c) If the scraper (5) needs to be replaced, contact maintenance

personnel.
2
3 5
4
2 Retaining ring
3 Dust seal ring
4 Dust collar
5 Scraper
2.9.6. Checking the grease level in the spider bearing

During the first few weeks of operation, the grease level should be
checked daily by unscrewing the plug in the spider cap. Beside the
grease nipple on one of the topshell arms there is a decal which shows
the type of grease pumped into the spider bearing before delivery. Do
not mix different types of grease. Refer to section Grease for spider
bearing lubrication in the Technical Specifications.
NOTE! The spider bearing should be filled with grease to the top of the
bushing, when the mainshaft is in its lowest position.
a) Make sure that the mainshaft is in its lowest position, see section
Adjusting the CSS on page 9.
b) Unscrew and remove the plug in the spider cap (not visible in the
illustration).
c) Examine the grease level by sticking a steel wire or equivalent into
the observation hole (not visible in the illustration) and feeling the
grease level. Make sure that you measure the grease level from
the mainshaft (3) and not from a screw (2) or the bushing (4).
Alternatively shine a flashlight into the hole and observe the level.
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d) If necessary, top up with grease to the correct level. This

corresponds to approximately the amount given in the table below.
• If the level is low, pump grease in through a pipe (1) inside
one of the topshell spider arms.
• If the level is very low, remove the spider cap and add grease
straight from the drum.
Grease quantity
Spider bearing 7-9 kg (15.4-19.8 lbs)
NOTE! The mainshaft in the illustration is not in its lowest position.
1 2 3 4
1 Grease pipe
2 Screw
3 Mainshaft
4 Bushing
2.9.7. Checking the air vent filter

a) Check the air vent filter (1).
b) If the filter is clogged, contact maintenance personnel.
1 Air vent filter
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3.1. Possible causes and corrective actions

If the crusher stalls with the crushing chamber full of
NOTICE material, see section Clearing out the crushing chamber on
page 9.
If the problem remains after you have followed the troubleshooting in

this chapter, or if the problem is not covered here, contact maintenance
personnel.
Before you carry out any corrective actions:
• Read and understand the instructions.

• Make sure that you have the required training and skills before
performing any corrective actions.
When you perform corrective actions, use appropriate approved
personal protective equipment.
3.2. The crusher does not start
Possible cause Corrective action

No “Ready for start” signal and oil pump Start the main lubrication oil pump.
not running
No “Ready for start” signal and If the return oil flow is low, wait a few minutes to see if it
lubrication oil flow low stabilizes.
Check that oil does not overflow over dust collar, see
section Starting the crusher in low ambient
temperatures on page 8.
Normal lubrication oil flow, but no Check the operation of the return oil flow switch, see
“Ready for start” signal section Checking the function of the return oil flow
switch on page 24.
Oil does not return to tank (in low See section Starting the crusher in low ambient
temperature) temperatures on page 8.
3.3. The crusher stops

The crusher stops when idling or with material in the chamber.

Oil pump not running Start the main lubrication oil pump.
Low lubrication oil flow Check that oil does not overflow over dust collar, see section
Starting the crusher in low ambient temperatures on page 8.
Normal lubrication oil flow Check the operation of the return oil flow switch. See section
Checking the function of the return oil flow switch on page 24.
Oil too hot See section The lubrication oil temperature is too high on page
37.
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If applicable: V-beltsslipping Reduce the load on the crusher. See Crusher’s drive motor
overloaded below.
Check the wear and tension of the V-belt, see section Checking the
wear and tension of the V-belt on page 30.
Crusher’s drive motor Increase the CSS if it is too small.
overloaded
Packing in crushing Is the material wet? Is the fine content high? Increase the CSS.
chamber
Tramp metal or blockage in See section Clearing out the crushing chamber on page 9.
crushing chamber Increase the CSS and remove the obstruction. Check the mantle
and concave for damage. Also check if they have come loose.
Contact maintenance personnel if necessary.
3.4. The lubrication oil temperature is too

high

Protective temperature Air/oil cooler: clean the cooler matrix. Check that there is
switch TS1 shuts down the sufficient cooling air. Refer to section Removing oil residues from
crusher the air/oil cooler in the Operator's instructions.
Protect the cooler and the tank unit from direct sunlight.
Check the contamination in the return oil screen OS1, see
section Checking the condition of the lubrication oil on page 21.
If the contamination has increased, contact maintenance
personnel.
Cooler cooling continuously See Protective temperature switch TS1 shuts down the crusher.
Incorrect temperature reading Check the temperature indicator against a reference
thermometer.
3.5. The CSS varies or the product is

oversized

Pressure relief valve If there are overload pressure peaks, check the feed arrangement
leaking. and the crushing chamber. Remove any obstacles.
Setting increase has caused
oil level to rise in the
Hydroset tank
Concave ovality Check the CSS at four points evenly spaced around the crushing
chamber, see section Checking the CSS with lead on page 24. The
difference between the largest and smallest reading is an
indication of the ovality.
If ovality is detected, contact maintenance personnel.
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3.6. The pinionshaft does not operate

correctly

Vibration in crusher, pinionshaft housing or If applicable: Clean off any dust from the V-belts.
motor
3.7. The crusher sounds different

