Sandvik Cone Crushers Ch660-01 - Im - S223.522.en-01

installation manual Doc. no. S 223.
522 en
SANDVIK CH660:01
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SANDVIK CH660:01
© 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.
HS6800_IM_fro_en.fm
Document number: S 223.522 en
Issue: 20080417
Version: 1
Sandvik SRP AB
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 40-40 90 00, Fax: +46 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 ............................................................. 18
2.1.1 Warning signs ........................................................ 18
2.1.2 Risk levels.............................................................. 18
2.1.3 Prohibition signs..................................................... 18
2.1.4 Mandatory signs..................................................... 18
2.2 Personnel............................................................................ 19
2.2.1 Personal protection ................................................ 20
2.3 General safety precautions................................................. 20
2.3.1 Machine safety guards........................................... 21
2.3.2 Machine access ..................................................... 22
2.3.3 Electrical safety...................................................... 22
2.3.4 Welding .................................................................. 22
2.3.5 Hydraulic systems.................................................. 23
2.3.6 Lifting and moving loads ........................................ 23
2.3.7 Feed and jams ....................................................... 24
2.4 Emissions ........................................................................... 24
2.4.1 Dust........................................................................ 24
2.4.2 Noise...................................................................... 25
2.4.3 Radioactivity........................................................... 25
3. Technical data
3.1 General data ....................................................................... 28
3.2 Crusher motor..................................................................... 30
3.3 Drive system ....................................................................... 30
3.4 Lubrication system.............................................................. 31
3.4.1 Main lubrication system ......................................... 31
3.4.2 Pinionshaft lubrication system ............................... 32
3.5 Hydroset system ................................................................. 32
CH660:01 © Sandvik SRP AB – Doc. no. 223.522 en Ver. 1 i

Table of contents
3.6 Oil cooling systems ............................................................. 33

3.6.1 Oil/water heat exchanger ....................................... 33
3.6.2 Oil/air heat exchanger ............................................ 33
3.7 Over-pressure dust exclusion system................................. 33
3.8 Corrosion protection............................................................ 34
3.9 Processing data .................................................................. 34
3.10 Tightening threaded fasteners ............................................ 34
3.10.1 Requirements for joints with threaded fasteners .... 35
3.10.2 Locking fluid for threaded fasteners ....................... 35
3.11 Electrical data ..................................................................... 36
3.11.1 Cable overview....................................................... 36
3.11.2 Instrumentation overview ....................................... 37
3.11.3 Sensor overview..................................................... 37
4. Installation preparations
4.1 General ............................................................................... 40
4.2 Crusher capacity and performance ..................................... 40
4.3 Installation preparations check list ...................................... 42
4.4 Placement ........................................................................... 43
4.5 Foundation .......................................................................... 44
4.5.1 Foundation loads.................................................... 44
4.5.2 Movement of the crusher ....................................... 45
4.5.3 Using an existing concrete foundation ................... 45
4.5.4 Using a steel supporting structure.......................... 46
4.6 Installation alternatives ....................................................... 46
4.6.1 Installation packages.............................................. 48
4.6.2 Direct drive installation package............................. 48
4.6.3 V-belt drive installation package............................. 48
4.6.4 Rubber dampers .................................................... 50
4.6.5 Crusher mounting feet............................................ 51
4.7 Crusher arrangement.......................................................... 52
4.7.1 Electrical installation for a cone crusher................. 52
4.7.2 Remote control system (option) ............................. 52
4.7.3 Process material .................................................... 52
4.7.4 Dust protection ....................................................... 52
4.7.5 Feed arrangement.................................................. 53
4.7.6 Discharge ............................................................... 56
4.7.7 Guards ................................................................... 57
4.7.8 Platforms and guard rails ....................................... 57
ii © Sandvik SRP AB – Doc. no. 223.522 enVer. 1 CH660:01

Table of contents
4.8 Operating in low temperatures............................................ 58

4.8.1 Measures that make starting and running easier
in cold weather....................................................... 58
4.8.2 Low temperature problems - Symptoms and
Remedies............................................................... 59
4.8.3 Insulation of the bottom of the component
section of the oil tank unit ...................................... 60
4.8.4 Installation of additional oil heaters........................ 60
4.8.5 Diesel heating system............................................ 60
4.8.6 Heating cables on oil lines ..................................... 61
4.8.7 Heating in the component section of the oil tank unit 61
4.8.8 Synthetic oils.......................................................... 62
4.8.9 Mineral oil for the winter season ............................ 63
4.8.10 A thermostatic valve to by-pass the oil cooler........ 63
4.8.11 Blanking off the oil cooler radiator.......................... 64
4.8.12 2-speed fan motor for oil cooler ............................. 65
4.8.13 Modified return oil flow switch interlock.................. 65
4.8.14 Insulation of the oil tank ......................................... 66
4.8.15 Continuous running of the lubrication oil pump...... 66
4.8.16 A heater in the Hydroset tank ................................ 67
5. Transport handling
5.1 Goods data ......................................................................... 70
5.1.1 Contents................................................................. 70
5.1.2 Loading and unloading goods signs ...................... 71
5.2 Lifting equipment ................................................................ 71
5.2.1 Overhead gantry or mobile crane .......................... 72
5.2.2 Fork lift ................................................................... 73
5.3 Unloading the goods........................................................... 73
5.3.1 Unpacking area...................................................... 73
5.3.2 Inspection of goods................................................ 73
5.4 Moving and Storage............................................................ 74
5.4.1 Moving ................................................................... 74
5.4.2 Storage of a non-assembled crusher ..................... 75
5.4.3 Pre-delivery rust prevention treatment................... 75
5.5 Unpacking the goods .......................................................... 76
5.6 Disposal/return of packaging material ................................ 76
CH660:01 © Sandvik SRP AB – Doc. no. 223.522 en Ver. 1 iii

Table of contents
6. Mechanical installation and connections

6.1 General requirements ......................................................... 78
6.1.1 Crusher with direct drive and rubber dampers,
on a concrete foundation........................................ 79
6.1.2 .......... Crusher with V-belt drive and rubber dampers,
on a concrete foundation........................................ 81
6.1.3 Crusher on a concrete foundation - fixed installation 83
6.1.4 Crusher with rubber dampers on a steel
supporting structure ............................................... 83
6.2 Motor and direct drive (alt. 1) .............................................. 84
6.2.1 Installing direct drive motor .................................... 84
6.3 Safeset coupling - description............................................. 85
6.3.1 Important information ............................................. 85
6.3.2 Safety regulations .................................................. 86
6.3.3 Lowering the pressure............................................ 86
6.3.4 Installation of Safeset coupling .............................. 87
6.3.5 Checking the lubrication oil level and refilling ....... 88
6.3.6 Pressure setting ..................................................... 89
6.3.7 Safeset coupling pump 100B ................................. 90
6.4 Assembly procedure for flexible coupling ........................... 91
6.4.1 Mounting the inner member of the flexible coupling
on the motor shaft .................................................. 91
6.4.2 Assembling the flexible coupling ............................ 92
6.4.3 Fitting rubber elements........................................... 93
6.4.4 Bolting up flanges................................................... 94
6.4.5 Shaft alignment ...................................................... 95
6.4.6 Storage of flex elements......................................... 96
6.4.7 Speed monitor for direct drive ................................ 97
6.4.8 Drive guard............................................................. 97
6.5 Motor and V-belt drive (alt. 2).............................................. 98
6.5.1 Installing V-belt drive motor .................................... 98
6.5.2 Installing V-belts ..................................................... 99
6.5.3 Speed monitor for V-belt drive................................ 99
6.5.4 Coupling and V-belt guards.................................. 100
6.6 Crusher assembly ............................................................. 101
6.6.1 Install feed hopper................................................ 101
6.7 Hoses and pipes - General ............................................... 102
iv © Sandvik SRP AB – Doc. no. 223.522 enVer. 1 CH660:01

Table of contents
6.8 Hydroset and lubrication systems..................................... 102

6.8.1 Oil tank unit .......................................................... 103
6.8.2 Water/oil heat exchanger (alternative) ................. 104
6.8.3 Air/oil heat exchanger (alternative) ...................... 105
6.9 Over-pressure system ...................................................... 106
6.10 Guards, platforms and covers........................................... 107
6.10.1 Guards and covers............................................... 107
6.10.2 Platforms.............................................................. 107
6.11 Lubricants ......................................................................... 107
7. Electrical installation
7.1 General requirements ....................................................... 110
7.2 Overview........................................................................... 110
7.3 Motors and heating elements ........................................... 110
7.3.1 M1 - Crusher motor.............................................. 110
7.3.2 M2 - Main lubrication pump................................... 111
7.3.3 M3 - Heat exchangers........................................... 111
7.3.4 M6 - Hydroset pump ............................................. 111
7.3.5 E7 - Oil heaters ..................................................... 111
7.3.6 M8 - Over-pressure blower ................................... 111
8. Final installation checks

8.1 Installation and connection checks ................................... 114
8.1.1 Lubrication system and Hydroset checks ............ 114
8.2 Electrical checks ............................................................... 114
8.3 Safety checks ................................................................... 115
8.4 Start-up ............................................................................. 115
9. Preparations for commissioning

9.1 General ............................................................................. 118
9.2 Presence and correctness checks.................................... 118
9.3 Supply value checks ......................................................... 118
9.4 Function checks................................................................ 119
9.4.1 Preparation .......................................................... 119
9.5 Health and safety checks.................................................. 119
9.6 Documentation.................................................................. 119
CH660:01 © Sandvik SRP AB – Doc. no. 223.522 en Ver. 1 v

Table of contents
10. Disassembly and removal

10.1 Draining the cone crusher................................................. 122
10.1.1 Draining procedure............................................... 122
10.2 Moving the cone crusher................................................... 122
10.2.1 Short moves and short-term storage.................... 122
10.2.2 Long moves and long-term storage ..................... 123
10.3 Storage of an assembled crusher ..................................... 124
10.4 Return to the manufacturer ............................................... 125
10.5 Disposal ............................................................................ 125
Appendix A: CH660:01
Installation drawings
A.1 General ................................................................................. 2
A.1.1 Mechanical drawings................................................ 2
A.1.2 Electrical drawings ................................................... 2
A.1.5 Mechanical connections ........................................... 4
vi © Sandvik SRP AB – Doc. no. 223.522 enVer. 1 CH660:01

1. Introduction
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 7

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.
Unless the crusher is part of a complete plant delivery, Sandvik SRP AB is
not responsible for the complete aggregate or mining process. Sandvik will
not accept any liability for damage to equipment or injury to personnel
caused by unauthorized or improper use or modification of this equipment.
Manufacturer
This Sandvik equipment has been manufactured by:
Sandvik SRP AB
Stationsplan
SE-233 81 Svedala
Sweden
www.sandvik.com
For maintenance
Contact the nearest Sandvik Rock Processing company, agent or
representative, or the manufacturer directly:
Sandvik SRP AB
Service department
SE-233 81 Svedala
Sweden
Telephone +46 (0)40 409000
Telefax +46 (0)40 409260
8 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 CH660:01

1. Introduction
Crusher identification
The figure below shows an example of the 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
4 Mass (kg)
5 Order number 8
7 Manufacturer 7
8 Year of manufacture
9 CE mark
Type:
10 Type and size of crusher 1 2 3 4 5 6
11 Crushing chamber (concave ring)
12 Mantle CH660-M/B/M-36/40/44/32:1
13 Filler ring
14 Eccentric throw (mm)
15 Mark number 9 10 12 13 14
11
CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 enVer. 1 9

1. Introduction
Tank unit identification

The figure below shows an example of the tank unit’s identification plate.
The identification plate contains data needed when contacting Sandvik
concerning this specific equipment.
16 Type
17 Part number
18 Serial number 22
19 Mass (kg)
21
20 Order number
21 Manufacturer
22 Year of manufacture
23 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.

