CS430-01 IM S223.514.en-01

installation manual Doc. no. S 223.
514
SANDVIK CS430:01
This document is valid for:
Serial no. / Machine no. Sign.
SANDVIK CS430:01
© Copyright 2007 Sandvik SRP AB
All rights reserved. No parts of this document may be reproduced or
copied in any form or by any means without written permission from
Sandvik SRP AB. All data and information in this manual may be
changed without further notice. Reservations for misprints.
Document number: S 223.514 en

Issue: 20070516
Version: 1
Sandvik SRP AB
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 40 90 00, Fax: +46 (0)40 40 92 60
www.sandvik.com
Table of contents
1. Introduction
1.1 Equipment information.......................................................... 8
1.1.1 Document information............................................ 11
1.2 Operating principles of a cone crusher ............................... 12
1.2.1 Description ............................................................. 14
2. Safety precautions
2.1 Hazard information ............................................................. 20
2.1.1 Warning signs ........................................................ 20
2.1.2 Risk levels.............................................................. 20
2.1.3 Prohibition signs..................................................... 20
2.1.4 Mandatory signs..................................................... 20
2.2 Personnel............................................................................ 21
2.2.1 Personal protection ................................................ 22
2.3 General safety precautions................................................. 22
2.3.1 Machine safety guards........................................... 23
2.3.2 Electrical safety...................................................... 24
2.3.3 Welding .................................................................. 24
2.3.4 Hydraulic system.................................................... 25
2.3.5 Lifting and moving loads ........................................ 25
2.3.6 Feed and jams ....................................................... 26
2.4 Emissions ........................................................................... 26
2.4.1 Dust........................................................................ 26
2.4.2 Noise...................................................................... 27
2.4.3 Radioactivity........................................................... 27
CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 1

Table of contents
3. Technical data
3.1 General data ....................................................................... 30
3.2 Crusher motor ..................................................................... 32
3.3 Drive system ....................................................................... 33
3.4 Lubrication system .............................................................. 34
3.5 Hydroset system ................................................................. 35
3.6 Oil cooling systems ............................................................. 36
3.6.1 Oil/water heat exchanger ....................................... 36
3.6.2 Oil/air heat exchanger ............................................ 36
3.7 Over-pressure dust exclusion system................................. 37
3.7.1 General .................................................................. 37
3.7.2 Blower motor .......................................................... 37
3.8 Corrosion protection............................................................ 38
3.9 Processing data .................................................................. 38
3.10 Tightening threaded fasteners ............................................ 39
3.10.1 Requirements for joints with threaded fasteners .... 39
3.10.2 Locking fluid for threaded fasteners ....................... 39
4. Installation preparations
4.1 General ............................................................................... 42
4.2 Crusher capacity and performance..................................... 43
4.3 Installation preparations check list ...................................... 44
4.3.1 Placement .............................................................. 45
4.3.2 Foundation for a cone crusher ............................... 46
4.3.3 Electrical installation............................................... 47
4.3.4 Remote control system .......................................... 47
4.3.5 Process material .................................................... 47
4.3.6 Dust protection ....................................................... 47
4.3.7 Feed arrangement.................................................. 48
4.3.8 Discharge arrangement.......................................... 51
4.3.9 Guards ................................................................... 52
4.3.10 Platforms and guard rails ....................................... 52
4.4 Operating in low temperatures............................................ 53
4.4.1 Measures that make starting and running easier in cold
weather .................................................................. 53
4.4.2 Low temperature problems –
symptoms and remedies ........................................ 54
4.4.3 Insulation of the bottom of the component section of the
oil tank unit ............................................................. 55
4.4.4 Additional oil heaters.............................................. 55
2 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

Table of contents
4.4.5 Diesel heating system............................................ 55

4.4.6 Heating cables on oil lines ..................................... 56
4.4.7 Heating in the component section of the oil tank unit 56
4.4.8 Synthetic oils.......................................................... 57
4.4.9 Mineral oil for the winter season ............................ 57
4.4.10 A thermostatic valve to by-pass the oil cooler........ 58
4.4.11 Blanking off the oil cooler radiator.......................... 59
4.4.12 2-speed fan motor for oil cooler ............................. 59
4.4.13 Modified return oil flow switch interlock.................. 60
4.4.14 Insulation of the oil tank ......................................... 61
4.4.15 Continuous running of the lubrication oil pump...... 61
4.4.16 A heater in the Hydroset tank ................................ 61
5. Transport handling
5.1 Goods data ......................................................................... 64
5.1.1 Contents................................................................. 64
5.1.2 Loading and unloading goods signs ...................... 65
5.2 Lifting equipment ................................................................ 65
5.2.1 Overhead gantry or mobile crane .......................... 66
5.2.2 Fork lift ................................................................... 67
5.3 Unloading the goods........................................................... 68
5.3.1 Unpacking area...................................................... 68
5.3.2 Inspection of goods................................................ 68
5.4 Moving and storage ............................................................ 69
5.4.1 Moving ................................................................... 69
5.4.2 Storage................................................................... 70
5.5 Unpacking the goods .......................................................... 71
5.6 Disposal/return of packaging material ................................ 72

Table of contents
6. Mechanical installation and connections

6.1 General requirements ......................................................... 74
6.2 Foundation .......................................................................... 75
6.2.1 Rubber dampers .................................................... 76
6.2.2 Crusher with rubber dampers on a new concrete
foundation .............................................................. 77
6.2.3 Crusher with rubber dampers on a steel supporting
structure ................................................................. 79
6.3 Crusher assembly ............................................................... 80
6.3.1 Install feed hopper.................................................. 80
6.4 Hoses and pipes – General ................................................ 81
6.5 Hydroset and lubrication systems ....................................... 82
6.5.1 Oil tank unit ............................................................ 82
6.5.2 Water/oil heat exchanger ....................................... 83
6.5.3 Air/oil heat exchanger ............................................ 84
6.6 Over-pressure system......................................................... 85
6.7 Guards, platforms and covers............................................. 87
6.7.1 Guards and covers................................................. 87
6.7.2 Platforms ................................................................ 87
6.8 Lubricants ........................................................................... 87
7. Electrical installation
7.1 General requirements ......................................................... 90
7.2 Overview ............................................................................. 90
7.3 Motors and heating elements.............................................. 91
7.3.1 M1 – Crusher motor ............................................... 91
7.3.2 M2 – Lubrication pump........................................... 91
7.3.3 M3 – Heat exchangers ........................................... 92
7.3.4 M6 – Hydroset pump.............................................. 92
7.3.5 E7 – Oil heaters ..................................................... 92
7.3.6 M8 – Over-pressure blower.................................... 92
8. Final installation checks

8.1 Installation and connection checks ..................................... 94
8.1.1 Lubrication system and Hydroset checks............... 94
8.2 Electrical checks ................................................................. 95
8.3 Safety checks...................................................................... 96
8.4 Start-up ............................................................................... 96

Table of contents
9. Preparations for commissioning

9.1 General ............................................................................... 98
9.2 Presence and correctness checks...................................... 98
9.3 Supply value checks ........................................................... 98
9.4 Function checks.................................................................. 99
9.4.1 Preparation ............................................................ 99
9.5 Health and safety checks.................................................... 99
9.6 Documentation.................................................................... 99
10. Disassembly, storage and removal

10.1 Moving and storage .......................................................... 102
10.1.1 Short moves and short-term storage ................... 102
10.1.2 Long moves and long-term storage ..................... 103
10.1.3 Regular inspection during storage ....................... 103
10.2 Return to the manufacturer............................................... 103
10.3 Disposal ............................................................................ 104
Appendix A:
Installation drawings
A.1 General ............................................................................. A-2
A.1.1 Mechanical drawings ........................................... A-2
A.1.2 Electrical drawings ............................................... A-2
A.1.3 Foundation loads ................................................. A-3
A.1.4 Mechanical connections....................................... A-4
A.1.5 Cable overview .................................................... A-6

Table of contents

1. Introduction
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.

1. Introduction
1.1 Equipment information

Purpose
The purpose of this Sandvik equipment is to be a crusher component in a
crushing and screening unit or site within an aggregate or mining process.
The machine reduces the size of rocks, minerals and similar materials. This
crusher component has been exclusively designed for this application. It is
not the responsibility of Sandvik SRP AB to secure the design and usage for
the complete aggregate, mining, or recycling process. Sandvik SRP AB will
not accept any liability for damage to equipment or injury to personnel
caused by unauthorized or improper use or modification of this equipment.
Manufacturer
This Sandvik equipment has been manufactured by:
Sandvik SRP AB
SE-233 81 Svedala
Sweden
www.sandvik.com
For maintenance
Contact the nearest Sandvik Rock Processing company, agent or
representative, or contact the factory directly:
Sandvik SRP AB
Service Department
SE-233 81 Svedala
Sweden
Telephone +46 (0)40 40 90 00
Telefax +46 (0)40 40 92 60

1. Introduction
Identification
The figure below shows the location and an example of the cone crusher’s
identification plate. The identification plate contains data needed when
contacting Sandvik concerning this specific equipment.
The “type” number is a designation system that describes the product.
Identification plate
1 Type
2 Part number
3 Serial number 8
4 Mass (Kg)
5 Order number
7
6 Manufacturer
7 Year of manufacture
8 CE mark
1 2 3 4 5 6
Type description
9 Type and size of crusher
CS430-EC/B-20/25/30/16:1
10 Crushing chamber (concave ring)
11 Mantle
12 Eccentric throw (mm) 9 10 12 13
13 Mark number 11

1. Introduction
Tank unit identification

The figure below shows the location and an example of the tank unit’s
identification plate. The identification plate contains data needed when
contacting Sandvik concerning this specific equipment.
14 Machine type
15 Part number
16 Serial number 22
17 Mass (Kg) 21
18 Order number
19 Manufacturer
20 Year of manufacture
21 CE mark
15 16 17 18 19 20
CE marking
This equipment complies with the basic health, environment and safety
regulations of the European Union and European Economic Area.
Sandvik will not take responsibility for this compliance when customers
modify any configuration of the cone crusher.