“Grating” step bearing components Reduce the crusher's operating load.
Check the contamination in the return oil screen OS1 see
section Checking the condition of the lubrication oil on page
21.
If the contamination has increased, contact maintenance
personnel.
Packing in crushing chamber Check the operating conditions and the CSS. Increase
Mantle and concave in “metal-to- the CSS.
metal” contact
3.8. The crusher's capacity drops

“Ski-slopes” on mantle and Check the feed arrangement. Make sure the crusher is choke fed.
concave Check the largest and smallest sizes of material fed to the crusher.
There must not be a large proportion of material smaller than the
CSS. See section Checking the CSS with lead on page 24. Also
refer to the Installation instructions.
If applicable: V-belts Clean off any dust from the V-belts.
slipping
Feed material or Altered fraction length and material hardness can lead to capacity
composition has been changes. Refer to the Installation instructions.
changed
Bridging or blocking in Check the material level in the feed hopper. If possible, limit the top
crushing chamber size of the feed.
3.9. A bearing in the crusher fails

High temperature or local Check for lead flakes in the return oil screen OS1, see
overheating and partial seizure in section Checking the condition of the lubrication oil on page
bushings or step bearing 21.
components If the there are lead flakes, contact maintenance personnel.
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3.10. The oil is contaminated

Contamination on the return oil screen: Check the contamination in the return oil screen OS1,
• Swarf see section Checking the condition of the lubrication oil
• Needle-like particles on page 21.
• Lead flakes If the contamination has increased, contact maintenance
• Bronze particles personnel.
• Dirt
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40 S 223.1079 - 2 en-US 06/02/2015 14:53:57

04.CH660-03 Operators Instructions S223.1079-02 en

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04.CH660-03 Operators Instructions S223.1079-02 en

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Lack of knowledge can lead to risky situations.

Read and understand the information in the manual. If anything is

2. Operator's inspection and care

2.7.5. Listening for abnormal noise............................................ 24

1.1. Starting and stopping the crusher

NOTE! The oil heating should run for 24 hours a day.

1.1.1. Starting the crusher

In low ambient temperatures, before normal operating temperature is

1.1.2. Stopping the crusher

1.2. Adjusting the CSS

1 Decrease the CSS

1.3. Clearing out the crushing chamber

Risk of equipment or property damage.

1.4. Opening the tank covers

1.5. Closing the tank covers

c) Refit the screws (1) and tighten them.

This page is intentionally left blank

2. Operator's inspection and

2.1. Determining inspection and

2.2. Daily inspection and care

Operation hours - Daily or every 8 hours of operation

Operation hours - Daily or every 8 hours of operation

2.3. Weekly inspection and care

Operation hours - Weekly or every 40 hours of operation

CHECKS AFTER STARTING

2.4. Monthly inspection and care

Operation hours - Monthly or every 160 hours of operation

Check the dust seal ring for wear 31

2.5. Checks before starting the pumps

2.5.1. Checking the guards and dust sealing

2.5.2. Checking the electrical cables and connectors

2.5.3. Checking the crushing chamber for wear

a) Visually inspect the crushing chamber through the inspection

2.5.3.3. Checking the A-dimension

2.5.4. Checking the movement between the flanges of

2.5.5. Checking the oil level in the main lubrication

b) The oil level must be at max. If necessary, top up with oil.

LI1 Level indicator for main and pinionshaft lubrication tank

2.5.6. Checking the shut-off valves between the tanks

V1 Shut-off valve, main lubrication system

NOTE! All valves are in closed position in the illustration above.

2.5.7. Checking the crusher for jammed material

2.5.8. Cleaning the air/oil cooler

Air flow direction

2.6. Checks after starting the pumps

2.6.1. Checking the oil level in the main lubrication

L1 Level indicator for main lubrication tank

2.6.2. Checking the condition of the lubrication oil

1 Return oil screen handle

2.6.3. Checking the oil hoses, pipes, valves,

2.7. Checks when idling

2.7.1. Checking the overpressure dust sealing system

2.7.1.2. Regulator for compressed air

2.7.2. Checking the pressure of the main lubrication

a) Check the pressure on the pressure indicator PI2.

H10 Warning lamp, main lubrication filter

2.7.3. Checking the return oil temperature

Return oil temperature during normal conditions 35 to 50°C (95 to 122°F)

b) If the temperature deviates from the values in the table, contact

2.7.4. Checking the CSS with lead