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
Figures in this manual

Some figures in this manual are based both on the CH430 and CH880 cone
crushers, which are similar to the CH660. Details of less or no importance
for instructions given can therefore differ from the CH660 design.
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
Technical publications related to installation and operation of this equipment
are:
• Installation manual (IM)
• Wear parts catalog (WPC)
• Operator’s manual (OM)
When ordering technical publications, always specify the language and quote
the machine’s identity number.
Technical publications related to maintenance of this equipment are:
• Maintenance manual (MM)
• Spare parts catalog (SPC)
These publications are only available to trained maintenance personnel.
Sandvik can provide adequate training and authorize personnel.
Read more about the document structure and accompanying work roles in
section 2.2 Personnel.
Number of pages
This document contains a total of 128 pages.
Feedback
If you have comments on this Operator’s manual or problems connected 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 (e. g. rock or ore) 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’s geometry, the crusher’s dynamics and the process material are the
most important factors.
The concave ring, mantle, 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 is the
spider bearing (1) that acts as the pivot point for this gyrating motion. The
mantle is fixed to the mainshaft and the concave ring is fixed to the
topshell (2). The gyration of the mainshaft means that the distance between
the mantle and any given point around 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 and the concave ring must be replaced regularly as they are
continuously worn. The rate at which this wear occurs depends on the
characteristics of the process material. Read more in the OM.
1 Spider bearing 1
2 Topshell
3 Concave ring 2
4 Mantle 3
5 Eccentric assembly
6 Mainshaft 4
5
6

1. Introduction
Setting adjustment
Due to the need to compensate for wear and the need to produce different
product sizes the crusher has a setting control system. It basically consists of
a robust hydraulic jack, named Hydroset, which supports the mainshaft and
adjusts its position. By moving the mainshaft up and down, the discharge
setting can be changed and the size of the crushed material can thereby be
changed. Read more in section 9. Preparations for commissioning.
setting decrease = finer product setting increase = coarser product
= =
Auxiliary lubrication systems

There are two separate circulatory lubrication systems – the main lubrication
system and the pinionshaft lubrication system. The main lubrication system
is described in OM.The pinionshaft lubrication system is described in OM.

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

1. Introduction
Cone crusher – side view
23
23 Inspection door
24 Feed hopper 24
25 Inspection hatch
25
Tank unit and auxiliary equipment
26 Over-pressure blower 26
27 Over-pressure air regulator
28 Tank unit
29 Water/oil heat exchanger
30 Air/oil heat exchanger 27
31 Charging kit for accumulator
28
29
30

1. Introduction

To ensure maximum safety, always read this section carefully before doing
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 are 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 (so that it cannot
inadvertently be switched on) before any maintenance work is started. Also
ensure that it is not possible for anyone else to switch the power on while
maintenance work is being carried out.
(Continued)

Avoid staying 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 matter 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 unless 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.
Make sure all defective guards and dust sealing components are checked,
repaired and replaced before starting the equipment.

2.3.2 Machine access

Every machine requires access for personnel who carry out inspections and/
or maintenance work. Suitable access platforms and guard rails shall be
installed. Walkways, stairs and ladders must be designed in accordance with
applicable regulations. (These parts are not included in the crusher’s standard
specification. For advice, contact Sandvik.)
Areas where access is required are indicated on installations drawings, see
the Installation manual.
2.3.3 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.
2.3.4 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
Rock Processing 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, the grounding cable must be attached to the
item itself. If a crusher component is to be welded, the grounding cable
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.

2.3.5 Hydraulic systems

CAUTION! Only personnel certified in hydraulics are permitted to perform mainte-
nance on the hydraulic system (except bleeding air from the Hydroset
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.
2.3.6 Lifting and moving loads

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

2.3.7 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 control.
Examples are dust extraction (vacuum) and dust suppression 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.

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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 CH660:01
Type Cone crusher
Application Mineral processing
Usage Outdoors/Indoors
Total mass 23 500 kg (51 810 lb.)
Length (with motor cradle) 5.26 m (207”)
Width 2.10 m (126")
Height 4.2 m (209")
Max. motor power 315 kW 422 Hp
Installed power 450-520 kW
Available crushing chambers 7 (EC, C, MC, M, MF, F and EF)
Close Side Setting (CSS) Approx. 10-55 mm depending on crushing chamber and eccen-
tric throw
Open Side Setting (OSS) Max. depends on chamber, Min. = CSS + ECC
CSS and ECC
Pinionshaft speed 1080 rpm / 50 Hz 1095 rpm / 60 Hz
Feed hopper Mass 570 kg (1 257 lb.)
Material Steel hopper
Thickness 10 mm incl. rubber lining
Height 1200 mm (47.24")
Inner diameter Ø 1950 mm (76.77”)
Capacity 10.8 ton with B.D = 1.6 ton/m3
Topshell Mass 6 950 kg (15320 lb.)
Diameter at lower flange Ø 2200 mm (86.61”)
Material Cast steel
Spider bushing lubrication Grease
Spider shields Number of shields 2 (1 per spider arm)
Mass of a shield 160 kg (353 lb.)
Material Manganese steel
Backing material No
Securing method Welding
Spider cap Mass 375 kg (827 lb.)
Securing method Bolts, seal with O-ring
Bottomshell Mass 10 100 kg (22 270 lb.)
Inner diameter at Ø 1970 mm (77.56”)
discharge opening
Min. shell thickness 60 mm (2.36”)
Bottomshell liners Number of liners 15
Different shapes 6
Material Wear-resistant hardened steel
Hardness 360-440 BHN
Securing method Tack welding
Bottomshell arm liners Material Manganese steel
Min. thickness 20 mm (0.78”)
Max. thickness 45 mm (1.77”)
Number of liners 3
Different shapes 2
Mass of heaviest liner 60 kg (132 lb.)
Securing method Welding

3. Technical data
Mantle Types A, B, EF, and HC
Min. thickness 40 mm
Max. thickness 90 mm
Outer diameter at bottom Ø 1340 mm
Material Manganese alloyed steel
Securing method Self-tightening head nut, burn-
ing ring
Sections 1
Mass of heaviest mantle 1200 kg
Concave ring Types EC, (C), (MC), (M), MF F, EF
Min. thickness 30 mm
Max. thickness 90 mm
Diameter Ø 1400 mm
Material Manganese alloyed steel
Mass of heaviest concave 1300 kg
Backing material No
Securing method Clamping ring, filler ring
Mainshaft Max. mainshaft travel 340 mm
Mainshaft position sensing Yes
Mass 5 050 kg (11 130 lb.)
Length 2340 mm (92.13")
Eccentric Adjustable throw Yes
Standard eccentric throws 18, 20, 24, 28, 32, 36, 40, 44, 48,
50,
Eccentric speed 290 rpm
Balancing Yes
Mass 820 kg
Eccentric assembly mass 1170 kg (2579 lb.)
Eccentric bushing mass 430 kg
Pinion Mass pinion 70 kg (50 Hz)
45 kg (60 Hz)
Pinionshaft housing mass 565 kg (1246 lb.)
Pinionshaft bearing mass 18 kg
Bevel gear mass 300 kg (50 Hz)
380 kg (60 Hz)

3. Technical data
3.2 Crusher motor

Other types of motor may be used together with the crusher. This is a typical
example:
Manufacturer WEG
Mass Max 4000 kg
Type Squirrel cage
Voltage To suit supply
Phases 3
Frequency 50/60 Hz
Power 315 kW
Typical power draw with crusher idling 50 kW
Speed 1485 rpm (50 Hz)
1785 rpm (60 Hz)
Design vibration resistance velocity 20 mm/s
Locked rotor current Depends on voltage
Full load current Depends on voltage
Enclosure TEFC
Insulation class F
Typical full load efficiency% Depends on voltage
approx. 97%
Bearing type Roller Bearings
Lubrication method Grease
Frame size 315/ 355
3.3 Drive system

Direct drive CH660:01
Coupling Manufacturer Voith
Model Safeset
Size ST-B 140
Coupling mass 175 kg (386 lb.)
Flexible coupling Model Holset
Rubber blocks PM18
Sub frame Mass 2 500 kg (5512 lb.)
Protection Drive guard mass 35 kg (77.16 lb.)
Slip detection device Speed monitor
V-belt drive CH660:01

Protection Drive guard Yes
Slip detection device Speed monitor
Drive guard mass 380 kg (838 lb.)
Drive belts Frequency 50 Hz 60 Hz
Specification SPC 8V
Belt size 3000 1400
Number of belts 12 12
Distance between pulleys c/c 792 mm 1036 mm
Sheave locking devices MGT QD
Motor pulley Pulley PCD 400 mm 15”
Mass 105 kg 100 kg
Crusher pulley Pulley PCD 500 mm 22.4”
Mass 140 kg 185 kg
Motor bracket and drive assembly Mass 2500 kg (5 512 lb.)

3. Technical data
3.4 Lubrication system

3.4.1 Main lubrication system
Main lubrication system Type Closed circuit with gravity
return
Tank mass 490 kg (1080 lb.)
Oil reservoir capacity 400 litres (106 US gal)
Oil type Normally ISO VG 150
Main lube pump Type Gear
Capacity 120 l/min.(50 Hz)
144 l/min.(60 Hz)
Number of pumps 1
Main lube pump motor Type TEFC
Motor power 4.0/4.4 kW 50/60 Hz
Motor speed 1440 rpm with 50 Hz supply
1728 rpm with 60 Hz supply
Voltage 220/380 – 240/420V (50 Hz)
250/440 – 280/480V (60 Hz)
Phases 3
Frequency 50 / 60 Hz
Service factor 1,00
Enclosure / Insulation IP 55 / F
Frame size IEC132S
Main oil filter Number of oil filters operating 4
Blocked filter sensor Pressure switch
Heating elements Type Electrical immersion heaters
Rating 1.66-1.78 kW/ heater depend-
ing on voltage
Method Indirect heating
Numbers of heating elements 2–4
Voltage 220/380 – 240/420V (50 Hz)
250/440 – 280/480V (60 Hz)
Phases 3

3. Technical data
3.4.2 Pinionshaft lubrication system

Pinionshaft lubrication system Type Closed circuit with gravity
return
Oil reservoir Shared with main lubrication
system
Oil type Normally ISO VG 150
Pinionshaft lube pump Type Gear
Capacity 0,75 l/min. (50Hz)
0,90 l/min. (60Hz)
Number of pumps 1
Pinionshaft lube pump motor Type TEFC
Motor power 0.25/0.30 kW with 50/60 Hz
Motor speed 935 rpm (50 Hz)
1122 rpm(60 Hz)
Voltage 220-240 / 380-420V (50Hz)
250-280 / 440-480V (60Hz)
Phases 3
Service factor 1,00
Frame size IEC 71B
Pinion oil filter Number of oil filters operating 1
Blocked filter sensor Yes, Pressure switch
3.5 Hydroset system