1. Introduction
1.1.1 Document information

Purpose of this Installation manual
The purpose of this Installation manual is to provide the technicians with
information on how to safely install this Sandvik equipment.
It is important to:
• keep the manual for the lifetime of the equipment
• pass the manual on to any subsequent holder or user of the equipment
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
manufacturing plant.
Technical publications
When ordering technical publications, always specify the language and quote
the identity and manufacturing numbers from the identification plate.
Technical publications related to the installation and operation of this
equipment are:
• Installation manual (IM)
• Wear parts catalog (WPC)
• Operator’s manual (OM)
Technical publications related to the maintenance of this equipment are:
• Maintenance manual (MM)
• Spare parts catalog (SPC)
The MM and SPC are only available to trained maintenance personnel.
Sandvik can provide adequate training and authorize personnel.
Read more about the document structure and the accompanying work roles
in section 2.2 Personnel.
Number of pages
This document contains a total of 106 pages.
Feedback
If you have comments on this manual or problems related to the crusher’s
documentation, send an e-mail to: manuals.srp@sandvik.com

1. Introduction
1.2 Operating principles of a cone crusher

In a cone crusher, the process material is crushed between two rigid surfaces.
The motion of the moving surface is independent of the load on the crusher.
The crushing action is achieved by an eccentric gyratory movement of the
mainshaft (6). Individual pieces of process material are nipped, compressed
and crushed between the mantle (4) and the concave ring (3).
The quality and quantity of the produced process material is a product of the
interaction between the crusher and the process material. The crushing
chamber geometry, the crusher’s dynamics, and the quality of the process
material are the most important factors.
The concave ring (3), mantle (4), eccentric assembly (5) and the location of
the pivot point determine the chamber geometry of the cone crusher. The
crusher’s drive motor rotates the eccentric assembly at a constant speed
through a gear transmission. The rotation of the eccentric assembly causes
the lower end of the mainshaft to gyrate. At the top of the mainshaft (6) is the
spider bearing (1) that acts as the pivot point for this gyrating motion.
The mantle (4) is fixed to the mainshaft (6) and the concave ring (3) is fixed
to the topshell (2). The gyration of the mainshaft (6) means that the distance
between the mantle (4) and any given point on the concave ring continually
varies. When this distance decreases the incoming process material will be
subjected to a compressing stress and will be crushed. When the mantle
moves away from the concave ring, the process material is able to flow down
through the chamber.
The mantle (4) and the concave ring (3) must be replaced regularly as they
are subject to continous wear. The rate of wear depends on the characteristics
of the process material. Read more in OM section 10.2.
1 Spider bearing
2
3
Topshell
Concave ring
1
4 Mantle 2
5 Eccentric assembly 3
6 Mainshaft 4
5
6

1. Introduction
Setting adjustment
To control fragment size and to compensate for wear the crusher has a setting
control system, called the Hydroset system. It basically consists of a robust
hydraulic jack which supports the mainshaft and adjusts its position. Moving
the Hydroset piston up and down will change the discharge setting and the
size of the crushed material.
Read more in section 9. Preparations for commissioning.
setting decrease = smaller fragments setting increase = larger fragments
= =
Auxiliary systems
The cone crusher has a circulatory system for lubrication of the main shaft.
The lubrication system is described in OM section 8.2.

1. Introduction
1.2.1 Description
The following figure shows an overview of the cone crusher’s nomenclature
and components. Grey areas indicate cross-sections.
Cone crusher – intersected view
1
3
1 Spider cap
2 Spider bushing
4 20
3 Head nut 5
4 Mantle 19
5 Concave ring 6 18
6 Mainshaft with head centre
7 Eccentric wearing plate
8 Bottomshell bushing
7 17
9 Eccentric
10 Eccentric bushing 8 16
11 Step bearing 15
12 Hydroset piston
13 Pinionshaft housing
14 Pinionshaft
15 Dust collar
16 Locating bar
17 Dust seal ring
9 14
18 Bottomshell
19 Topshell 10
13
20 Concaves 11
12

1. Introduction
Cone crusher – side view

21 Hole for level indicator
22
23
Inspection door
Feed hopper
21
24 Inspection hatch 22
23
24

1. Introduction
Tank and auxiliary equipment

25 Over-pressure blower
26 Over-pressure air regulator
27 Tank unit
28 Water/oil heat exchanger 25
29 Air/oil heat exchanger
26
27
28
29

1. Introduction
This page is intentionally left blank

1. Introduction

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

2.1 Hazard information

2.1.1 Warning signs
General danger Dangerous voltage Risk of crushing
Hanging load Risk of crushing Flying fragments
2.1.2 Risk levels

Throughout the manual, levels of risk is indicated as “DANGER”,
“WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels
are accompanied by a warning sign (see above).
Failure to observe information marked “DANGER!” can result in life-

threatening injuries!
DANGER!
Failure to observe information marked “WARNING!” can result in
personal injury and/or serious damage to, or destruction of,
equipment!
WARNING!
CAUTION! Failure to observe information marked “Caution!” can result in damage
to equipment!
2.1.3 Prohibition signs
Do not remove
guards
2.1.4 Mandatory signs
Disconnect current Read the manual

before any work

2.2 Personnel
All work on the equipment is to be carried out only by trained or authorized
personnel.
– “Trained” means that the person in question has been given practical
instruction by an authorized person on how the various tasks are to be
carried out.
– “Authorized” means that a person has undergone a theoretical and
practical test of knowledge, organized by Sandvik. He/she is therefore
judged to have the knowledge and competence to carry out the tasks
assigned to the appropriate role.
All expected work tasks on this production equipment have been defined by
Sandvik as belonging to one of three categories – work roles – based on
different competence profiles. These three work roles are:
• Installation
• Operation
• Maintenance
Sandvik provides technical documentation appropriate to all three work
roles:
• Installation manual
• Operator’s manual and Wear parts catalog
• Maintenance manual and Spare parts catalog
Sandvik can provide adequate training for all three work roles and can carry
out authorization of trained personnel.
The technical documentation from Sandvik covers only work on the
production equipment itself – it does not cover work tasks associated with
other equipment or routines at the site.
It is the responsibility of the plant management to assign responsibility for:
• The production equipment and the work area around the equipment
• All personnel in the vicinity of the equipment
• Compliance with national and local safety regulations
• Checking that all safety devices are fully operational
Sandvik declines all responsibility for injury or damage resulting from non-
compliance with the instructions in this manual.

2.2.1 Personal protection

Sandvik strongly recommends that personal protective equipment is always
worn when working in the vicinity of the equipment.
The Sandvik recommendation for personal protective equipment includes:
Ear protection Safety helmet Eye protection
Protective gloves Safety boots Mask or breathing

apparatus
2.3 General safety precautions

Falling stones
Clear the feed arrangement from process material before any
maintenance work is carried out inside or below the crusher, to
WARNING! prevent stones from falling down.
Always switch off power and lock out the equipment (secure it cannot be
switched on) before any maintenance work is started. Also ensure that it is
not possible for anyone else to switch the power on while maintenance work
is being done.
(Continued)

Avoid remaining on the crusher, unless necessary for maintenance work.
Risk of crushing
Never remain on the crusher while crushing. Moving parts constitute a
risk of crushing. Falling into the crusher implies danger of being
DANGER! crushed.
Risk of crushing
If the crusher is mounted on rubber dampers, there is a risk of
crushing between the oscillating parts of the crusher and the
WARNING! stationary frame.
Ejection
Never look into the crusher while crushing. Fragments and possibly
harmful substances fed to the crusher may be ejected.
WARNING!
2.3.1 Machine safety guards

Do not remove guards
Make sure that all guards are in place and functioning, to prevent
exposure to flying fragments and rotating parts. Never operate the
PROHIBITION! equipment unles guards are mounted.
Rotating parts
Exposure to rotating parts of the equipment shall be prevented by
guards. Always attach guards after maintenance work.
WARNING!
Flying fragments
Fragments ejected upwards may fall down in the vicinity of the
crusher. Provide adequate guards and warning signs at appropriate
WARNING! places around the danger zone.
Upwardly ejected fragments may fall down in the vicinity of the crusher.
Therefore Sandvik recommends additional protection.
Platforms with guard rails shall be installed around the crusher’s feed
opening. Walkways, stairs and ladders must be designed in accordance with
applicable regulations. (These parts are not included in the crusher’s standard
specification).
Make sure all defective guards and dust sealing components are checked,
repaired and replaced before starting the equipment.

2.3.2 Electrical safety

CAUTION! Only electrical personnel working according to European Standard
EN 50110 or similar are permitted to perform electrical operations on
the crusher.
Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven
dead by proper testing procedures.
DANGER!
Make sure all broken or damaged electrical cables and connectors are
checked, repaired and replaced before starting the equipment.
Control cabinets must be lockable.
2.3.3 Welding
CAUTION! Welding on the crusher is only permitted when and as described in the
manual. For all other welding operations on the crusher local Sandvik
service personnel must be consulted.
CAUTION! Only welders qualified according to European Standard EN 287 or sim-

ilar are permitted to perform welding operations on the crusher.
If welding an item to the crusher, ground must be attached to the item itself.
If a crusher component is to be welded, ground should be attached as near to
the welding area as possible.
Toxic gases
Inhalation of welding fumes can be dangerous to health. Always follow
instructions provided by the welding equipment supplier.
WARNING! Some parts of the crusher are made of manganese steel. Long-term
exposure to manganese oxide can affect the nervous system.

2.3.4 Hydraulic system

CAUTION! Only personnel certified in hydraulics are permitted to perform opera-
tions on the hydraulic system.
Oil pressure
Pressurized oil is dangerous if released incorrectly. Relieve all
pressure before carrying out maintenance or repair work on the
WARNING! hydraulic system.
CAUTION! Never adjust pressure relief valves beyond the recommended values.
Oil temperature
Hydraulic oil can get very hot in operation. Allow the oil to cool before
working on the hydraulic system.
WARNING!
Make sure all defective hoses, valves or fittings are checked, repaired and
replaced before starting the equipment.
2.3.5 Lifting and moving loads

CAUTION! Only personnel with adequate lifting training are permitted to perform
lifting operation.
Hanging load
Never work or stand underneath a crane that is lifting material. Keep a
safe distance from a hanging load.
DANGER!
Make sure that the capacity of the lifting equipment is adequate and that the
equipment itself is in good working order.
If a lifting tackle has to be made up by joining separate components, make
sure that the joints are secure and have the same lifting capacity as the rest of
the tackle.
NOTE! Always use lifting tackle certified in accordance with local conditions.
Always engage the safety clips on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and maneuver loads. Do not use hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.