Hydroset tank Oil reservoir capacity 85 litres (22.5 US gal)
Oil type ISO VG 68
Hydroset pump Type Reverse gear pump
Capacity 8.6 l/min. (50Hz)
10.3 l/min. (60Hz)
Number of pumps 1
Hydroset pump motor Type TEFC
Motor power 2.2/2.5 kW 50/60 Hz
Motor speed 2980 rpm (50 Hz)
3575 rpm (60 Hz)
Voltage 220-240 / 380-420V (50 Hz)
250-280 / 440-480V (60 Hz)
Phases 3
Service factor 1,00
Frame size IEC90L
Oil filter Number of oil filters operating 1
Blocked filter sensor No

3. Technical data
3.6 Oil cooling systems

3.6.1 Oil/water heat exchanger
Mass 53 kg (116.8 lb.)
Number of oil/water heat exchangers operating 1
Material Stainless steel
Oil temperature detector Yes
Pressure drop oil side 86 kPa
Max cooling capacity 30 kW
Water flow rate max. 85 l/min.
Water temperature < 30°C
Max water feed pressure 300 kPa
Oil flow rate 120 l/min. (50 Hz)
144 l/min. (60 Hz)
3.6.2 Oil/air heat exchanger

Mass (exclusive oil) 190 kg (419 lb.)
Number of oil/air heat exchangers operating 1
Material Aluminium
Pressure drop Approx. 200 kPa
Motor power (fan) 4.0/4.6 kW 50/60 Hz
Motor speed 1 450/1 740 rpm 50/60 Hz
Air flow 13 200 m3/h (50 Hz)
15 840 m3/h (60 Hz)
Sound level 92 dBa ± 3 (50 Hz)
96 dBa ± 3 (60 Hz)
3.7 Over-pressure dust exclusion system

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)
Motor power (blower) 0.37/0.43 kW (50/60 Hz)
Voltage 220-240 / 380-420V (50 Hz)
250-280 / 440-480V (60 Hz)
Phases 3
Speed 2 800/3350 rpm (50/60 Hz)
Frame size IEC71A

3. Technical data
3.8 Corrosion protection

Paint system CH660:01
Primer Zinc-phosphate
Procedure Spray painting
Thickness min. 40 µm
Second coating Alkyd enamel
Procedure Spray painting
Thickness min. 40 µm
3.9 Processing data

Characteristics (depending on crushing chamber) Data
Max. feed size 65 to 275 mm
CSS min–max 10 to 55 mm
Nominal capacity 150 to 650 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.
3.10 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 8.8 12.9
M (mm) Bright zinc-coated Untreated
Nm (ft lbs) Nm (ft lbs)
8 21 (15) 40 (30)
10 40 (30) 79 (58)
12 70 (52) 136 (100)
16 169 (125) 333 (246)
20 331 (244) 649 (479)
24 572 (422) 1120 (826)
30 1130 (833) 2210 (1630)
36 1960 (1446) 3850 (2840)
42 3130 (2309) 6140 (4529)
48 4690 (3459) 9190 (6778)

3. Technical data
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.
– Max. 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
3.11 Electrical data

3.11.1 Cable overview
This cable overview shows general information about what electrical cables
should be connected to the cone crusher. It also shows general information
about various signal cables for control. Site specific signals are not included
in this presentation.
NOTE! All cable types and dimensions must meet local legislation.
Cable Object Cable path Motor power Motor power Cable sup- Notes
designation 50 Hz typical 60 Hz Typical plied and con-
nected by
Sandvik
From To l
W1-M1 Crusher's main motor M1 Switchgear Motor M1 No
W1-M2 Lubrication oil pump M2 Switchgear Oil tank -L9 box No
(main)
W2-M2 Oil tank -L9 box Motor M2 4.0 kW 4.6 kW Yes
W1-M3 Cooling fan M3 Switchgear Motor M3 4.0 kW 4.6 kW No
W1-M6 Hydroset pump M6 Switchgear Connection box No
ASRi-L3
W2-M6 Connection Oil tank -L9 box No
ASRi-L3 box
W1-E7 Heating element in oil Switchgear Oil tank -L9 box No
tank E7 (main)
W11-E7 Oil tank -L9 box Heating element 1.5 kW (400V) 2.2 kW (460V) Yes Option
#1 E7.1
W12-E7 Oil tank -L9 box Heating element 1.5 kW (400V) 2.2 kW (460V) Yes
#2 E7.2
W13-E7 Oil tank -L9 box Heating element 1.5 kW (400V) 2.2 kW (460V) Yes
#3 E7.2
W14-E7 Oil tank -L9 box Heating element 1.5 kW (400V) 2.2 kW (460V) Yes Option
#4 E7.4
W1-M8 Over-pressure fan M8 Switchgear Motor M8 0.37 kW 0.41 kW No
W1-M9 Lubrication oil pump M9 Switchgear Oil tank -L9 box No
(pinionshaft)
W1-CV Power supply signals Switchgear Oil tank -L9 box No
and work lamp
W2-CV Signals for switches Oil tank -L9 box Oil tank -L9 box No
W1-S10 Switch for light Oil tank -L9 box Lamp -S10 Yes Option
W1-H10 Work light Switchgear Connection box - Yes Option
L11
W1-TG1 Temperature switch -TG1 Oil tank -L9 box -TG1 Yes No
(return oil)
W1-TG2 Temperature switch -TG2 Oil tank -L9 box -TG2 Yes
(in oil tank)
W1-TG3 Temperature switch -TG3 Oil tank -L9 box -TG3 Yes
(cooling thermostat)
W1-OG1 Flow switch -OG1 (return Oil tank -L9 box -OG1 Yes
oil)
W1-PG2 Pressure switch -PG3 Oil tank -L9 box -PG2 Yes
(Main)
W1-PG3 Pressure switch -PG3 Oil tank -L9 box -PG3 Yes
(pinionshaft)
W3-H11 Signal: pressure drop Oil tank -L9 box Lamp -H11 Yes
indicator
W1-H12 Signal: pressure drop Oil tank -L9 box Lamp -H12 Yes
indicator

3. Technical data
3.11.2 Instrumentation overview

The instrumentation overview shows (See Appendix, Instrument list) general
information about which instruments that are connected to the cone crusher.
Below there is a glossary for the id.no shown in the instrument list.
ID Instrument type Application
Site Tag No. SRP Tag No.
-TI1 Thermometer Return oil temperature (main)
-PI1 Pressure gauge Hydroset pressure
-PI2 Pressure gauge Oil pressure (main)
-LI1 Oil level indicator Oil level in tank
-LI2 Oil level indicator Oil level in tank (hydroset)
3.11.3 Sensor overview

Thes sensor overview shows (See Appendix Sensor list) general information
about which sensors that are/will be connected to the cone crusher.
Below there is a glossary for the id.no shown in the sensor list.
ID Sensor type Application
Site Tag No. SRP Tag No.
-TG1 Thermostat Return oil temp
-TG2 Thermostat Oil cooling
-TG3 Thermostat Oil heating
-OG1 Flow indicator Return oil flow
-PG2 Pressure guard Filter diff. pressure (mainshaft)
-PG3 Pressure guard Filter diff. pressure (pinionshaft)
-B1N Position sensor Mainshaft position
-B2N Press. transmitter Hydroset pressure
-B3N Temp. transmitter Return oil temperature
-U1N Power transducer Drive motor power draw

3. Technical data


4.1 General
Ensure that the dimensions of the installation site and the positions of
connections correspond with the information given in the drawings, see
appendix A: CH660:01 Installation drawings and any site-specific
installation drawings.
NOTE! Check that the required service areas, as shown in the drawings, comply with
the installation site. Check that the installation site is accessible for spare and
wear part delivery.
Check that the cone crusher meets the local legislation demands regarding
personnel safety, emissions or other legal aspects. In case of doubt, please
consult local authorities or local authorized personnel.
It is possible to prepare parts of the installation before the main installation
of the cone crusher is carried out especially concerning placement,
foundation and electricity.
If the site does not meet all of the specifications given in this manual, please
contact Sandvik for guidance and customizing.
4.2 Crusher capacity and performance

A cone crusher is normally a component in a crushing and screening process.
The performance of the crusher is dependent on the operation and design of
the whole process including conveyors, feeders, feed hoppers, motors, site
design and structure, etc. The following factors will also have an effect on
the capacity and performance of a cone crusher:
• Choice of crushing chamber
• Choice of eccentric throw
• Feed size distribution and particle top size
• Feed rate
• Discharge system designed to match crusher’s capacity
• Screening capacity
• Automation controls (options), both ASRi and main control system for
the crushing plant

The following factors will very likely lower the capacity and performance of
a cone crusher:
• 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
• Motor power less than recommended

4.3 Installation preparations check list

Comments to the installation preparations check list are found below the
table.
System Checks Remarks Date/sign
Placement Site access checked for cone crusher
dimensions.
Smallest area through which the cone
crusher components must pass?
(W × H) × m
Available service space? × ×
(L × W × H) m
Available lifting device on site? Type:
Length of oil hoses and pipes? m
Length of V-belts (if applicable) m
Foundation Foundation constructed according to
drawings?
Electrical system All necessary cables arranged to the
crusher?
Cable lengths? m
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 cor-
ment rectly?
Discharge Discharge arrangement is ready to be
connected to outlet of the crusher?
Guards Need for additional guards?
Platforms and Comply with local regulations?
guard rails Designed so they don’t interfere with
crusher’s function?

4.4 Placement
Sandvik recommends:
– marking with paint the limits of service areas in the vicinity of the
crusher.
– fencing in the site to avoid damage and unauthorized operation, if
applicable.
Make sure that there is easy access to the crusher. A well planned installation
will result in better overall performance of the cone crusher and lower down-
time.
All requirements for the service area must be met. Dimensions required
for this purpose are found in appendix A: CH660:01 Installation drawings.
Note the actual service area reserved for the cone crusher in the check list on
the previous page.
Make sure there is access to a lifting device meeting the requirements stated
in section 5. Transport handling.
Note the type of lifting device available for the installation in the check list
on the previous page.
Consider additional clearance for the feed arrangement (e.g. chute, feeder or
other equipment).
Consider additional clearance for the discharge arrangement - see section
4.7.6 Discharge.
Consider the placement of the motor for a cone crusher with V-belts. There
are several possible installation arrangements for a crusher with a V-belt
drive. If the optional Sandvik motor bracket is used, ensure that the motor is
correctly positioned and aligned.
Lubrication and Hydroset system
The oil tank unit must be installed in a place where it is easily accessible and
is protected against falling objects, stones and water etc. Ensure that there is
sufficient room to drain out oil. Place the tank unit as close to the crusher as
possible to give the shortest possible return pipe runs and thus reduce flow
resistance to a minimum. Connection boxes on the main tank must be
protected against direct sunlight and water (L10.2 and L9).
Consider the lengths of Hydroset hoses. The hoses and pipes must have
sufficiently large diameters, appropriate lengths and as few bends as
possible. Excessively long pipe runs and many pipe bends will have an
adverse effect on the performance of the cone crusher.