2.3.6 Feed and jams

CAUTION! When the crushing chamber is empty, avoid feeding solitary round
rocks.
CAUTION! Never feed combustible process material into the crusher.
Flying fragments
Never use wedges etc. to clear jams in the feed opening. Stones and
fragments can be thrown out at high speed from the crushing
WARNING! chamber.
Explosives
Never remove blocking boulders from the crusher by blasting.
Blasting may cause personal injury and seriously damage bearings or
WARNING! other parts. Sandvik takes no responsibility for injury to personnel or
damage to the equipment when blasting is used.
Risk of crushing
Never stand inside the crusher when a blockage is removed. You might
be pulled forcefully and suddenly downwards together with the
DANGER! material in the crushing chamber and be crushed.
In some cases it is possible to increase the CSS (closed side setting)

temporarily to clear a jam.
Always follow local regulations when attempting to clear a jam.
2.4 Emissions
2.4.1 Dust
Health hazard
Crushing and processing material will create dust. Such dust can be
more or less dangerous to the health. Use a breathing mask.
DANGER!
Sandvik strongly recommends using additional equipment for dust
suppression. Examples are dust extraction (vacuum) and dust encapsulation
by water spray or foam. Such equipment is not included in the crusher’s
standard specification.
Sandvik declines all responsibility for any health hazards caused by dust,
generated when processing minerals in the crusher.

2.4.2 Noise
Health hazards
Crushing and processing material will create noise. Such noise can be
more or less dangerous to the hearing. Use ear protection.
WARNING!
2.4.3 Radioactivity
Health hazards
Radon is a radioactive gas that occurs naturally in bedrock. Radon
may cause lung cancer. Mineral type, ventilation and water are all
DANGER! factors that influence the contents of radon gases.
Sandvik declines all responsibility for any health hazards caused by the
release of radon or any other harmful substances when processing minerals
in the crusher.


3. Technical data

3. Technical data
3.1 General data

The data presented below are typical values. Specific data may vary
depending on installation and machine configuration
Characteristics CS430:01
Type Cone crusher
Application Mineral processing
Usage Outdoors/Indoors
Total mass 12000 kg (26500 lb)
Length 1950 mm (77")
Width 1950 mm (77")
Height 2850 mm (112")
Max. motor power 160 kW
Installed power 75–160 kW
Available crushing chambers 3 (EC/C/MC)
Closed Side Setting (CSS) Approx. 19–54 mm
depending on crushing chamber and eccentric throw
Open Side Setting (OSS) Maximum depends on chamber, CSS and ECC
OSS = CSS + ECC
Pinionshaft speed 1390 rpm (50 Hz)
1670 rpm (60 Hz)
Feed hopper Mass 360 kg (800 lb)
Material Steel plate
Thickness 6 mm (0.24")
Height 1710 mm (67")
Inner diameter Ø 1770 mm (67")
Capacity 2140 kg (4720 lb)
B.D. = 1600 kg/m3 (100 lb/ft3)
Topshell Mass 5100 kg (11200 lb)
Diameter at lower flange Ø 1550 mm (61")
Material Cast steel
Spider bushing lubrication Grease
Spider cap Mass 140 kg (310 lb)
Securing method Bolts, seal with O-ring
Bottomshell Mass 3920 kg (8600 lb)
Inner diameter at Ø 1400 mm (55")
discharge opening
Min. shell thickness 45 mm (1.77")
Bottomshell liners Number of liners 11
Different shapes 6
Material Wear-resistant hardened steel
Hardness 360–440 BHN
Securing method Tack welding
Bottomshell arm liners Number of liners 2
Different shapes 1
Material Manganese steel
Securing method Welding
Mantle Types A/B
Outer diameter at bottom Ø 1810 mm (71")
Material Manganese alloyed steel
Securing method Self-tightening head nut, burn-
ing ring and metal contact
Backing material No
Mass of heaviest mantle 760 kg (1680 lb)

3. Technical data
Concaves Types EC/C/MC
Number of plates 6
Diameter Ø 1225 mm (48")
Backing material No
Securing method Clamping ring, filler ring and
metallic contact
Mass of heaviest concave 80 kg (180 lb)
Concave ring Types EC/C/MC
Diameter Ø 1100 mm (43")
Backing material No
Securing method Clamping ring, filler ring and
metallic contact
Mass of heaviest concave ring 600 kg (1320 lb)
Mainshaft Mainshaft position sensing No
Mass 2700 kg (6000 lb)
Length 1920 mm (76")
Eccentric Alternative throws Yes
Standard eccentric throws 16/20/25/30
Eccentric speed 340 rpm
Balancing Yes
Eccentric assembly mass 410 kg (900 lb)
Eccentric bushing mass 75 kg (165 lb)
Pinionshaft assembly Pinion mass 15 kg (33 lb)
Pinionshaft assembly mass 250 kg (550 lb)

3. Technical data
3.2 Crusher motor

The table below is a description of the motor that Sandvik recommends.
Manufacturer WEG
Type HGF Squirrel cage
Voltage 220/380 – 240/420V (50 Hz)
250/440 – 280/480V (60 Hz)
Phases 3
Frequency 50/60 Hz
Power 75–160 kW
Speed 1475 rpm (50 Hz)
1770 rpm (60 Hz)
Typical full load efficiency 95 %
Enclosure TEFC
Insulation F
Protection IP55
Frame IEC 315 S/M
Bearing type Anti-friction, regreasable
Lubrication method Grease
Mass 800–1000 kg (1760–2200 lb)
depending on motor size

3. Technical data
3.3 Drive system

V-belt drive CS430:01
Drive belts Manufacturer Rexnord
Size 8V SPC
Banded belts No No
Number of belts 6 6
Standard distance between 1047 mm (41 in) 607 mm (24")
pulleys c/c (50Hz)
607 mm (24") (60
Hz)
Sheave locking devices Taper lock bushing
Motor pulley Pulley PCD 18" 335 mm
Crusher pulley Pulley PCD 16" 375 mm (50 Hz)
450 mm (60 Hz)

3. Technical data
3.4 Lubrication system

Lubrication system Type Closed circuit, gravity return
System pressure 0.15–0.5 MPa (22–72 psi)
Tank mass 310 kg (680 lb)
Oil reservoir capacity 150 litres (40 US gal)
Oil type Normally ISO VG 150
Lubrication pump Type Gear
Capacity 33 l/min (50 Hz)
40 l/min (60 Hz)
Number of pumps 1
Lubrication pump motor Type Squirrel cage
Power 1.5 kW (50Hz)
1.7 kW (60 Hz)
1175 rpm (60 Hz)
Voltage 220/380 – 240/420V (50 Hz)
250/440 – 280/480V (60 Hz)
Phases 3
Frequency 50/60 Hz
Service factor 1.00
Enclosure TEFC
Insulation F
Protection IP55
Frame IEC 132
Main oil filter Number of oil filters 1
Blocked filter sensor Differential pressure sensor
Oil heater Type Electrical immersion heaters
Rating (per heater) 1.24–1.64 kW
depending on voltage
Method Indirect heating
Numbers of heaters 2–5
Voltage 220/380 – 240/420V (50 Hz)
250/440 – 280/480V (60 Hz)
Phases 3
Frequency 50/60 Hz

3. Technical data
3.5 Hydroset system

Hydroset system Oil reservoir capacity 40 litres (10.6 US gal)
Oil type ISO VG 68
Hydraulic cylinder size Ø 400 mm (15.8")
Maximum pressure 7.5 MPa (1088 psi)
Hydroset pump Type Reversible gear pump
Number of pumps 1
Capacity 4.3 l/min (50Hz)
5.1 l/min (60Hz)
Hydroset pump motor Type Squirrel cage
Motor power 1.1 kW (50 Hz)
1.3 kW (60 Hz)
Motor speed 950 rpm (50 Hz)
1175 rpm (60 Hz)
Voltage 220/380 – 240/420V (50 Hz)
250/440 – 280/480V (60 Hz)
Phases 3
Frequency 50/60 Hz
Service factor 1.00
Enclosure TEFC
Insulation F
Protection IP55
Frame IEC 71
Oil filter Number of oil filters 1
Method Filtering
Blocked filter sensor No

3. Technical data
3.6 Oil cooling systems

3.6.1 Oil/water heat exchanger
Number of oil/water heat exchangers 1
Material Stainless steel
Oil temperature detector Yes
Oil pressure drop 0.37 MPa (54 psi)
Oil flow 38 l/min
Water flow 25–35 l/min
Water temperature < 40°C (< 104 °F)
Max water feed pressure 3.0 MPa (435 psi)
3.6.2 Oil/air heat exchanger

Number of oil/air heat exchangers 1
Material Aluminium
Oil pressure drop 0.38 kPa (5.5 psi)
1.7 kW (60 Hz)
Motor speed 1450 rpm (50Hz)
1740 rpm (60 Hz)
Max air flow 4650 m3/h (2700 ft3/min)
Sound level 79 dBa ±3 (50 Hz)
83 dBa ±3 (60 Hz)

3. Technical data
3.7 Over-pressure dust exclusion system

3.7.1 General
Type Over-pressure blower or
compressed air system
Air quality Filtered
Air flow 0.3 m3/h (0.18 ft3/min)
Air pressure 0.6–1 kPa (0.09–0.15 psi)
3.7.2 Blower motor

0.43 kW (60 Hz)
Voltage 220/380 – 240/420V (50 Hz)
250/440 – 280/480V (60 Hz)
Phases 3
Frequency 50/60 Hz
3350 rpm (60 Hz)
Enclosure TEFC
Insulation F
Protection IP55
Frame size IEC 71

3. Technical data
3.8 Corrosion protection

Primer Type Zinc-phosphate
Procedure Spray painting
Thickness 40 µm
Second coating Type Alkyd enamel
Procedure Spray painting
Thickness 40 µm
3.9 Processing data

Maximum feed size 300–360 mm ( 11.8–14.2 ")
Closed Side Setting 19–54 mm
Nominal capacity 205–600 tonnes/h
The data above are typical. The capacity of the cone crusher is dependent on
the crushing chamber, the eccentric throw, the crusher’s setting and the feed
material’s bulk density, crushability, size analysis, moisture content, etc.
Consult Sandvik regarding application of the crusher.