4.5 Foundation
The crusher must have a stable, adequately dimensioned foundation. A well
designed level foundation is of the utmost importance for the successful
operation of the cone crusher. This can take the form of a cast concrete
foundation or a steel supporting structure.
The design and construction of the concrete foundation or steel supporting
structure must be undertaken by qualified and experienced personnel.
NOTE! The concrete foundation or steel supporting structure must be designed and
constructed in accordance with the applicable National and local engineering
regulations and building codes, etc.
The foundation must be designed to accommodate the static and dynamic
loads generated by the crusher, with an adequate safety factor. See appendix
A: CH660:01 Installation drawings.
Anchor plates and/or foundation bolts must be sufficiently strong and must
be well anchored.
NOTE! Anchor plates and/or foundation bolts for casting into the concrete
foundation are not included in Sandvik 's supply.
The foundation must be constructed to accurate dimensions. The crusher's
mounting points must be level (max ± 1 mm deviation at load application
points).
NOTE! It is important to decide on the position of the drive motor before the
foundation is designed. For a crusher with a V-belt drive it is possible to
install the motor on either side of the crusher. This is done by changing the
positions of the mounting feet on the crusher. See section 4.6.5 Crusher
mounting feet
For general information on placement, see section 4.4 Placement. Contact
Sandvik to discuss any questions about the way in which you plan to install
the crusher.
4.5.1 Foundation loads

In appendix 4: Foundation loads you will find information on the static and
dynamic forces transmitted to the foundation via the crusher's mounting
points and on the frequency of the dynamic forces. The information on
dynamic loads applies for the crusher's maximum eccentric throw.

4.5.2 Movement of the crusher

If the crusher is mounted on rubber dampers, it will oscillate horizontally up
to ± 15 mm during normal operation. During starting and stopping the
movement is greater - up to ± 50 mm. Make sure that there is room for the
crusher's movement all around.
If the crusher is mounted on rubber dampers, the sub-frame or motor bracket,
the motor and the drive assembly will move with the crusher. Provide
sufficient space all around the sub-frame or motor bracket, the motor and the
drive assembly.
The feed hopper is bolted to the crusher's topshell and thus moves with the
crusher. Do not attach any chute or conveyor to the feed hopper, as this
would subject the crusher and the other attachment points to abnormal loads.
Hoses and cables attached to the crusher and motor will also move. Provide
adequate space for this movement and protect hoses and cables from falling
stones and dust.
For further information on foundations, see section 4.5.1 Foundation loads.
4.5.3 Using an existing concrete foundation

If you intend to utilize an existing concrete foundation that has previously
been used for another type of cone crusher, it is essential to check that it can
cope with the dimensions and loads of the CH660 crusher, with due regard
paid to the condition of the concrete and reinforcement. See the relevant
drawing in appendix A: CH660:01 Installation drawings.
• Thoroughly clean and inspect the top surface of the foundation.
• If the foundation is in good condition, make sure that the attachment
points for the crusher (support pads) are firmly anchored and are level.
NOTE! It is essential that the support pads are firmly anchored so that they can
withstand the loads generated by the CH660 crusher.
• If the existing foundation is damaged or has cracks on the top, it must be
repaired in an appropriate way.
• It is often convenient to install a large installation plate on top of the old
foundation (> 30 mm thick steel plate), but it is essential that it is
properly anchored. If the old crusher's foundation bolts are still in place
and are in good condition, it may be possible to use them to anchor the
new installation plate. Make sure that the upper ends of the old bolts are
cut off at the correct level so that they do not interfere with the new
installation.
• If you are using one of Sandvik's standard installation packages, make
sure that anchor plates are provided in the correct positions - and at the
correct levels - for the rubber dampers. See appendix A: CH660:01
Installation drawings for more details.

4.5.4 Using a steel supporting structure

If the crusher is to be placed on a steel supporting structure, the structure
must be carefully designed for the duty. Take the following points into
consideration:
• Design the steel supporting structure so that it is strong enough to
accommodate the loads to which it will be subjected. See the load
information given on the appropriate drawing in appendix A: CH660:01
• It is important that the supporting structure has no natural frequencies
close to the operating speeds (frequencies) of the crusher's eccentric and
the motor. See appendix A: CH660:01 Installation drawings for
information on these frequencies.
• If you are using one of Sandvik's standard installation arrangements,
remember that the two smaller (Type B) rubber dampers beneath the
motor are not at the same level as the four larger (Type A) rubber
dampers beneath the crusher. See the appropriate installation drawing for
details.
• Make sure that the crusher's mounting points are level (max. ± 1 mm
deviation at load application point).
Make sure that the structure is mounted horizontally and rests on a firm
foundation. If the foundation is not sufficiently stable, the supporting
structure will vibrate and thus be subjected to abnormal stresses.
4.6 Installation alternatives

The CH660 crusher can be installed in many different ways, to suit the
requirements of the individual installation:
• On a new foundation or on an existing foundation, previously used for
another cone crusher
• On a concrete foundation or on a steel supporting structure
• With a direct drive or with a V-belt drive
• On rubber dampers or directly on the foundation or supporting structure
NOTE! If the crusher is mounted directly on a foundation without the rubber
dampers, the dynamic loads transmitted to the foundation or supporting
structure will be higher.

In this Installation Manual, Sandvik provides installation drawings and

detailed descriptions of installation sequences for the two installation
alternatives, for which Sandvik can supply a standard installation package:
• Crusher with direct drive and rubber dampers - crusher and motor
mounted on common sub-frame - on a concrete foundation, with dust
sealing ring (see section 4.6.2 Direct drive installation package and
section 6.1.1 Crusher with direct drive and rubber dampers, on a
concrete foundation drawing 452.0331).
• Crusher with V-belt drive and rubber dampers - with motor on motor
bracket attached to crusher - on a concrete foundation, with dust sealing
frame (see section 4.6.3 V-belt drive installation package and section
6.1.2 Crusher with V-belt drive and rubber dampers, on a concrete
foundation and drawing 442.9864).
In appendix A: CH660:01 Installation drawings you will find information
that will be useful for the design of other installation alternatives:
• Crusher on a concrete foundation - fixed installation (see section
6.1.3 Crusher on a concrete foundation - fixed installation.
NOTE! If the crusher is fixed rigidly to the foundation, the dynamic forces
transmitted to the foundation will be higher than when rubber dampers are
used. Make sure that the foundation is designed accordingly.
NOTE! As the motor is installed directly on the foundation, there is no machined
structure (sub-frame or motor bracket) between the motor and the crusher. It
is therefore extremely important that the alignment of the motor is very
carefully checked.
• Crusher with rubber dampers on a foundation, and with motor fixed (see
section 6.1.4 Crusher with rubber dampers on a steel supporting
structure).
NOTE! If the crusher is mounted on rubber dampers it will gyrate (see section
4.5.2 Movement of the crusher). If the motor is fixed to the foundation, there
will be relative movement between the crusher and the motor. This normally
means that a V-belt drive will be used in such a case. If so, make sure that the
center line of the motor's shaft is within 15° of the vertical plane through the
center line of the crusher's pinionshaft. There is otherwise a major risk of
problems with the V-belt drive.
Sandvik recommends that the motor is mounted on a frame, similar to the
arrangement used in Sandvik's standard V-belt drive installation package.
See section section 4.6.3 V-belt drive installation package.
NOTE! As the motor is installed directly on the foundation, there is no machined
structure (sub-frame or motor bracket) between the motor and the crusher. It
is therefore important that the alignment of the motor is very carefully
checked.
Other installation arrangements are possible, to suit the individual
requirements of the plant in question. Please contact Sandvik to discuss the
way in which you intend to install your cone crusher.

4.6.1 Installation packages

The installation components supplied by Sandvik depend on what has been
ordered in each individual case. Sandvik offers two different installation
packages, one with a direct drive and one with a V-belt drive.
4.6.2 Direct drive installation package

The direct drive installation package, as shown on installation drawing
452.0331, includes:
• motor
• direct drive assembly, with guard
• sub-frame (for crusher, motor and drive)
• rubber dampers
• dust sealing ring
The crusher is bolted to a sub-frame constructed of steel sections, with the
crusher's four mounting feet. The motor is also mounted on the sub-frame.
Between the motor and the crusher there is a flexible coupling and a torque-
limiting coupling. This arrangement makes it easy to keep the motor, drive
and crusher in the correct alignment.
The sub-frame is supported by six rubber dampers, fixed on the foundation.
Between the sub-frame and the foundation there is a dust sealing ring,
consisting of a sponge rubber sealing strip positioned in a divided mounting
ring that is fixed to the foundation.
4.6.3 V-belt drive installation package

The V-belt drive package, as shown on installation drawing 442.9864
includes:
• motor
• V-belt drive assembly
• motor bracket
• rubber dampers
• dust sealing frame
The crusher is mounted on four rubber dampers fixed to the top of the dust
sealing frame, which incorporates a sponge rubber sealing strip.
The crusher has two normal mounting feet and two connector-type mounting
feet, to which the motor bracket is attached. Two additional rubber dampers
are installed beneath the motor bracket.
Mounted on the motor bracket is a motor frame that carries the motor and a
jackshaft assembly. Between the motor and the jackshaft is a flexible
coupling, with a guard. The jackshaft carries a V-belt pulley. A set of V-belts
transmits power to the crusher's drive pulley, protected by a guard. Pulleys
and V-belts have either SPC or 8V profiles.

As the motor and the jackshaft assembly are mounted on a single motor
frame, it is easy to tension the V-belts.
The entire V-belt drive assembly can be fitted to either side of the crusher
(viewed from the outer end of the pinionshaft) and the components are
delivered from the factory set up for the desired side. If it is necessary to
change from one side to the other, follow the instructions given in section
4.6.5 Crusher mounting feet.

4.6.4 Rubber dampers

To reduce the stresses in the concrete foundation or steel supporting
structure, it is advisable to install the crusher on anti-vibration compression
mountings which absorb the vibrations generated when the crusher is
running.
Risk of crushing
If the crusher is mounted on rubber dampers, there is a risk of
crushing fingers etc. when the machine is running, especially when
WARNING! starting and stopping. Make sure that there is room for the crusher's
horizontal movement. Information on this movement is given on the
installation drawing.
Two different rubber dampers are used:

Four of the larger dampers (Type A) are used beneath the crusher.
Two of the smaller dampers (Type B) are used beneath the motor, when the
crusher and motor are mounted on a common sub-frame or when the motor is
mounted on a motor bracket attached to the crusher itself.
For details of the rubber dampers, see the figures below.
To ensure that the crusher's motion is harmonic, the rubber dampers must be
adjusted vertically to the correct level(s), as shown on the appropriate
drawing.
Type A1 -Fitted to crusher mounting foot
Type A2 -Fitted to sub-frame 11, 12
1 Rubber compression mounting
10
2 Screw A1 9 A2
3 Washer 14 15
4 Lower fixing plate 2,3
9 Upper fixing plate 1
10 Spacer
11 Washer
4
12 Locking nut
14 Crusher mounting foot
15 Sub-frame
13
Type B -Fitted to sub-frame or motor B 6, 7
bracket
5 Rubber compression mounting 5
6 Screw 8
7 Washer
8 Lower fixing plate
13 Upper fixing plate
NOTE! The crusher can also be mounted directly on the foundation without the
rubber compression mountings, but dynamic loads will in this case be higher.

4.6.5 Crusher mounting feet

The crusher has four mounting feet, bolted to the bottomshell. If the crusher
is mounted on a sub-frame (as in the case of Sandvik's direct drive
installation package), on four rubber dampers (without a sub-frame or a
motor bracket) or directly on the foundation (i.e. a fixed installation), the
four mounting feet are all of the normal type.
If Sandvik's V-belt drive installation package is used, the crusher has two
“normal” mounting feet and two “connector type” mounting feet, to which
the motor bracket is bolted.
The crusher is delivered with the mounting feet already fitted, so if either of
Sandvik's installation packages is ordered, the mounting feet will be correct.
If the crusher is delivered with mounting feet for the V-belt drive installation
package, two of the mounting feet will be of the “connector type”, placed
according to the drive side specified in the order. If it is necessary to move
the V-belt drive assembly mounting feet must be switched. Unbolt all four
mounting feet. Fit the two “connector type” mounting feet on the side where
the V-belt drive assembly is to be placed, and then fit the two “normal”
mounting feet on the other side.
Tighten the attachment bolts to the correct torque.
Tightening torque
Tightening torque:
2800 Nm 2065 ft lbss

4.7 Crusher arrangement

4.7.1 Electrical installation for a cone crusher
Make sure all local requirements are fulfilled, even the ones that are site
specific.
External cables, disconnecting switches and fuses must be ordered before
installation. See section 7. Electrical installation for further information.
Contact Sandvik for further information about the cables, switches and fuses.
4.7.2 Remote control system (option)

At most sites a main control system is used to control the process. Has the
main control system been prepared for the addition of the cone crusher?
4.7.3 Process material

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

The inhalation of dust from the process material can be unhealthy with many
types of material. Dust 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.

4.7.5 Feed arrangement

The efficiency of the cone crusher is directly dependent on the design of the
feed arrangement. To achieve maximum crusher capacity, following
parameters must be met:
• The material is fed into the crusher at a sufficiently high rate
• The material is evenly distributed around the crushing chamber
• The material fed to the crusher is not segregated.
However it is important to design the infeed so the construction is removable
to facilitate easy maintenance of the cone crusher. The CH660 is normally
delivered with a feed hopper and with or without a splitter to control the
distribution of the process material into the cone crusher. The feed hopper is
divided so that the machine can be disassembled without the need to remove
the feed conveyor or feeder. 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 feed arrangement must be electronically connected and interlocked in
such away that it cannot be started before the crusher and the discharge
system are running.
Sandvik recommends that you:
• mount a level monitor in the feed hopper to stop the feed to the crusher if
the material level rises too high or if it is too low. Another method is to
use a variable speed drive to adjust the feed rate in such a way that a
constant material level is maintained in the feed hopper.
• install a screen ahead of the crusher to remove fine material before
crushing to increase the performance and capacity of the crusher.
• install a magnet conveyor 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.
The drawing below shows a crusher without a splitter. The spider arms must
be aligned with the feeder or conveyor.

The process material should be de-segregated before it is fed into the

crushing chamber. This can be accomplished in different ways, for instance
with a splitter. The drawing below shows a cone crusher with a splitter. The
spider arms are at right angles to the feeder or conveyor.
Regulate the feed so there is a build-up of process material in the feed hopper
(choke feed). The process material should be level with the top of the spider
cap. This manner of feeding will create a better result in the form of a finer
and more uniform product size. This will also make the crusher run more
smoothly and lower the power consumption.
If a splitter is not used, it is important to optimize the feed arrangement as far
as possible. This can be accomplished with a feed box above the crusher's
feed hopper, as shown below. The feed box must be designed so it can be
moved longitudinally to correctly guide the material.
Feed from a belt conveyor Feed from a chute. Feed from a feeder without
The chute can be attached a feed box. The feeder
to a belt conveyor must be adjustable

Feed arrangements for fine crushing

Fine crushing gives rise to the highest loads on the crusher. To obtain correct
feeding, always us a splitter for feed sizes up to 80 mm (3.150") This part is
not included in the normal scope of supply from Sandvik. The splitter
prevents segregation and also distributes the material evenly around the
crushing chamber.
For installation dimensions of the feed hopper, see the installation drawing.
NOTE! The topshell arms must be correctly oriented relative to the splitter.
The material must be led into the splitter through the area outlined by a red
line in the drawing. This area can normally be adjusted. The duty of the
splitter is to split up the material stream into equal parts on either side of the
topshell spider arms.
Feed arrangements with EC or C crushing chamber

To prevent damage to the crusher and unnecessary wear on the spider cap
and arm liners, the feed to the crusher must be arranged so that the material
falls onto a “stone box” before it falls into the crusher itself. This reduces the
drop height and reduces the speed of the material and is particularly
important for crushers with EC or C crushing chambers as these machines
are fed with relatively coarse material. In such cases it is advisable to keep
the level of material in the feed hopper a little lower than with fine or
medium crushing chambers due to the risk of bridging. The “stone box” also
contributes to a reduction of segregation in the feed material.

4.7.6 Discharge
Design the discharge arrangement so there is no possibility for material to
build up beneath the crusher and damage the crusher’s dust seal ring. Protect
the lubrication and Hydroset lines from falling material.
• The diameter of the cone crusher’s discharge opening is 1930 mm
• Concrete foundations or discharge arrangements below the cone crusher
must be constructed with a larger inner diameter than the diameter of the
cone crusher’s discharge opening to minimize wear.
The volume of the discharge below the cone crusher must be larger than the
volume of the process material in the crusher and the feed hopper together.
This volume is approx. 4 m3. If a discharge conveyor stops, the feed
arrangement must stop and allow the process material in the crusher to pass
out from the crusher.
Always design the discharge arrangement with an inspection door for
cleaning or inspection. It is important to design the discharge arrangement so
the construction is accessible to facilitate easy access to the cone crusher’s
Hydroset cylinder.
Consider incorporating a ledge or shelf inside the discharge compartment to
absorb the impact of the material falling onto the discharge conveyor.
If a chute is used, consider using a slope with an inclination of at least 45° to
the horizontal, to avoid the build up of process material. 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.

4.7.7 Guards
All moving and rotating parts on the machine must be covered with guards.
The belt drive and coupling or direct drive coupling should always be
equipped with guards.
Flying fragments
Occasional stones which are not properly gripped in the crushing
chamber can be thrown violently up out of the crusher and fall down in
WARNING! the vicinity of the machine.
Conveyors and feed arrangements always present a potential risk of falling

process material. Design overhead conveyors and feed arrangement so
guards protect walkways and platforms from falling process material.
4.7.8 Platforms and guard rails

All crushers need inspection and maintenance. It is important to design
suitable platforms for this purpose. The standard scope of supply for a cone
crusher from Sandvik does not include platforms and guard rails.
A well-designed platform never relies on the cone crusher for support as
vibrations and movement of the crusher make it unsuitable. The floor of the
platform should preferably be “solid” (instead of wire mesh) to avoid the risk
of falling tools or equipment accidentally falling and hitting someone down
below. Use kicking boards and wire mesh on the sides under the handrails for
the same reason.
NOTE! Never use conveyors as gangways. Always design walkways along the
conveyors with guard rails.

4.8 Operating in low temperatures

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

cold weather
The following suggestions are all based on making the lubricating oil flow
more easily and thus facilitating the movement of oil through the crusher.
The order in which they are presented does not mean that they must be
carried out in this order.
The order in which they are applied should be judged in each individual case.
It may well be best to use a combination of several of the suggested methods.
– Heating cables on oil lines
– Installation of additional oil heaters
– Diesel heating system
– A thermostatic valve to “by-pass” the oil cooler
– A 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
– 2-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 crusher fitted with “low temperature equipment” will normally be

equipped with:
– An insulated bottom in the component section of the oil tank unit
– Extra heating elements
– Modified oil monitor interlocks

4.8.2 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 temperature, the Start with 50% blanked
return oil line. Clean out 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 cover the feed opening.
to by-pass around the oil In addition, the lubrica-
cooler. Does oil flow back tion oil pump can be run
to the tank? continuously.
Install low temperature In very low temperature

equipment in the tank. the radiator core can be
(Heating in component sec- “thawed out” with a fan
tion, insulated tank bot- 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 problems

4.8.3 Insulation of the bottom of the component section

of the oil tank unit
Normally, the component section of the oil tank unit is completely open at
the bottom. This is because - under most conditions - a bottom plate is
unnecessary. In fact, it is usually desirable to provide good ventilation in this
area so that the lubrication and Hydroset oil pump motors are properly
cooled. During the winter, however, it can be desirable to keep filters and dirt
traps etc. warm to reduce pressure drop in the lubrication system. Bottom
plates are available for the oil tank units of CH/CS660 crushers:
Crusher Modification kit Tank drawing No.
CH/CSS660 442.9014-00 1.442.8946
4.8.4 Installation of 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 can be ordered under the part number given below:
Crusher Modification kit Tank drawing Voltage Rating Connection

No. (V) (W) diagram
CH/CS660 2 off 984.0605-00 1.442.8946 265/460 2x2190 3.194.0191
240/415 2x1785
220/380 2x1500
4.8.5 Diesel heating system

In plants where there is no electric power during the night - e.g. transportable
plants with diesel generators - the installation of a diesel heating system can
be a useful addition. With the help of a battery and a timer, the system goes
into operation and starts to heat oil up to three hours before the electrical
supply is available.
A diesel heating system can of course be used together with electrical
heating. Tank units for an CH/CS660 crusher are prepared for diesel heating.
The diesel heating system uses a 12 V DC supply.
Diesel heating systems can be ordered under the part numbers given below.
Crusher Modification kit Tank drawing No.
CH/ 442.9993-90 1.442.8946
CS660CS66
0

4.8.6 Heating cables on oil lines

At low temperatures, the oil in the lines between the tank unit and the crusher
can solidify and form a “plug” which interferes with the flow of oil during
starting. This problem can be minimized by insulating the oil lines and
installing heating cables. Before heating cables are installed, the slope of the
return oil line should be increased, if it is possible.
The heating cable should have a rating of 8-10 W/m and 40 mm thick
insulation should be used.
Install the heating cable on the underside of the oil line and use insulating
tape to keep the cable in place.
If the oil lines are >50 mm in diameter and when it is desired to heat the oil 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, in compliance
with the relevant regulations. Heating cable is normally supplied for 230 V. It
is usually most convenient to purchase the heating cable from a local
supplier who can also install it.
It is preferable to use a heating cable of the self-regulating type which needs
no thermostat. See appendix A: Electrical drawings.
4.8.7 Heating in the component section of the oil tank

unit
To make it easier to start a crusher it can sometimes be advisable to provide
additional heat in the component section of the oil tank unit. This heat is
intended to keep oil in filters, valves, pumps, pipes etc. easy-flowing.
Extra heat can conveniently be provided by a fan heater with a rating of
about 600 W and equipped with a thermostat which prevents overheating.
Since the manufacturers are always changing the fan heater models
available, Sandvik has not prepared any modification kits with fan heaters. It
is easiest for the crusher owner to select the heater which he finds most
suitable.
Position the fan heater so that no oil can drip onto it.

4.8.8 Synthetic oils

These oils are in all respects superior to mineral-based oils. The
characteristics of synthetic oils can in general be described as:
• Longer life, thanks to high stability which gives lower cost for oil
changes.
• Easier starting in low temperatures.
• Lower energy consumption due to lower friction.
• Wider temperature range.
• Elimination of the risk of dangerous oxidation and "coking".
It could be said that if starting difficulties are experienced with mineral-
based oil at -10ºC, for instance, the use of suitable synthetic oil will mean
that the temperature can drop about 10ºC - i.e. to about -20ºC - before similar
difficulties are experienced.
The following synthetic oils can be recommended. Other brands can also be
used but the selection of a suitable type must be discussed with the supplier.
Supplier Type Min. pour point °C Viscosity (cSt) at 40°C
Mobil oil SHC 629 - 48 142
Nynäs Mereta 150 - 42 150
The oils mentioned here can be mixed with mineral-based lubricating oils
but the crusher and oil tank should be carefully emptied so that the synthetic
oil is diluted as little as possible.
If a change is made to synthetic lubricating oil it is also advisable to change
over to a synthetic Hydroset oil. This is in order to reduce the dilution which
can occur in the lubricating oil if there is any leakage past the Hydroset
packing. In addition, a synthetic oil will give smoother operation than a
mineral oil in valves and pipes.
The oil normally used in the Hydroset system is a grade with viscosity 68 cSt
at 40°C but when synthetic oil is used, a grade with a viscosity down to 30
cSt at 40°C can be selected.