3. Technical data
3.10 Tightening threaded fasteners

Unless otherwise specified, the threaded fasteners used in the crusher must
be tightened to the correct torque for the size in question.
STRENGTH GRADE (SS-ISO 898/1)
THREAD M 8.8 bright zinc-coated 10.9 Dacromet 12.9 untreated
mm Nm (ft lbs) Nm (ft lbs) Nm (ft lbs)
6 - 12 (9) -
8 21 (15) 28 (21) 40 (30)
10 40 (30) 56 (41) 79 (58)
12 70 (52) 98 (72) 136 (100)
16 169 (125) 238 (176) 333 (246)
20 331 (244) 465 (343) 649 (479)
24 572 (422) 804 (593) 1120 (826)
30 1130 (833) 1580 (1170) 2210 (1630)
36 1960 (1446) 2760 (2040) 3850 (2840)
42 3130 (2309) 4390 (3240) 6140 (4529)
48 4690 (3459) 6590 (4860) 9190 (6778)
56 - 10500 (7740) -
3.10.1 Requirements for joints with threaded fasteners

– Steel screws of grade 8.8, bright zinc-coated finish.
– Nuts of grade 8, bright zinc-coated finish.
– Hardened washers – at least HB200 (bright zinc-coated finish).
– Lightly oiled components.
– Threads in castings cleaned out.
– Tightening carried out with a torque wrench which can be calibrated,
or with a bolt/nut runner with a torque limiter.
– Maximum permissible torque spread: + 10%.
3.10.2 Locking fluid for threaded fasteners

In some places in this manual you will come across the recommendation to
use locking fluid. Unless otherwise stated, this normally means using Loctite
243 or an equivalent. Use Loctite 577 or an equivalent to seal pipe threads in
the lubrication system, where no other sealing is used. For pipes up to 3/4" in
size – and in the Hydroset system – use Loctite 543, or an equivalent. When
a previously used screw is to be reinstalled, it is important to clean oil and
Loctite from the threads first.
Follow the manufacturer’s instruction for the application of locking fluid.

3. Technical data


4.1 General
Check that the dimensions of the installation site and the positions of the
connections comply with the drawings in appendix A: Installation drawings
and with any site-specific installation drawings. If the site does not meet the
specifications, please contact Sandvik for guidance and customizing.
NOTE! Make sure that the service area at the installation site matches the
requirements in the drawings, and that the installation site is accessible for
spare and wear part delivery.
Check that the cone crusher meets the local legislation demands. In case of
doubt, consult the local authorities or local authorized personnel.
Prepare the installation site as much as possible by installing electricity and
water supply, foundation, etc. before starting the main installation.
Use the check list in section 4.3 Installation preparations check list as a
guide when carrying out and documenting the installation procedure

4.2 Crusher capacity and performance

A cone crusher is normally a component in a crushing and screening process.
Its performance depends on the operation and design of the whole process
including conveyors, feeders, feed hoppers, motors, site design and structure.
Capacity and performance also depend on:
• Choice of crushing chamber
• Choice of eccentric throw
• Feed size distribution and particle top size
• Feed rate
• Discharge system capacity
• Screening capacity
• Automation controls
The following factors will lower capacity and performance:

• Adhesive or moist process material in feed
• Excessive amount of fines in feed
(> 20% of process material smaller than CSS value)
• Very tough process materials
• Uneven distribution in crushing chamber
• Not operating the crusher with a choke feed
• Insufficient feed control
• Incorrect feeding and screening arrangement
• Incorrect discharge design
• Insufficient drive motor power

4.3 Installation preparations check list

Comments to the installation preparations check list are found in the
following pages.
System Checks Remarks Date/sign
Placement Site access checked for cone crusher
dimensions?
Smallest area that the cone crusher
components must pass through?
(W × H) ×
Available service area?
(L × W × H) × ×
Available lifting device on site? Type:
Length of oil hoses and pipes?
Length of drive belts?
Foundation Foundation constructed according to
drawings?
Electrical system All necessary cables to the cone
crusher arranged?
Length of cables?
All necessary switchgear installed?
All necessary connections to plant
control system arranged?
Electrical power available?
Process material Process material tested by Sandvik?
Dust protection Dust protection complies with local
regulations?
Feed arrange- Feed arrangement designed
ment correctly?
Discharge Discharge arrangement ready to be
connected to outlet of crusher?
Guards Need for additional guards?
Platforms and Comply with local regulations?
guard rails Designed so they do not interfere with
the cone crusher’s function?

4.3.1 Placement
Cone crusher
Place the crusher so that it is easily accessible for operation, service and
maintenance, but protected from damage and unauthorized access.
Make sure that all requirements for the service area are met, see appendix
A: Installation drawings. If possible, mark the limits of the service area with
paint. Note the dimensions of the actual service area in the check list.
Make sure that there is access to a lifting device meeting the requirements in
section 5. Transport handling. Note the available type of lifting device in the
check list.
Consider additional clearance for the feed and discharge arrangements. See
section 4.3.7 Feed arrangement and section 4.3.8 Discharge arrangement.
Make sure that the drive motor can be correctly positioned and aligned.
Lubrication and Hydroset system
Place the oil tank unit so that it is easily accessible but protected against
damage. Make sure that there is sufficient room to drain out oil.
Place the tank unit as close to the cone crusher as possible. Excessively long
oil line runs with many or sharp bends will increase flow friction and lower
performance.

4.3.2 Foundation for a cone crusher

The foundation must meet the requirements stated in this manual in order to
prevent low performance and excessive wear.
To reduce stresses in a concrete foundation or steel supporting structure,
install the crusher on anti-vibration compression mountings.
For more information on the foundation see section 6.2 Foundation.
Risk of crushing
There is a risk of crushing when the machine is running, especially
when starting and stopping. Make sure that there is room for horizontal
WARNING! movement as given on the installation drawing.
Steel supporting structure

A steel supporting structure or transportable frame must be level and resting
on a firm foundation, or it will vibrate and be subjected to abnormal stresses.

4.3.3 Electrical installation

Make sure that all local and site-specific requirements for electrical
installations are fulfilled.
External cables, disconnecting switches and fuses must be ordered before
installation. See section 7. Electrical installation.
Contact Sandvik for further information about cables, switches and fuses.
4.3.4 Remote control system

At most sites a main control system is used to control the process. Make sure
that the control system is prepared for the addition of the cone crusher.
4.3.5 Process material

Process material wears the cone crusher and adjacent equipment in varying
ways. Sandvik recommends the prior testing of the quality of the material
that is to be processed. Sandvik can assist with such testing.
4.3.6 Dust protection

The inhalation of dust from the process material can cause death or severe
injuries. Sandvik recommends installing dust protection equipment to
prevent dust spreading from the process equipment, see section 2.4.1 Dust.

4.3.7 Feed arrangement

The efficiency of the cone crusher is directly dependent on the feed
arrangement. To maximize capacity, make sure that the process material is
• fed into the cone crusher at a sufficiently high rate
• evenly distributed around the crushing chamber
• not segregated
Design the infeed so that the construction is removable for easy maintenance
of the cone crusher.
The Cone crusher is normally delivered with a feed hopper which is divided
to simplify removal.
The feed arrangement must be electrically interlocked in such a way that it
cannot be started unless the crusher and the discharge system are running.
Sandvik recommends that you:
• mount an ultrasonic level monitor in the feed hopper to stop the feed if
the material is too high or too low. Another method is to use a variable
speed drive to maintain a constant material level in the feed hopper.
• install a screen ahead of the cone crusher to remove fine material before
crushing. This increases the performance and capacity of the crusher.
• install a magnet ahead of the cone crusher to remove magnetic metal
from the process material, and a metal detector to prevent metal objects
from entering the crusher.
Regulate the feed so there is a build-up of process material in the feed hopper
(choke feed). The process material in the feed hopper should be level with
the top of the spider cap. Choke feeding will create a finer and more uniform
product size, and the cone crusher will run more smoothly and with lower
power consumption.
If a belt conveyor or a chute is used to feed the crusher, the coarser material
will tend to separate from the finer material (segregation). The material
should be de-segregated before it is fed into the crushing chamber.
It is important to optimize the feed arrangement as far as possible. This can
be accomplished with a “feed box” above the feed hopper, as shown below.

The feed box must be designed in such a way that it can be moved
longitudinally to correctly guide the material.
Feed from a belt conveyor. Feed from a chute. The chute can Feed from a feeder without a feed
be attached to a belt conveyor. box. The feeder must be adjustable.

Feed arrangements with EC or C crushing chamber

To prevent damage and/or unnecessary wear on the spider cap and arm
liners, the feed should be arranged so that the material falls onto a “feed box”
before it enters the crusher. This reduces the drop height and speed of the
material – particularly important with EC or C crushing chambers that are
fed with relatively coarse material. The feed box also reduces segregation.
With an EC or C crushing chamber, the mass and dimensions of the larger
feed lumps will be greater than with finer crushing chambers. Design the
feed box accordingly!
When processing coarse material, keep the level of material in the feed
hopper a little lower to prevent bridging.
You are welcome to contact Sandvik for advice on the design of feed
arrangements.

4.3.8 Discharge arrangement

Design the discharge arrangement so that material cannot build up beneath
the cone crusher and damage the dust seal ring.
Protect the lubrication and Hydroset lines from falling material.
Concrete foundations or discharge arrangements below the cone crusher
must have an inner diameter that is larger than the cone crusher’s discharge
opening. See section 3. Technical data.
The volume of the discharge area below the cone crusher must be larger than
the total volume of the process material in the cone crusher and the feed
hopper. See section 3. Technical data.
If a discharge conveyor stops, the feed arrangement must also stop to allow
the process material to pass out from the crusher.
The discharge arrangement must have an inspection door for cleaning and
inspection. The Hydroset cylinder must be easily accessible.
A ledge or shelf inside the discharge compartment will absorb the impact of
the material falling onto the discharge conveyor.
Chutes should have a slope angle of at least 45° to avoid material build up. In
some cases, the inclination needs to be steeper. Contact Sandvik for further
information.
Crusher mounted on a concrete Crusher mounted on concrete foundation

foundation or steel supporting structure where the foundation forms two sides of
with discharge hole in floor. Openings are the discharge hopper. The two remaining
blanked off. sides and the hopper bottom are attached
to anchor plates cast into the foundation.

4.3.9 Guards
All moving parts on the machine, including the belt drive, must be covered
with guards.
Flying fragments
Stones which are not properly gripped in the crushing chamber can be
thrown out of the cone crusher.
WARNING!
Design overhead conveyors and feed arrangement so that guards protect the
walkways and platforms from falling process material.
4.3.10 Platforms and guard rails

The cone crusher must have suitably designed platforms for inspection and
maintenance. The supply from Sandvik does not include platforms and guard
rails.
The floor of the platform should be solid (not wire mesh) to avoid the risk of
tools or equipment falling from the platform. Use kicking boards and wire
mesh on the sides under the handrails for the same reason.
Platforms must not be attached to the cone crusher, because of its constant
vibration and movement.
NOTE! Never use conveyors as gangways. Always design walkways with guard rails
along the conveyors.