The following synthetic oils can be used in the Hydroset system:

Supplier Type Min. pour point °C Viscosity (cSt) at 40°C
Other brands can be used but the selection of a suitable type must be
discussed with the supplier. Whatever the type selected, it must be possible
to mix the lubricating and Hydroset oils used in the crusher.
4.8.9 Mineral oil for the winter season

In low ambient temperatures - below 0ºC - an ISO VG 100 oil can be used.
It is vital that the Tank Instrumentation Monitoring System (TIMS) is
programmed in accordance with the recommendations given in section
Lubricants in OM.
4.8.10 A thermostatic valve to by-pass the oil cooler

Operation of the thermostatic valve
When a crusher is started up with cold oil, the largest single cause of pressure
drop is the air/oil heat exchanger. This pressure drop can be minimized with
the help of a thermostatic valve.
The thermostatic valve is mounted on the oil cooler and operates in such way
that as long as the oil temperature is below 35ºC, the oil goes from port 1 (1)
to port 2 (2) inside the valve, and port 3 (3) is closed.
From port 2 (2), the oil flows through an external line to the cooler's outlet
manifold. It passes through the manifold (4) and flows to the crusher. When
it passes through the cooler's outlet manifold (6), the oil gives up some of its
heat energy to the cooler which is thus warmed up. This results in a lower
pressure drop across the cooler when the thermostatic valve gives free
passage from port 1 to port 3, as described below.
When the oil temperature rises above 35ºC, the thermostatic valve starts to
allow some of the oil to go to the cooler through port 3. At an oil temperature
of 45ºC the “by-pass” line (port 2) is completely closed off and all of the oil
goes through the cooler.

Thermostat and mounting kit

Crusher Cooler Mounting kit
CHCS660/CS660 Part No. Designation Part. No.
910.0103-00 995012 A0 442.9842-00
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
4.8.11 Blanking off the oil cooler radiator

This section applies to a crusher with one or two air/oil heat exchangers.
When the oil temperature rises so high that the cooling fan starts, it can
happen that the cooling is too effective. The pressure drop across the cooler
rises so high that the pressure relief valve ahead of the cooler opens. If this
happens, the oil is not cooled at all - it can be too hot even though the
ambient temperature is low.
The easiest way to avoid stoppages of this kind is to blank off the radiator so
that a smaller mass of air is passed through the radiator core. The degree of
blanking must be determined by trial-and-error in each individual case.

4.8.12 2-speed fan motor for oil cooler

Compared to the method described in Section section 4.8.11 Blanking off the
oil cooler radiator, a more sophisticated way of reducing the air flow
through the radiator is to use a 2-speed motor on the cooling fan.
The fan starts at low speed at a certain temperature. If this provides sufficient
cooling - i.e. the oil temperature does not rise further - the fan continues to
run at low speed as long as cooling is required. If, on the other hand, the oil
temperature rises further, the fan switches to high speed at a pre-set
temperature.
Examples of suitable switching points if an ISO VG 150 oil is used are given
below.
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
If a 2-speed motor is fitted, the Tank Instrumentation Monitoring System

(TIMS) must be reprogrammed. For more information, contact Sandvik.
4.8.13 Modified return oil flow switch interlock

When the crusher is to be started it can sometimes be useful to by-pass the
return oil flow switch interlock for a short period during the starting phase.
The crusher's drive motor can then be started without the return oil flow
switch interlock giving a "crusher ready for start" signal. With the crusher
in motion the oil is effectively heated by friction so that it becomes easier for
the oil to pass through the bearings and other restricted passages. This results
in higher oil flow through the crusher.
Technically this means that the lubrication oil pump is started and run for a
pre-set time, for example 20 seconds. When this time has elapsed, a new time
period is started. During this second period, the "crusher ready for start"
signal is given and the return oil flow switch interlock is by-passed. This
second period can also be around 20 seconds, for example, and during this
time the crusher's drive motor can be started. If oil reaches the return oil flow
switch before this second period has expired, the crusher will continue to
run. If oil has not reached the return oil switch within this time, the crusher's
drive motor will stop.

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, there is a risk that the crusher becomes over-filled with oil. Oil
will overflow over the dust collar inside the crusher and drop down onto the
discharge conveyor.
The components needed for this interlock by-pass can be obtained from
Sandvik. It is usually most convenient if a local electrician installs the
components although Sandvik can of course do the job if required. See
appendix A: Electrical drawings.
4.8.14 Insulation of the oil tank

In order to heat the oil to the correct temperature during the winter, it can be
advisable to insulate the tank. This means that it will be easier to start the
crusher after a cold night since the oil temperature is higher than it would be
if the tank were not insulated.
When the ambient temperature rises (i.e. when the winter gives way to
spring) it may be necessary to remove the insulation if the cooling capacity
of the system is insufficient.
Sandvik does not have standard off-the-shelf insulation kits. 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.
4.8.15 Continuous running of the lubrication oil pump

In low temperatures it may be difficult to start the crusher since oil has
solidified in the oil lines and in the crusher itself. This can be avoided or
minimized if the oil pump is allowed to run continuously during the time
when the crusher is standing still. The heaters in the oil tank must be
switched on and the crusher's feed opening must be covered over to avoid
excessive cooling by cold air passing freely through the crushing chamber. If
this is allowed to happen, the heating power installed in the tank will
probably be insufficient.

4.8.16 A heater in the Hydroset tank

In our combined lubrication and Hydroset oil tank units, the Hydroset oil has
no heating element but is instead heated indirectly by the lubricating oil.
Under extreme conditions it can be desirable to install a heating element in
the Hydroset oil tank section as well.
Crusher Modification kit Voltage (V) Rating (W) Connection diagram

CH/CS660 442.8463-00 220/380 670 3.190.3590
Since there is not much space in the component section of the oil tank, the
heating element in these modification kits has had to be positioned on the
back of the tank unit. This means that space is required behind the tank
(approx. 200 mm).
The thermostat, which is mounted in the element itself, is set at 25ºC. This is
a sufficiently high temperature for the oil to pass easily through the control
valve etc. In addition, this reduces the time the element is switched on and
reduces “coking”.



5.1 Goods data

The Cone crusher is delivered in sections. Some basic measurements (mm) /
(inch) are given in the table below to indicate the space required by the
equipment during transportation. The number of sections delivered may
vary, depending on the crusher variant and auxiliaries.
NOTE! It is possible that the delivered packages do not have the same numbering as
in the table below.
No. Part name Option Mass Measurements (mm) / (inch)
(kg) / (lb.) LxWxH
1 Cone crusher No 24 750 / 54 560 2850 × 2440 × 3350 / 112.2 × 96.1 × 131.9
2 Main lubrication tank No 800 / 1 760 1900 × 1500 ×1350 / 74.8 × 59.1 × 53.1
3 Water/oil heat exchanger Yes 235 / 518 1170 × 1170 × 920 / 46.1 × 46.1 × 36.2
4 Tool box etc. No 400 / 882 1170 × 1170 × 920 / 46.1 × 46.1 × 36.2
5 Feed hopper No 850 / 1 874 2200 × 2200 × 1100 / 86.6 × 86.6 × 43.3
6 Feed hopper cone No 350 / 772 1400 × 1250 × 650 / 55.1 × 49.2 × 25.8
7 Frame Yes 1 420/ 3 131 4770 × 2795 × 425 / 188 × 110 × 16.7
8 Motor 50/60 Hz Yes 3000 / 6614 2300× 1200 × 425 / 90.5 × 47.2 × 16.7
9 V-belt guard Yes 140 / 309 1584 × 848 × 421 / 62.4 × 33.4 × 16.6
10 ASRi Yes 60 / 133 800 × 600 × 620 / 31.5 × 23.6 × 24.4
5.1.1 Contents
A packing list is attached on 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 to a harbour or to the 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.
Use the forks here Overhead lifting point
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 comply with
the minimum values given in the following table:
NOTE! A completely assembled crusher weighs >24 000 kg (52 910 lb.).
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 Nominal load to Notes

or tackle be lifted
(kg) / (lb.)
Overhead 25 000 / 55120 26 000 kg required if gantry does not have gradual accelera-
gantry tion/deceleration ramps.
Mobile crane 25 000 / 55120 26 000 kg required if crane does not have gradual accelera-
tion/deceleration ramps.
Lifting chains, 25 000 / 55120
cables, ropes or slings
Fork lift 26 000 / 57320

5.2.1 Overhead gantry or mobile crane

Hanging load
Keep clear of suspended loads. See section 2. Safety precautions.
Check the gross weight of the components to be lifted and make sure
DANGER! that the lifting equipment is suitable.
The following instructions apply to this cone crusher.

a) Make sure that the lifting chains, hooks and other equipment are in a
good state and attended to according to instructions from the
manufacturer.
b) Make sure that the lifting chains have the correct lengths for the angle
from the vertical at which they are to be used.
c) Make sure that the lifting equipment has a sufficient SWL (Safe Working
Load) for the weight to be lifted and the method of lifting the cone
crusher.
d) Follow the applicable lifting standard for the equipment used.
e) Place the lifting equipment according to the symbols found 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 gear. Make sure that the hooks are
secure in the lifting eyes of the component. If necessary, adjust the gear
to distribute the load evenly.
h) Check that the chains/lifting gear 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 try to use hands or feet to guide the load. Keep clear of the load.

5.2.2 Fork lift

Risk of crushing!
Keep clear of suspended loads. See section 2. Safety precautions.
Check the gross weight of the components to be lifted and make sure
DANGER! that the lifting equipment is suitable.
The following instructions apply to this cone crusher.

a) Make sure that the forks are of the correct length and lifting capacity for
the crusher component on its transport platform.
b) Set the lifting forks to the correct width for lifting the load from the side.
c) Make sure that the load is firmly attached to the transport platform.
d) If the transport platform of the component is fitted with fork tubes,
manoeuvre the forks inside these to lift the component.
e) Make sure that the destination is clear and able to support the weight
before lifting.
f) Lift and move the load carefully and calmly.
g) Lower the load gently to the floor.
5.3 Unloading the goods

5.3.1 Unpacking area
The required unpacking area for the different machine variants should ideally
have the approximate dimensions given below.
Installation (mm) / (") Area required L x W x H
CH660 4800 × 18 000 × 4400 / 189 × 709 × 173
NOTE! These dimensions allow about 1 000 mm (39") of free space around and
above the cone crusher parts.
5.3.2 Inspection of goods

Please inspect the outside of the packages before starting to unload. Report
any damage to the person responsible for the installation of the crusher. If the
damage is severe and prevents the parts from being installed, submit a
damage claim to the transport company directly without delay. Document the
damage with a camera.
Note! If any damage has occurred during transport to the installation site, please
also report this immediately to Sandvik’s shipping department. The address
can be found on the packing list.

5.4 Moving and Storage

Important notes
If the cone crusher must be stored before installation, make sure that the
storage area meets the requirements given in section 5.4.2 Storage of a non-
assembled crusher.
If installation starts immediately, check whether it is possible to move the
crusher components to the installation site/unit. Unpacking and installation
can be performed together.
When moving the crusher components to the installation site/unit, deposit
them so that they can be lifted out and positioned without being turned
around.
Wait until installation can start before unpacking the crusher components.
5.4.1 Moving
Hanging load
Keep clear of hanging loads. See section 2. Safety precautions. The
cone crusher weighs approximately 23 500 kg (51 810 lbs). Make sure
WARNING! that the lifting equipment is suitable.
a) Lift the crusher components only enough to clear the floor and as
instructed above, see section 5.2 Lifting equipment.
b) Make sure that the load remains stable on the lifting equipment.
CAUTION! Move the crusher components slowly and gently.
c) Move the crusher components to the assembly destination.

d) Lower the crusher components gently to the floor. Leave enough room
for access to all sides.
e) Make sure that the crusher components are firmly supported.
f) Remove the lifting equipment.
g) Remove any screws holding the transport platform to the crusher
component.

5.4.2 Storage of a non-assembled crusher

CAUTION! Sandvik recommends storing the cone crusher indoors. Exposure to
moisture or too high or too low temperatures may damage the cone
crusher if it is stored for a longer time.
NOTE! For an assembled crusher see section 10.3 Storage of an assembled crusher.
a) Make sure that the storage area is sufficient for access.
b) Make sure that the indoor storage environment meets the conditions
given in the table below.
Characteristic Value Notes

Min - max temperatures 5-40 °C (41-104 °F)
Max relative humidity 80% Non-condensing
c) Manoeuvre the crusher component into position. If the ground/floor is

uneven, place blocks or plates under the crusher components to provide
steady support.
d) Make sure that the crusher component is stable and remove the lifting
equipment.
e) Inspect the rust prevention treatment and touch-up or repeat the
treatment if necessary.
f) Screw in the lifting eye in the top end of the mainshaft. Lift the
mainshaft assembly out of its transport frame and set it down on wooden
blocks placed beneath the lifting eye and the lower edge of the mantle.
Avoid contact with the bearing surfaces on the two ends of the
mainshaft.
g) Inspect the stored components regularly and check that the rust
prevention film is intact and that the components have not been
damaged.
h) Cover the oil tank unit with a tarpaulin if it is stored outdoors.
NOTE! Store seals and gaskets in a dark, dust-free, dry place. Keep them in their
packaging until they are required. Never tie seals with steel wire or hang
them on nails or pins during storage. Rubber components must be stored free
from any stresses in order to avoid cracking and deformation.
5.4.3 Pre-delivery rust prevention treatment

Before delivery from the factory, the crusher and oil tank unit are treated
with rust preventatives sufficient for approx. 30 days of transport and
storage. The internal bearing surfaces of the crusher are covered with oil and
then sealed off from the outside environment. In special cases, additional rust
prevention treatment can be specified in the order.
The same procedure is followed for the tank unit.

5.5 Unpacking the goods

a) Remove all loose boxes and packages.
If using an overhead gantry or mobile crane, see section 5.2.1 Overhead
gantry or mobile crane.
If using a fork lift, see section 5.2.2 Fork lift.
CAUTION! If the crusher components are not supported evenly, they may be sub-
jected to damaging torsional forces.
b) Use the packing list to check that nothing is missing from the crusher
delivery.
c) Inspect the crusher components for damage.
d) Inspect the crusher’s accessories for damage.
e) Open the boxes containing smaller components and inspect these for
damage.
f) Open the tool box and locate the packing list for the contents.
g) Check the contents of the tool box.
h) Check that the data on the identification plate corresponds with the data
given in the packing list. See section 1.1 Equipment information.
i) Take additional spare and wear parts to the spare part store.
j) If needed, send a transport damage report to Sandvik.
NOTE! If possible, document any damage with a camera.
5.6 Disposal/return of packaging material

NOTE! Packaging (including crates, wrapping, boxes etc.) is normally not returned
to the manufacturer.
a) Check if there is a special agreement for the return of the packaging to

the manufacturer.
b) If the packaging must be returned to the manufacturer, prepare an area to
store pallets, transport frames and any other returnable packaging.
c) Check if there is a special arrangement for recycling packaging material.
d) If packaging is not to be returned or recycled, check with the local
authorities how to separate and dispose of packaging material.
e) Dispose of pollutant waste (like bubble wrapping, plastic bags, expanded
polystyrene, etc.) in accordance with local regulations.

6. Mechanical installation
and connections

6.1 General requirements

Contact Sandvik to discuss any questions you may have regarding your
installation plan for the conecrusher.
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: CH660:01 Installation drawings. If any
adjacent machines on the site cannot be stopped, take measures to
prevent accidental contact.
c) Make sure that lighting is adequate and arrange 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 5.2 Lifting
equipment.
Packing
Leave wrapping and ties on the parts until they are ready for use.
Leave the plastic plugs in the oil line openings until they are ready to be
connected, but do not forget to remove them before connecting the pipes.
Installation sequence
The sequence that should be followed when the crusher is to be installed is
determined by the relevant installation alternative.
In this Installation Manual, detailed Assembly sequence instructions are
given for the two installation alternatives that are described above, i.e. with
Sandvik's standard direct drive installation package or standard V-belt drive
installation package.

6.1.1 Crusher with direct drive and rubber dampers, on a

concrete foundation
See installation drawings in appendix
A: CH660:01 Installation drawings
452.0331 for direct drive
Preparatory checks
Check that the foundation matches the dimensions given on the installation
drawing.
Make sure that anchor plates are provided in the correct positions - and at the
correct levels - for the four larger (Type A) rubber dampers beneath the sub-
frame (below the crusher) and the two smaller rubber dampers (Type B)
beneath the motor end of the sub-frame. See the installation drawing for
more details.
NOTE! The max. deviation is ± 1 mm at each load application point. If the deviation
is >1 mm, use shims to level.
a) Carefully clean any dust and oil from the area where the crusher is to be
installed.
b) Place the six rubber dampers (Four Type A plus two Type B) on the
foundation. See section 4.6.4 Rubber dampers. Make sure that the upper
and lower fixing plates (4, 8, 9, 13) are attached.
c) Turn the rubber dampers to the positions shown on the installation
drawing.
d) Spot weld the six lower fixing plates (4, 8) to the anchor plates on the
foundation.
e) Lower the sub-frame into position on the rubber dampers.
f) Spot weld the six upper fixing plates (9, 13) to the sub-frame.
g) Remove the screws and washers (2, 3, 6, 7) and then lift the sub-frame
away from the foundation.
h) Remove the six rubber dampers (1, 5).
i) Turn the sub-frame over and weld all around the six upper fixing plates
(9, 13).

j) Install the foam rubber dust seal ring (16, 17) between the sub-frame
(15) and the foundation (18). See drawing.
15 Sub-frame 15
16 Foam rubber strip
16
17 Dust seal ring segments
18 Foundation
17
18
k) Weld all around the six lower fixing plates (4,8) to the anchor plates in
the foundation.
l) Put the six rubber dampers back into position on top of the lower fixing
plates (4,8) and fit the lower screws (2,6) and washers (3,7).
m) Reinstall the sub-frame and fit the upper screws (2,6) and washers (3,7).
n) Lower the bottomshell onto the sub-frame.
NOTE! Make sure that the pinionshaft is pointing in the correct direction.
o) Tighten the screws at the connection points between the bottomshell and
the sub-frame.
Tightening torque:
For information about the installation of the motor and direct drive, see
section section 6.2 Motor and direct drive (alt. 1).

6.1.2 Crusher with V-belt drive and rubber dampers, on a

concrete foundation
See installation drawings in appendix
A: CH660:01 Installation drawings
442.9864 for V-belt drive
Preparatory checks
Check that the foundation matches the dimensions given on the installation
drawing.
Make sure that anchor plates are provided in the correct positions - and at the
correct levels - for the four larger (Type A) rubber dampers beneath the sub-
frame (below the crusher) and the two smaller rubber dampers (Type B)
beneath the motor end of the sub-frame. See the installation drawing for
more details.
NOTE! The max. deviation is ± 1 mm deviation at each load application point. If the
deviation is < 1 mm, use shims to level.
a) Carefully clean any dust and oil from the area where the crusher is to be
installed.
b) Place the six rubber dampers (Four Type A plus two Type B) on the
foundation. See section 4.6.4 Rubber dampers. Make sure that the upper
and lower fixing plates (4, 8, 9, 13) are attached.
c) Turn the rubber dampers to the positions shown on the installation
drawing.
d) Spot weld the six lower fixing plates (4, 8) to the anchor plates on the
foundation.
e) Lower the sub-frame into position on the rubber dampers.
f) Spot weld the six upper fixing plates (9, 13) to the sub-frame.
g) Remove the screws and washers (2, 3, 6, 7) and then lift the sub-frame
away from the foundation.
h) Remove the six rubber dampers (1, 5).
i) Turn the sub-frame over and weld all around the six upper fixing plates
(9, 13).

j) Install the foam rubber dust seal ring (16, 17) between the sub-frame
(15) and the foundation (18). See drawing.
15 Sub-frame 15
16 Foam rubber strip
16
17 Dust seal ring segments
18 Foundation
17
18
k) Weld all around the six lower fixing plates (4,8) to the anchor plates in
the foundation.
l) Put the six rubber dampers back into position on top of the lower fixing
plates (4,8) and fit the lower screws (2,6) and washers (3,7).
m) Reinstall the sub-frame and fit the upper screws (2,6) and washers (3,7).
n) Lower the bottomshell onto the sub-frame.
NOTE! Make sure that the pinionshaft is pointing in the correct direction.
o) Tighten the screws at the connection points between the bottomshell and
the sub-frame.
Tightening torque:
For information about the installation of the motor and V-belt drive, see
section 6.5 Motor and V-belt drive (alt. 2).

6.1.3 Crusher on a concrete foundation - fixed

installation
See installation drawing 442.9864 and 442. 9865 in section Appendix
The installation sequence for a crusher that is to be fixed on a concrete
foundation steel supporting structure must be tailored to suit the design of the
installation in question. You should therefore draw up a new installation
sequence, using the directions given in the relevant parts of this installation
manual.
6.1.4 Crusher with rubber dampers on a steel supporting

structure
See installation drawing 442.9864 and 442. 9865 in section Appendix
Assuming that rubber dampers are used, the installation of a crusher on a
steel supporting structure follows - in principle - the sequence described for
installation on a concrete foundation, although it must be tailored to the
design of the structure in question. You should therefore draw up a new
installation sequence, using the directions given in the relevant parts of the
instructions above for the installation of a crusher on a new concrete
foundation.
See section 6.1.1 Crusher with direct drive and rubber dampers, on a
concrete foundation or section 6.1.2 Crusher with V-belt drive and rubber
dampers, on a concrete foundation.