4.4 Operating in low temperatures

Cone crushers need special preparations for reliable operation in low
temperatures. The following section describes Sandvik’s recommendations
for such preparations.
4.4.1 Measures that make starting and running easier in

cold weather
The following methods will increase the oil flow at low temperatures. The
order in which these methods are applied should be judged in each individual
case. A combination of several methods may be necessary.
Part numbers for ordering the modification kits are listed under the
respective methods.
– Heating cables on oil lines
– Additional oil heaters
– Diesel heating system
– Thermostatic valve to bypass the oil cooler
– Heater in the Hydroset oil tank
– Heating in the component section of the oil tank unit
– Synthetic oils
– Mineral oil for the winter season
– Blanking off the oil cooler radiator
– Two-speed fan motor for oil cooler
– Modified return oil flow switch interlock
– 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
– Modified return oil flow switch interlock
– Insulated bottom in the component section of the oil tank unit

4.4.2 Low temperature problems –

symptoms and remedies
Start
Start the oil pump. Does Has the crusher started Start crushing when the
No the “Crusher ready for and continued to run nor- crusher has warmed up.
start” signal appear within mally?
40 s?
Yes
Oil returns to the tank, but Stop the oil pump. Has oil Does the crusher stop The ambient air tempera-
not in sufficient quantity. run back through the oil line due to interruptions in ture is too low, which
Wait 3.5 min. to drain the to the return oil flow switch? return oil flow? makes the oil cooler too
crusher and then make a effective. The oil is
new attempt to start up. slowed down and blocks
the passages in the radi-
ator core!
Blank off the radiator
Has oil overflowed over the During long periods with completely or partially.
There is a blockage in the dust collar? very low temperatures, Start with 50% blanked
return oil line. Clean out the the crusher should be off.
blockage. If necessary, heated during the night
install heating cables on the to avoid excessive cool-
return oil line. Does the oil ing. Position a fan heater
flow back to the tank? beneath the crusher and
Install a thermostatic valve Alternatively, fit a 2-speed
cover the feed opening.
to by-pass around the oil motor to the cooling fan.
In addition, the lubrica-
cooler. Does oil flow back tion oil pump can be run
to the tank? continuously.
Install low temperature Under very low tempera-

equipment in the tank. tures the radiator core
(Heating in component sec- can be “thawed out” with
tion, insulated tank bot- a fan heater.
tom, time delay for oil
monitor interlocks.) Does
oil flow back to the tank?
Change to synthetic oil. Alternatively, use an ISO

Does oil flow back to the VG 100 oil.
tank?
Install heating cables on the

oil lines. Does oil flow back
to the tank?
Insulate the oil tank. Does

oil flow back to the tank?
Sometimes it can be advisa-

ble to run the lubrication oil
pump continuously to mini-
mize starting problem

4.4.3 Insulation of the bottom of the component section

of the oil tank unit
The component section of the oil tank unit is normally open at the bottom to
provide good ventilation and cooling of the oil pumps. In the winter it might
be necessary to insulate the tank to keep the oil at working temperature and
prevent pressure drop.
Modification kit Drawing
442.6965-00 1.442.8911
4.4.4 Additional oil heaters

In order to heat the oil to the correct temperature, it can be necessary to
install extra heaters. Installation is easiest if this equipment is ordered
together with a new crusher, but extra heaters can also be fitted in the tanks
of older crushers.
Modification kit Drawing Voltage (V) Rating (W) Connection
diagram
984.0607-00 (2 x) 1.442.8911 265/460 2 x 1640 3.194.0191
240/415 2 x 1340
220/380 2 x 1125
4.4.5 Diesel heating system

In plants without 24-hour electrical power, a timer-controlled diesel heating
system can be used. The system starts heating the oil up to three hours before
electrical power is available.
The tank unit is prepared for diesel heating.
The diesel heating system uses a 12 V DC supply.
Modification kit Drawing
442.9993-90 1.442.8911

4.4.6 Heating cables on oil lines

See appendix A: Installation drawings.
At low temperatures, the oil in the lines between the tank unit and the crusher
can solidify and block the lines. This problem can be minimized by
insulating the oil lines and installing heating cables.
It is preferable to use a heating cable of the self-regulating type which needs
no thermostat. The heating cable should have a rating of 8–10 W/m and 40
mm insulation.
Install the heating cable on the underside of the oil line and use insulating
tape to keep the cable in place. If possible, increase the slope of the return oil
line before installing heating cables.
If the oil lines are >50 mm in diameter, or if the oil should be heated to a
temperature 50ºC above the ambient temperature, the heating cable can be
led backwards and forwards on the same line.
Heating cables are in many countries considered as high voltage equipment
and must therefore be installed by an authorized electrician. The heating
cable can be purchased from a local supplier who can usually also install it.
Heating cable is normally supplied for 230 V.
4.4.7 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. The heater must have a thermostat which prevents
overheating. Position the fan heater so that oil cannot drip onto it.
Sandvik does not supply modification kits with fan heaters. Select a suitable
heater from any supplier.

4.4.8 Synthetic oils

Synthetic oils will allow for trouble-free starting at about 10ºC lower
temperature than a mineral-based oil, and are in all respects superior to
mineral-based oils:
• Longer change intervals due to high stability
• Easier starting at low temperatures
• Lower energy consumption due to lower friction
• Wider temperature range
• No oxidation and “coking”
The following synthetic oils are recommended by Sandvik for the lubricating
system. Other brands can be used after consulting the supplier.
Brand Type Minimum pour point Viscosity (cSt) at 40°C
Mobil oil SHC 629 -48 °C 142
Nynäs Mereta 150 -42 °C 150
The recommended synthetic oils can be mixed with mineral-based oils, but
should be diluted as little as possible. Empty the crusher and oil tank
carefully before refilling with synthetic oil.
To reduce the risk of dilution of a synthetic lubricating oil, the Hydroset oil
should also be synthetic. A grade with a viscosity down to 30 cSt at 40°C can
be selected for the Hydroset system.
CAUTION! It must be possible to mix the lubricating and Hydroset oils used in the
crusher. Consult the oil supplier if in doubt.
The following synthetic oils are recommended by Sandvik for the Hydroset
system. Other brands can be used after consulting the supplier.
Brand Type Minimum pour point Viscosity (cSt) at 40°C
4.4.9 Mineral oil for the winter season

In ambient temperatures below 0ºC, an ISO VG 100 oil can be used.

4.4.10 A thermostatic valve to by-pass the oil cooler

When a cone crusher is started up with cold oil, the largest single cause of
pressure drop in the system is the air/oil heat exchanger. This pressure drop
can be minimized with the help of a thermostatic valve.
Operation of the thermostatic valve
The oil enters the thermostatic valve from the oil tank at port 1.
At oil temperatures < +35ºC, port 3 is closed, and the oil flows only through
port 2 and the external bypass line to the outlet manifold (6), bypassing the
heat exchanger completely.
At oil temperatures > +35ºC, oil flow is gradually shifted from port 2 to port
3, which is connected to the heat exchanger’s inlet manifold.
At oil temperature +45ºC, port 2 and the bypass line are closed, and the oil
flows only through port 3 and the heat exchanger.
through
NOTE! At low temperature the bypassed oil flow warms the heat exchanger to some
extent as it passes through the outlet manifold. This will result in a lower
pressure drop when the oil starts flowing through the heat exchanger.
Thermostat and mounting kit
The thermostatic valve is mounted on the air/oil heat exchanger.
Heat exchanger Mounting kit
Part No. Designation Part. No.
910.0101-00 995011 A0 442.9845-00
1 Port 1
2 Port 2 2
3 Port 3
3
4 Inlet manifold 1
5 From oil tank
6
6 Outlet manifold 4
7 To crusher via tank
5

4.4.11 Blanking off the oil cooler radiator

If the cooling fan is started at low ambient temperature, the pressure drop
across the cooler will cause the pressure relief valve ahead of the cooler to
open. The oil is then not cooled at all and can overheat.
The easiest way to avoid this is to blank off the radiator so that less air passes
through the radiator core. The degree of blanking depends on the ambient
temperature and must be determined by trial-and-error.
4.4.12 2-speed fan motor for oil cooler

Another way to reduce the air flow through the radiator is to use a two-speed
motor on the cooling fan. The speed of the cooling fan is determined by the
oil temperature in the return line.
Examples of switching points with ISO VG 150 oil:
Return oil temperature Cooling fan
Rising oil temperature 43°C (109°F) The fan starts at low speed
43–46°C (109-115°F) Runs at low speed
Over 46°C (115°F) Runs at high speed
Falling oil temperature Over 43°C (109°F) Runs at high speed
43–40°C (109-104°F) Runs at low speed
40°C (104°F) The fan stops

4.4.13 Modified return oil flow switch interlock

See appendix A: Electrical drawings.
It can sometimes be useful to by-pass the return oil flow switch interlock for
a short period during the starting phase. The drive motor can then be started
without a “crusher ready for start” signal. With the crusher in motion the oil
will be heated by friction, increasing the oil flow through the crusher.
Starting sequence with interlock by-pass
a) The lubrication oil pump relay (K2M) triggers Timer 1 (K21T) which is
run for a pre-set time period, e.g. 20 seconds.
b) When Timer 1 expires Timer 2 (K22T) is started. The return oil flow
switch (OG1) is now bypassed, and the crusher can be started even if no
oil is detected in the return line.
c) When Timer 2 expires the by-pass is removed. If oil has reached the
return oil flow switch, the crusher drive motor will continue to run.
Otherwise the drive motor will stop.
-K21T
-K2M
-K1M Relay, crusher A1 A2
motor
-K2M Relay, lubrication oil
-K22T
pump
-K21T Timer 1 -K21T A1
B1
A2
15 18
-K22T Timer 2 16
-OG1 Oil flow switch

-TG1 Temperature switch
-OG1 -TG1 -K1M
C NO 1 2 A1 A2
NC
-K22T
15 18
16
NOTE! A new start attempt should not be made until the oil which has been pumped
into the crusher has run back to the tank. If a new start attempt is made
prematurely, the crusher may overfill with oil which will overflow over the
dust collar and fall onto the discharge conveyor.
The components needed for interlock bypass can be obtained from Sandvik.
Installation can be carried out by a local electrician.

4.4.14 Insulation of the oil tank

Insulating the oil tank will reduce the overnight drop in oil temperature at
low ambient temperatures. In warmer weather the insulation should be
removed to prevent overheating.
Insulation can easily be installed by the plant personnel. A suitable material
is Rockwool 1330-00, 50 mm thick. The insulation material must be
protected from moisture, as it will otherwise lose its insulating properties.
Insulation kits are not supplied by Sandvik.
4.4.15 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.
Leave the oil tank heaters switched on. Cover the crusher’s feed opening to
prevent excessive cooling by cold air passing through the crusher chamber.
4.4.16 A heater in the Hydroset tank

The Hydroset oil is normally heated indirectly by the lubricating oil. At very
low ambient temperatures it may be necessary to also install a heating
element in the Hydroset oil tank section.
Modification kit Voltage (V) Rating (W) Connection diagram
442.8462-00 220/380 225 3.190.3590
The heating element has to be positioned on the back of the tank unit. This
means that approximately 200 mm space is required behind the tank.
The thermostat is mounted in the element and set at +25ºC, sufficient for the
oil to pass easily through the system. This temperature also reduces the time
that the element is switched on, and prevents coking.



5.1 Goods data

The cone crusher is delivered as a complete assembled unit. Auxiliary and
optional components are delivered in separate packages.
The table below indicates the space required for the equipment during
transport. The number of packages delivered may vary depending on the
cone crusher variant and the auxiliaries.
Part name Mass Measurements L × W × H

kg (lb) mm (inch)
Crusher, complete 11800 (26000) 2000 × 1900 × 2850 (79 × 75 × 112)
Tank unit 450 (990) 1450 × 1050 × 1070 (57 × 41 × 42)
Tool box 400 (880) 1170 × 1170 × 920 (46 × 46 × 36)
Feed hopper 360 (790) 1800 × 1800 × 900 (71 × 71 × 35)
5.1.1 Contents
A packing list is attached to one of the packages in the delivery.
NOTE! If the crusher is collected from the factory, check before transport that the
equipment corresponds with the items in the packing list.
If the crusher is delivered by Sandvik either to a harbour or to the work site,

check immediately after arrival that the equipment corresponds with the
items in the packing list.

5.1.2 Loading and unloading goods signs

Make sure that the handling personnel understand and follow the mandatory
and warning symbols used on the packages.
885.0260-00
Use the forks here Overhead lifting point
885.0250-00
Center of gravity
Lifting point for chain
5.2 Lifting equipment

Different types of lifting equipment
The following types of equipment can be used to lift and move the goods:
• overhead gantry
• mobile crane
• fork lift
Equipment specifications
Make sure that the lifting capacities of the equipment and tackle meet the
requirements in the following table.
NOTE! The lifting capacity of a mobile crane varies with the lifting radius. Make
sure that the lifting capacity is sufficient at the appropriate lifting radius.
Equipment or tackle Lifting capacity
kg (lb)
Overhead gantry 13500 (30000 )
Mobile crane 13500 (30000 )
Lifting chains, cables, ropes or slings 13500 (30000 )
Fork lift 14000 (31000 )

5.2.1 Overhead gantry or mobile crane

Hanging load
Keep clear of hanging loads. See section 2. Safety precautions.
Make sure that the SWL (Safe Work Load) of the lifting equipment is
WARNING! sufficient for the weight to be lifted.
a) Make sure that the lifting chains, hooks and other lifting equipment are
in a good state and attended to according to the manufacturer’s
instructions.
b) Make sure that the lifting chains have the correct lengths for the angle
from the vertical in which they are to be used.
c) Make sure that the SWL (Safe Work Load) of the lifting equipment is
sufficient for the weight to be lifted.
d) Follow the applicable lifting standard for the equipment used.
e) Position the lifting equipment according to the symbols in section
5.1.2 Loading and unloading goods signs.
f) Check that the load lies against the saddles of the hooks. Never put load
on the tip of a hook.
g) Slowly take up the slack in the lifting chains. Make sure that the hooks
are secure in the lifting eyes of the component. If necessary, adjust the
chains to distribute the load evenly.
h) Check that the chains can straighten out correctly. Never lift with a
twisted chain.
i) Make sure that the destination is clear and able to support the weight
before lifting.
j) Lift, move and lower the load carefully and calmly. Avoid twitches and
jerks.
k) Never use hands or feet to guide the load. Keep clear of the load.

5.2.2 Fork lift

Hanging load
a) Make sure that the forks have the correct length and lifting capacity for
the load.
b) Set the lifting forks to the correct width for lifting the load.
c) Make sure that the load is firmly attached to the transport platform.
d) If the transport platform is fitted with fork tubes, manoeuvre the forks
inside these to lift the component.
e) Before lifting, make sure that the destination is clear and able to support
the load.
f) Lift, move and lower the load carefully and calmly.

5.3 Unloading the goods

5.3.1 Unpacking area
The unpacking area should have approximately 1 m (3 ft) of free space
around and above the cone crusher.
Minimum recommended unpacking area L × W × H
CS430 3 × 3 × 4 m (10 × 10 × 12 ft)
5.3.2 Inspection of goods

Inspect the outside of the packages before unloading. Report any damage
immediately to the person responsible for the installation.
If the damage is severe enough to prevent installation, submit a damage
claim to the transport company without delay. If possible, document the
damage with a camera.
NOTE! If damage has occurred during transport, report this immediately also to the
Sandvik shipping department. The address is found on the packing list.

5.4 Moving and storage

If the cone crusher must be stored before installation, make sure that the
storage area meets the requirements in section 5.4.2 Storage.
If possible, place the cone crusher and oil tank unit at the installation site
before unpacking. Do not unpack the components until immediately before
starting installation.
Position the packages on the installation site so that the crusher and oil tank
unit can be lifted out and installed without being turned around.
When lifting, follow the instructions in section 5.2 Lifting equipment.
5.4.1 Moving
Hanging load
a) Attach the lifting equipment according to the instructions in section

5.2 Lifting equipment.
b) Lift the component only enough to clear the floor.
c) Make sure that the component remains stable on the lifting equipment.
d) Move the load into position and lower it gently to the floor. Leave
enough room for access to all sides.
e) Make sure that the component is firmly supported.
f) Remove the lifting equipment.
g) Remove any screws holding the transport platform to the component.

5.4.2 Storage
Hanging load
CAUTION! Sandvik recommends storing the cone crusher indoors. Long-term ex-
posure to moisture or very high or low temperatures may damage the
cone crusher.
a) Prepare a storage area large enough to store the components with at least
1 m (3 ft) of free space around and above them for access and
ventilation.
b) Make sure that the storage area environment meets the conditions in the
table below:
Characteristic Value Notes
Min–max temperatures 5–40 °C (41–104 °F)
Max relative humidity 80% Non-condensing
c) Lift the components into position according to the instructions in section

5.4.1 Moving. If the ground/floor is uneven, place blocks or plates under
the components to provide a steady support.
d) Make sure that the components are stable before removing the lifting
equipment.
NOTE! Before delivery from the factory, the cone crusher and oil tank unit are
treated with rust preventatives sufficient for approximately 30 days of
storage. If the cone crusher is to be stored for a longer period, it must be
checked regularly and re-treated with rust prevention if necessary.

5.5 Unpacking the goods

Hanging load
a) Remove any loose boxes and packages before unpacking the main
components.
b) Unpack and check each item against the delivery note.
c) Check the unpacked components and accessories for damage. In case of
damage, send a transport damage report to Sandvik SRP AB.
See also section 5.3.2 Inspection of goods.
d) Open the tool box and remove the documentation.
e) Locate the packing list.
f) Check that the data on the cone crusher and tank unit identification
plates correspond with the packing list.
See section 1.1 Equipment information.
g) Move spare and wear parts to the spare part store.
h) Dispose of the packaging material according to the instructions in
section 5.6 Disposal/return of packaging material.

5.6 Disposal/return of packaging material

The packaging material includes all pallets, crates, wrapping, boxes and
other protective material that are not part of the equipment. Packaging is
normally not returned to the manufacturer.
• Check if there is a special agreement for the return of the packaging to
the manufacturer.
• If the packaging must be returned, prepare an area to store pallets,
transport racks and any other returnable packaging.
• Check if there is a special arrangement for recycling packaging material.
• If the packaging is not to be returned or recycled, check with the local
authorities how to separate and dispose of packaging material.
• Dispose of pollutant waste (bubble wrapping, plastic bags, expanded
polystyrene, etc.) in accordance with local regulations.

6. Mechanical installation
and connections

6.1 General requirements

Personnel
Only qualified installation personnel are authorized to install the cone
crusher. 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, see appendix A: Installation drawings. If any adjacent
machines on the site cannot be stopped, take measures to prevent
accidental contact.
c) Make sure that the lighting on the installation site is adequate. Use
additional portable lights if necessary.
Lifting equipment, tools and materials
The equipment used for lifting and moving the crusher components can also
be used for unpacking and installing the cone crusher.
See section 5.1.2 Loading and unloading goods signs.
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.

6.2 Foundation
The cone crusher must have an adequately dimensioned foundation. Sandvik
recommends a concrete foundation or a steel supporting structure.
A steel supporting structure or a transportable frame must be mounted
horizontally and rest on a firm foundation. If the foundation is not
sufficiently stable the supporting structure will vibrate and be subjected to
abnormal stresses.
In appendix A: Foundation loads you will find information on the forces
transmitted to the concrete foundation or steel supporting structure via the
crusher’s mounting points at maximum eccentric throw.
See also section 4.3.2 Foundation for a cone crusher and section
4.3.8 Discharge arrangement.
NOTE! Make sure that the crusher’s mounting points are level. Maximum deviation
at load application point should be ±1 mm.
NOTE! The drive motor can be installed on either side of the crusher. It is important
to decide on the position of the motor before the foundation is designed.
For general information on placement, see section 4.3.1 Placement.

6.2.1 Rubber dampers

Risk of crushing
If the crusher is mounted on rubber dampers there is a risk of crushing body
parts. Make sure that there is enough room for the crusher’s horizontal
WARNING! movement. See appendix A: Installation drawings.
1
1 Locking nut
2
2 Washer 9 3
3 Upper fixing plate 6 6
4 Rubber compression 8 5
mounting
4 4
5 Screw
6 Washer
5 5
7 Lower fixing plate 6 6
8 Screw
7 7
9 Locking nut
Rubber damper, crusher and Rubber damper, crusher with
motor on sub-frame motor bracket
Adjust the mountings so that the rubber dampers are equally compressed.
NOTE! The crusher can be mounted directly on the foundation with foundation bolts.
Dynamic loads will then be much higher.
Foundation bolts are not supplied by Sandvik.

6.2.2 Crusher with rubber dampers on a new concrete

foundation
Design the concrete foundation and its reinforcement to match the load
information in the installation drawings. Consider also the bearing strength
and nature of the ground under the foundation.
The concreting work must be carried out by experienced personnel.
Installation
Hanging load
The cone crusher weighs approximately 12000 kg (26500 lb). Make
WARNING! sure that the SWL (Safe Work Load) of the lifting equipment is
sufficient for the load.
1
1 Locking nut
2
2 Washer
3 3 Upper fixing plate
6 4 Rubber compression
mounting
5
5 Screw
4
6 Washer
5 7 Lower fixing plate
Rubber dampers on
anchor plates 6
7
a) Cast in anchor plates for the four rubber compression mountings.
Use anchor plates which are at least 25 mm (1") thick.
NOTE! Anchor plates are not supplied by Sandvik.
b) Make sure that the mounting points are level and properly grouted. Use
shims to level. Max deviation at load application point: ±1 mm.
c) Carefully clean any dust and oil from the area beneath the crusher.
d) Install the rubber dampers on the crusher’s feet. Make sure that the lower
fixing plates (7) are attached to the dampers.
(Continued)

e) Lower the crusher until the lower fixing plates (7) are resting on the
anchor plates.
NOTE! Make sure that the crusher is centered over the discharge opening and that
the pinionshaft is pointing in the correct direction.
f) Spot weld the lower fixing plates (7) to the anchor plates.
g) Remove the screws (5) and washers (6) from the upper fixing plates (3).
h) Lift the crusher away from the rubber dampers.
i) Weld all around the lower fixing plates (7) to the anchor plates.
See drawing in appendix A: Installation drawings.
j) Lower the crusher onto the rubber dampers.
k) Fit the washers (6) and screws (5).

6.2.3 Crusher with rubber dampers on a steel supporting

structure
Design the steel supporting structure and its reinforcement to match the load
information in the installation drawings. Consider also the bearing strength
and nature of the ground under the foundation.
Installation
Hanging load
The cone crusher weighs approximately 12000 kg (26500 lb). Make
WARNING! sure that the SWL (Safe Work Load) of the lifting equipment is
1
1 Locking nut
2
2 Washer
3 3 Upper fixing plate
6 4 Rubber compression
mounting
5
5 Screw
4
6 Washer
5 7 Lower fixing plate
Rubber dampers on steel
supporting structure 6
7
a) Make sure that the crusher’s mounting points are level. Use shims to
level. Max deviation at load application point: ±1 mm.
b) Carefully clean any dust and oil from the area beneath the crusher.
c) Install the four rubber dampers on the crusher’s feet. Make sure that the
lower fixing plates (7) are attached to the dampers.
d) Lower the crusher until the lower fixing plates (7) are resting on the
supporting structure.
e) Center the crusher over the discharge opening.
f) Spot weld the lower fixing plates (7) to the supporting structure.
g) Remove the screws (5) and washers (6) from the upper fixing plates (3).
h) Lift the crusher away from the rubber dampers.
i) Weld all around the lower fixing plates (7) to the supporting structure.
See drawing in appendix A: Installation drawings.
j) Lift the crusher onto the rubber dampers.
k) Fit the washers (6) and screws (5).

6.3 Crusher assembly

6.3.1 Install feed hopper
a) Lift the feed hopper (1) onto the topshell rim.
b) Fit the screws (3), washers (4) and nuts (5).
Make sure that the spider arms are aligned with the feeder or feed conveyor.
1 Feed hopper
2 -
3 Screw 1
4 Washer
5 Nut 3, 4, 5
Feed hopper on topshell

6.4 Hoses and pipes – General

NOTE! Hoses and pipes are not supplied by Sandvik.
Route all pipes and/or hoses to and from the crusher along the same path.
The inclination of return lines is critical. See section 6.5.1 Oil tank unit.
For a description of hoses, pipes and connections on the tank unit and
crusher, see appendix A.1.4 Mechanical connections.
NOTE! When starting the crusher for the first time, make sure there are no leakages.
If there are leakages, use a suitable compound to seal.

6.5 Hydroset and lubrication systems

6.5.1 Oil tank unit
Hanging load
The oil tank unit weighs approximately 310 kg (680 lb).
WARNING! Make sure that the SWL (Safe Work Load) of the lifting equipment is
a) Install the oil tank unit in a suitable location.

See also section 4.3.1 Placement.
1
1 Lifting lugs
NOTE! The tank unit must be placed below the level of the cone crusher.
Distance tank – crusher Inclination of return oil hose
<3m 5°
>3m 10°
b) Connect the oil lines to the tank unit, see appendix A: Installation
drawings.
NOTE! The connections are already fitted to the crusher. Hoses, 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.
– Use high-pressure piping and hoses for Hydroset oil lines.
Minimum pressure rating of hoses/pipes in the Hydroset system:
CH420 20 MPa / 290 psi

6.5.2 Water/oil heat exchanger

See also appendix A: Installation drawings.
S1 S4
1 Oil in
2 Water out
3 Water in
4 Oil out (to crusher)
S3 S2
NOTE! Pipes and pipe fittings are not supplied by Sandvik.

a) Install the water/oil heat exchanger on the back of the tank unit.
b) Connect water piping or hoses to the heat exchanger. This must be
arranged at the site to suit local conditions.
NOTE! Use clean fresh water. If only contaminated water is available, contact
Sandvik first!
c) Connect the piping or hoses to the tank unit.
d) Set the thermostatic valve (TG2) to “3” on the scale initially.
NOTE! If a water/oil heat exchanger is used, thermostats should be set at the values
for “Normal Operating Conditions” regardless of the ambient temperature.
See OM section 8.2.11 Thermostats
TG2

6.5.3 Air/oil heat exchanger

CAUTION! If the crusher is installed at high altitude and/or extremely high or low
ambient air temperatures, a special cooling system is required.
NOTE! The heat exchanger and the piping must be shielded from direct sunlight.
The air/oil heat exchanger can be installed directly on the oil tank unit or in a
suitable place close to it. Piping and hoses can be used to connect to the oil
tank unit. Hoses must always be fitted to the heat exchanger.
If the ambient air contains a lot of dust, it is advisable to lead fresh air to the
heat exchanger through a duct from a dust-free place. The duct must be
correctly dimensioned so that air flow is not restricted, and it must not be
rigidly connected to the heat exchanger.
To reduce the amount of dust which settles in the radiator matrix, the air/oil
heat exchanger is best placed so that the fan blows towards the crusher.
Air flow
NOTE! Pipes and pipe fittings are not supplied by Sandvik.

a) Install the air/oil heat exchanger close to the tank unit.
b) Connect the hoses to the heat exchanger.
c) Connect piping or hoses to the tank unit.

6.6 Over-pressure system

Minimum and maximum length of hoses 2–15 m
Minimum and maximum pressure 600–1000 Pa
Minimum blower capacity at 600 Pa 0.3 m3/min
The cone crusher and the oil tank unit are equipped with a common over-
pressure system to exclude dust from the equipment. A correctly functioning
over-pressure system is important for the performance of the crusher.
Normally the system consists of a blower and two hoses: one from the
blower and one from the tank unit. The hoses are joined in a T-connector on
the crusher bottomshell. The lengths of the hoses depend on the position of
the blower and tank unit.
NOTE! Hoses, pipes and pipe fittings are not supplied by Sandvik.
As an alternative to the blower installation, a connection can be made to a
compressed air system via a regulator and a filter. If possible, the regulator
and filter should be installed in a heated space.
NOTE! The air which is introduced into the crusher and the tank must be free from
moisture and dust.
CAUTION! It is important to install the blower in a dust free environment. Dust will
damage the blower and result in malfunction of the cone crusher.
a) The blower (1) can be mounted horizontally or vertically. If a regulator

assembly (2) is used, it must be installed horizontally.
b) When connecting the blower motor, make sure that the direction of
rotation corresponds to the arrow on the blower housing. If the direction
of rotation is incorrect, the output of the blower will be insufficient.
NOTE! Install the blower or regulator at least 0.5 m above the oil tank unit. This will
prevent oil running back to it from the tank.
c) Measure the hose lengths required and cut the appropriate lengths from
the hose coil supplied with the crusher.
d) Connect one hose (3) between the crusher T-connection (4) and the hose
coupling on the blower (1) or regulator (2). Use hose clips.
e) Connect a second hose (5) between the crusher T-connection (4) and the
tank over-pressure coupling (6). Use hose clips.

3
1
6
1 Blower
5
2 Regulator
3 Hose
4 T-connection on crusher
5 Hose
6 Over-pressure coupling on tank

6.7 Guards, platforms and covers

6.7.1 Guards and covers
If the specific design of the crushing plant makes it possible to access
moving parts of any equipment, it is the responsibility of the plant owner to
design and install appropriate guards and covers to protect the personnel.
See section 4.3.9 Guards for further information.
6.7.2 Platforms
Sandvik recommends installing platforms at least 50 mm away from the
crusher. When the crusher is mounted on rubber compression mountings
there is a risk of pinching between the oscillating parts of the crusher and the
stationary structure.
See section 4.3.10 Platforms and guard rails for further information.
6.8 Lubricants
Fill the required amounts of oil into the tanks.
See OM Section 7 – Lubrication for further information.



7.1 General requirements

Electricians
Electricians should be certified according to local regulations and have
experience of similar types of installations, proven skills in reading and
working from drawings and cable lists, and knowledge of local safety
regulations regarding power and automation circuits. Work with electrical
equipment must be performed only by skilled or instructed technicians.
See section 2.2 Personnel for further information.
7.2 Overview
The purpose of the electrical system is to power the crusher with its auxiliary
systems and to control the operation of the cone crusher.
Full electrical drawings are collected in appendix A: Installation drawings.

7.3 Motors and heating elements

Starting equipment for the drive motor, auxiliary motors and heating
elements are normally not supplied by Sandvik. Fuses, relays, motor
protectors and control units must be installed in the appropriate switchgear
cabinets.
7.3.1 M1 – Crusher motor

The power supply to the motor must incorporate the necessary fuses, relay
and motor protector, all installed in an appropriate switchgear cabinet.
The main drive motor of the crusher can be started in several different ways,
depending on the power supply available:
• Direct on-line starter
• Electronic soft starter
Starting and stopping can be made possible either by buttons or via software.
NOTE! The M1 relay must be interlocked with the power supply to the crusher’s
drive motor, so it is only possible to run the crusher when the lubrication
pump M2 is in operation.
7.3.2 M2 – Lubrication pump

The power supply to the motor must incorporate the necessary fuse, relay
and motor protector, all installed in an electrical cabinet. Starting and
stopping can be made possible either by buttons or via software.

7.3.3 M3 – Heat exchangers

Every crusher has at least one water/oil or air/oil type heat exchanger in the
lubrication system.
The power supply to each air/oil heat exchanger motor must incorporate the
necessary fuse, relay and motor protection built into an appropriate
switchgear cabinet.
With a water/oil heat exchanger it can be convenient to open/close the
cooling water supply with a magnetic valve. The temperature is controlled by
a thermostatic valve (TG2). See OM 8.4 Water/oil heat exchanger.
7.3.4 M6 – Hydroset pump

Starting and control equipment for the Hydroset pump is normally delivered
by Sandvik. The delivered electrical cabinet L3 contains fuses, relays and
motor protection for operation of the Hydroset pump.
7.3.5 E7 – Oil heaters

The power supply to the oil heaters must incorporate the necessary fuse,
relay and motor protection built into an appropriate switchgear cabinet.
7.3.6 M8 – Over-pressure blower

The power supply to the over-pressure blower must incorporate the
necessary fuse, relay and motor protection built into an appropriate
switchgear cabinet.


8.1 Installation and connection checks

See section 6. Mechanical installation and connections for further details on
the following checks.
No. Checks Done

1 The cone crusher is level, transversely and longitudinally
(± 1 mm/m).
2 The crusher is secured to the foundation or steel supporting
structure.
3 The discharge system is sufficient and connected/positioned.
4 The feed arrangement is connected/positioned.
5 The drive arrangement has been correctly installed.
6 All transport and packing materials have been removed from the
parts.
8.1.1 Lubrication system and Hydroset checks

No. Checks Done
1 The brand names and types of oil and grease are recorded.
2 The oil tank unit is properly installed and correctly positioned in
relation to the cone crusher.
3 The Hydroset and lubrication systems are correctly installed.
4 Heat exchanger/s is/are installed properly.
5 Piping and hosing has been installed according to the recommen-
dations in the IM.

8.2 Electrical checks

See section 6. Mechanical installation and connections for further details on
the following checks.
No. Checks Done
1 All electric cables are correctly connected.
2 All motors have the correct rotation direction.
Check the pressure drop sensor (PG2)

The pressure drop sensor is of normally open (NO) type. This means that if
the sensor malfunctions, it will not indicate the need for oil filter exchange.
Perform this check with the power on.
a) Locate the pressure drop sensor (PG2) (2).
b) Remove the clip on top of the indicator (2).
c) Remove the indicator (2) by pulling straight up from the oil filter
assembly (3).
d) Turn the indicator (2) upside down and position the indicator back on the
tube. The pressure drop lamp (1) on the panel will lit if the indicator
works.
e) Turn the indicator (2) back to its normal position.
f) Fit the clip on top of the indicator (2).
1 Pressure drop lamp 1
2 Pressure drop sensor (PG2)
3 Oil filter assembly

8.3 Safety checks

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

9. Preparations for
commissioning

9.1 General
Perform the following checks even if an actual commissioning test is not
required.
NOTE! Commissioning covers only the cone crusher itself. A line performance test
is still required to check the functioning of the cone crusher as part of a
production line. Contact the local service organization about arrangements
for a line performance test.
9.2 Presence and correctness checks
No. Checks Done

1 The data on the machine identification plate corresponds with
the machine specification document.
2 The ordered wear and spare parts have been delivered and
deposited in the spare part store.
3 All the documents correspond to the specific cone crusher:
- Operator’s manual
- Installation drawings
- Factory acceptance test report
- Machine specification document
- Machine deviation report (if relevant)
4 Sufficient process material is available for commissioning
purposes.
9.3 Supply value checks

No. Checks Done
1 Hydroset and lubrication systems:
- Systems have been thoroughly cleaned
- Lubricants of the correct types are available
2 Electrical power supply:
- Voltage
- Max voltage fluctuation within limits
- Frequency
- Fuse rating

9.4 Function checks

9.4.1 Preparation
Start the cone crusher according to OM section 4. Starting up the cone
crusher.
No. Checks Done

1 No unusual noises which could indicate misaligned parts or faults.
2 Hydroset pressure within limits.
4 Oil heating elements operate correctly.
5 Return lubrication oil temperature within limits.
6 Over-pressure dust exclusion system functions correctly.
7 No contact between oscillating crusher and stationary structure.
9.5 Health and safety checks

No. Checks Done
1 The cone crusher stops when the Emergency stop button
(if applicable) is pressed. Test must be made with the cone
crusher running.
2 The cone crusher stops when the Stop button is pressed.
3 All necessary guards are in place.
9.6 Documentation
– Compile the Installation report.
List all work, besides the installation work, that was performed to
ensure correct functioning.
The installation work covered by this manual is now complete.


10. Disassembly, storage
and removal
106

10.1 Moving and storage

10.1.1 Short moves and short-term storage
Hanging load
Risk of electrocution
High voltage. Disconnect electrical power before disassembling the
cone crusher.
WARNING!
CAUTION! Sandvik recommends storing the cone crusher indoors. Long-term ex-
posure to moisture or very high or low temperatures may damage the
cone crusher.
If the cone crusher is to be taken out of operation and moved into storage,
carry out the following steps:
a) Shut off the process material flow.
b) Shut off and disconnect the electrical power, cooling water and
compressed air supplies.
c) Drain the oil from the lubricating system.
See OM section 8.3.1 Draining the main lubrication system.
d) Drain the water circuit at the lowest point. Make sure that no water
remains in the heat exchanger.
e) Plug or protect any open connections on the cone crusher and on the oil
tank unit.
f) Prepare a storage area large enough to store the components with at least
1 m (3 ft) of free space around and above them for access and
ventilation. Make sure that the storage area environment meets the
conditions in the table below:
Characteristic Value Notes
Min–max temperatures 5–40 °C (41–104 °F)
Max relative humidity 80% Non-condensing
g) Disassemble the cone crusher to the extent necessary for the planned
transport/storage. See IM and MM for information on how to
disassemble.
h) Move the crusher to the storage area according to the instructions in
section 5.4 Moving and storage.
i) Cover the crusher and oil tank unit with suitable covering if stored
outdoors.

10.1.2 Long moves and long-term storage

If the cone crusher is to be moved into storage for more than 30 days, the
following steps should be carried out.
a) Carry out the steps in section 10.1.1 Short moves and short-term storage.
b) Wrap any loose components in bubble wrap or other suitable wrapping
to prevent damage.
c) Pack the equipment using suitable packing, crates and transport
platforms. Use the original packing, crates and transport platforms if
possible. Make sure that all parts are adequately protected.
d) Fill the bottomshell with lubricating oil until a little oil overflows the
dust collar.
e) Fill the spider bushing with grease to prevent condensation on bearing
surfaces.
f) Coat the exposed part of the mainshaft sleeve (between the spider and
the head nut) with grease. Make sure that this area is protected from
contamination.
g) Fill the oil pumps with oil.
10.1.3 Regular inspection during storage

The following checks should be carried out every two weeks during the
storage period:
• Inspect the cone crusher and oil tank unit for damage and make sure that
it is protected from rust and contamination.
• If the crusher has not been in operation before being stored, check that
the rust prevention film is undamaged, and renew it if necessary.
• Rotate the crusher pulley by hand through at least four revolutions.
10.2 Return to the manufacturer

a) Prepare the equipment for transport according to the instructions in
section 10.1 Moving and storage.
b) Contact the local service organization for further instructions on
arranging transport.

10.3 Disposal
If the cone crusher is to be permanently disposed of, follow the sequence
given below.
Toxic gases
When dismantling and scrapping the crusher it can be necessary to
cut the parts. This process can create toxic gases. Provide good
WARNING! ventilation and use breathing apparatus.
Environmental hazard
Disposed crusher parts can leak toxic substances into the subsoil
water and soil during long-term storage. Recycle or dispose of all
WARNING! material and components in compliance with local regulations.
a) Shut down and disconnect the cone crusher according to the instructions
in section 10.1 Moving and storage.
b) Disassemble the equipment as much as possible and separate the
following parts and material:
– Stainless steel
– Cast steel (frame etc.)
– Cast manganese steel (mantle, concave ring, etc.)
– 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 of all material and components in compliance with
local regulations.



CS430-01 IM S223.514.en-01

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installation manual Doc. no. S 223.

Serial no. / Machine no. Sign.

Document number: S 223.514 en

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 1

2 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

4.4.5 Diesel heating system............................................ 55

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 3

6. Mechanical installation and connections

8. Final installation checks

4 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

9. Preparations for commissioning

10. Disassembly, storage and removal

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 5

6 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 7

1.1 Equipment information

8 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 9

Tank unit identification

10 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

1.1.1 Document information

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 11

1.2 Operating principles of a cone crusher

12 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 13

14 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

Cone crusher – side view

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 15

Tank and auxiliary equipment

16 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

This page is intentionally left blank

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 17

18 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 19

2.1 Hazard information

General danger Dangerous voltage Risk of crushing

Hanging load Risk of crushing Flying fragments

2.1.2 Risk levels

Failure to observe information marked “DANGER!” can result in life-

2.1.3 Prohibition signs

2.1.4 Mandatory signs

Disconnect current Read the manual

20 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 21

2.2.1 Personal protection

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or breathing

2.3 General safety precautions

22 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

Avoid remaining on the crusher, unless necessary for maintenance work.

2.3.1 Machine safety guards

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 23

2.3.2 Electrical safety

CAUTION! Only welders qualified according to European Standard EN 287 or sim-

24 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

2.3.4 Hydraulic system

2.3.5 Lifting and moving loads

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 25

2.3.6 Feed and jams

CAUTION! Never feed combustible process material into the crusher.

In some cases it is possible to increase the CSS (closed side setting)

26 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 CS430:01

CS430:01 © Sandvik SRP AB – Doc. no. S 223.514 en Ver. 1 27