6.2 Motor and direct drive (alt. 1)

6.2.1 Installing direct drive motor
a) Position the hook(s) of a crane vertically above the electric motor (5) and
connect the hook(s) to the lifting eyes on the motor (5).
b) Take up the slack in the lifting tackle.
Hanging load
An electric motor weighs up to 4 000 kg. Handle the motor with care.
The tackle should now be tight but not lifting the motor.
DANGER! Keep clear of hanging loads, see section 2. Safety precautions.
c) Lift the electric motor (5) onto the sub-frame (6).

d) Position the motor on the motor frame on the sub-frame (6).
e) Remove the lifting equipment.
f) Fasten the screws that attach the electric motor (5) to the motor frame.
g) Install the electric cables in the electric motor’s (5) connection box.
h) Install the Safeset coupling (3). See section 6.3 Safeset coupling -
description for further information.
i) Install the guard (4) over the Safeset coupling (3).
6 5 4 3 2
1 Cone crusher
2 Pinionshaft 1
3 Omega coupling
4 Guard
5 Motor
6 Sub-frame

6.3 Safeset coupling - description

The Safeset coupling consists in principle of an outer member and an inner
mounting sleeve, see figure in section 6.3.4 Installation of Safeset coupling.
The outer member is connected to the drive motor via an intermediate spacer
and a flexible coupling (see figure in section 6.4.1 Mounting the inner
member of the flexible coupling on the motor shaft), whilst the inner
mounting sleeve is fitted on the end of the crusher's pinionshaft. The outer
member incorporates an annular cavity, close to the bore. Under normal
conditions, oil under high pressure clamps the outer member on the inner
mounting sleeve so that the two parts act as a solid coupling. The clamping
force is dependent on the oil pressure inside the cavity.
If the coupling is subjected to a higher torque then the clamping force can
withstand, the outer member rotates relative to the inner mounting sleeve.
This relative motion cuts the ends off two shear tubes and releases the oil
pressure. The clamping force disappears and the outer member can then
rotate freely on the inner mounting sleeve, so that the coupling no longer
transmits torque - the crusher is isolated from the drive motor.
To ensure reliable operation, two anti-friction bearings are incorporated.
These bearings are lubricated by the same type of special oil as is used to
pressurize the annular cavity, but the lubrication oil is separate from the
pressurization oil. There are two plugs (in the outer member) for each
bearing. One is used as a filler plug and the other as a level plug. There is
also a port for the pressurizing oil, adjacent to one of the shear tubes.
6.3.1 Important information

As described above, the Safeset torque-limiting coupling incorporates a
hydraulic torque setting system. By adjusting the hydraulic pressure the
release torque can be set to the required level.
When the pre-set torque is exceeded, the Safeset coupling slips and the tops
of the shear tubes are sheared off by the shear ring, releasing the oil pressure
in the coupling and allowing it to run freely on the shaft.
Due to its design, the Safeset coupling has a limited ability to take up other
types of loads, such as bending torque and radial loads. For this reason, the
Safeset coupling cannot take up alignment faults. The Safeset coupling used
with the CH660 crusher is installed together with a flexible coupling, which
can take up these faults. See section 6.4 Assembly procedure for flexible
coupling.
The combination must not lead to reaction forces such as loads or bending
torque on the Safeset coupling.

Transport locking
CAUTION!
The Safeset coupling is pressurised before delivery to prevent the coupling
Coupling is pressurised to
20 – 35 MPa for transport from rotating during transport. A warning label is located close to the shear
only!
tube.
6.3.2 Safety regulations

Protective glasses must be worn during the pressurization and whenever
handling a Safeset coupling which is under pressure.
CAUTION! Never pressurize the Safeset coupling before installation.
CAUTION! When setting or releasing the pressure, release the shear tube or tight-
en the valve before removing the pump.
CAUTION! When the Safeset coupling releases, oil and parts of the shear tubes are
thrown out of the coupling at very high speed.
CAUTION! A guard is provided for the drive assembly. The crusher must not be run
without the guard in place.
6.3.3 Lowering the pressure

See figure in section 6.3.5 Checking the lubrication oil level and refilling.
a) Remove the plastic plug from the filling connection (5), using the M8
screw provided.
b) Connect the pump to the filling connection (5). Check that there is
enough room in the pump to evacuate the oil.
c) Open the unloading valve on the pump (see figure in section
6.3.7 Safeset coupling pump 100B).
d) Unscrew the shear tube (next to the filling connection) ½ turn to release
pressure.
e) Remove the shear tubes when the pressure has dropped to 0 MPa.
f) Disconnect the pump.

6.3.4 Installation of Safeset coupling

a) Install the spacer (1) on the pinionshaft.
b) Fit the key (7).
c) Check that the shear ring (6) is secured by the screws (11) to the Safeset
coupling. Tightening torque 17 Nm (12.54 ft lbs)
NOTE! Secure the screws(11) with Loctite 270.
d) Heat the complete Safeset coupling to 60-80°C (140-176°F) in an oven
or in oil.
e) Coat the inner mounting sleeve (12) and the free end of the crusher's
pinionshaft with thin oil.
f) Install the complete Safeset coupling, which has a close running fit.
g) If necessary, use the end washer (8) together with an M20 threaded rod,
to push the coupling on to the shaft.
h) If the end washer (8) is removed, place the O-ring (13) in position on the
end washer.
i) Check that there is a gap of min 0.5 mm (0.01969 in) between the end
washer (8) and the shaft end.
j) Install the end washer (8). Use Loctite 242 to secure the end washer
screws (9) and tighten to the correct torque, 40 Nm (29.5 ft lbs). Install
the end washer centre screw (10).
k) Check the level of oil in the Safeset coupling and if necessary, fill the
Safeset coupling with oil. See section 6.3.5 Checking the lubrication oil
level and refilling.
4 3 2
5
1
4
13
1 Spacer
2 Safeset outer member 9
7 5
3 Shear tubes (2 pcs) 11 8
4 Seal ring
5 Bearings 10
6 Shear ring
7 Key 11 12
8 End washer
5
9 End washer screws 9
10 End washer centre screw
11 Shear ring screws 4
12 Inner mounting sleeve
13 O-ring 14
14 Pressure setting cavity
6 3
0,5 mm

6.3.5 Checking the lubrication oil level and refilling

Oil for lubrication of bearings and for pressure setting cavity
The special oil, which is delivered with the coupling, must always be used
both for the bearings and in the pressure setting cavity. (Safeset oil 9-0024).
High oil pressure

The coupling must be depressurised during the following operation!
See section and also section 2.3.5 Hydraulic systems.
WARNING!
Lubricant filling procedure
a) Rotate the coupling so that two lubrication ports are in an upper vertical
position.
NOTE! The lubrication and level ports are identical. Use whichever two are most
conveniently placed for filling and use the other two as level plugs.
b) Unscrew the plugs from the two lubrication ports (6) and the two level
ports (2).
c) Use the lubrication injector (1) to add Safeset oil until a clear flow of oil
emerges from the level ports.
d) Reinstall the lubrication and level plugs.
1 Lubrication injector
2 Level ports
1
3 Lubrication oil 6
4 Shear tube
5 Filling connection for
pressure setting cavity 2
6 Lubrication ports
6
7 Pressure setting 7
cavity
3
7 4
5

6.3.6 Pressure setting

Setting the torque
A Calibration diagram is enclosed with every coupling. The coupling has a
number close to the filling connection and the diagram is marked with the
same number. The diagram shows the pressure required for a given torque
setting.
CAUTION! If you intend to change the torque setting of your Safeset coupling,
contact Sandvik first.
The release torque setting is ~22 000 Nm (16 230 ft lbs), corresponding to 53
MPa (7 687 p.s.i.). To set the release torque, follow this procedure (see figure
in section 6.3.5 Checking the lubrication oil level and refilling):
• If the coupling is pressurized, release the pressure. See section
6.3.3 Lowering the pressure.
• If the coupling has released, remove the damaged shear tubes, if
applicable.
a) Screw in the new shear tubes until they bottom in their holes. The tip of
the shear tube is then formed to fit the valve seat at the bottom of the
hole. Tighten the shear tubes carefully - tightening torque 30-35 Nm (22-
25.8 ft lbs). This makes the pressure cavity absolutely leak proof.
b) Unscrew the shear tube (4) beside the filling connection (5) ½ turn. See
picture in section 6.3.7 Safeset coupling pump 100B.
c) Pull out the protection plug from the filling connection for the pressure
setting cavity using the M8 screw provided. Press the injection fitting on
the pump into the filling connection on the coupling.
d) Pump oil into the coupling until the pressure gauge shows the correct
pressure 53 MPa (7 687 p.s.i.).
e) Carefully tighten the shear tube beside the filling connection, tightening
torque 30 - 35 Nm (22 - 25.8 ft lbs).
CAUTION! Lower the pressure before removing the pump
f) Open the unloading valve on the pump (6). See picture in section
6.3.7 Safeset coupling pump 100B.
g) Reinstall the protection plug in the filling connection hole.

6.3.7 Safeset coupling pump 100B

Vent the pump before use
a) Tighten the unloading valve (6).
b) Turn the pump to a vertical position so that the injection fitting is
pointing upwards.
c) Pump with the pump handle, until a steady flow of oil comes out, free
from bubbles. The pump is now ready for use.
When the pump is empty
a) Pull the chain with the ring until the filling plug (3) comes out of the
handle.
b) Unscrew the plug and fill with Safeset oil. Vent the pump before use.
c) The pressure control valve (4) is positioned on the pump body (5).
d) The pressure control valve must be set at about 5 MPa (725 p.s.i.) higher
than the required pressure for the Safeset coupling. This is to prevent the
pressure in the Safeset coupling exceeding the maximum level.
e) To test the pump and to set the pressure control valve, use the protective
cap (7) as a plug.
f) Push the protective cap onto the injection fitting (1) and start pumping
until the pressure control valve opens. The reading should now be 85
MPa (12 330 p.s.i.) on the pressure gauge (2).
1 Injection fitting
2 Pressure gauge
3 Filling plug
4 Pressure control valve
5 Pump body
6 Unloading valve
7 Protective cap 7 1 2 6 4 5 3
Set the pressure control valve
The setting of the pressure control valve is adjusted by changing the
thickness of the shim washer package beneath the screw (4). A total of 11
shim washers - with a total thickness of 5 mm - are delivered with the pump.
(3 off t=1 mm, 3 off t=0.5 mm and 5 off t=0.1 mm).
The pump is preset to approx. 85 MPa (12 330 p.s.i.) before delivery from
the manufacturer.
The shim washers not fitted on the pump are supplied loose in the tool box
supplied with the pump.
Reducing the number of shim washers under the pressure control valve
screw increases the pressure which can be pumped into the coupling.
A shim washer package thickness of 5 mm = P ≈ 30 MPa (4 350 p.s.i.)

6.4 Assembly procedure for flexible coupling

Exploded view of basic coupling components.
1 Outer member
2 Inner member
3 Rubber blocks
4 Cover
1 2
3
4
NOTE! The flexible coupling used for the H/S6800 has 16 rubber blocks and the
inner and outer members have 8 blades each.
6.4.1 Mounting the inner member of the flexible coupling

on the motor shaft
a) Completely disassemble the flexible coupling.
NOTE! If the motor and drive are delivered by Sandvik, the inner member will have
been bored to the correct diameter.
b) Place the cover over the motor shaft before fitting the inner member of
the coupling on the shaft.
c) Fit the key.
d) Heat the inner member to 120°C/248°F in either an oil bath or an oven.
(This applies for the recommended H7/m6 hub/shaft fit).
Hanging load
Handle the hot components with care. Make sure that the lifting chains
hold the inner member securely.
WARNING!
e) Lift the inner member from the heating device using steel lifting chains
wrapped around the blades of the inner member.
f) Fit the inner member on the motor shaft.
g) The end face of the inner member must be flush with the end of the
motor shaft.

h) Allow the inner member to cool.

Safeset coupling Intermediate Flexible coupling
spacer
B
H
B B
B
Crusher Motor
Shaft
B
6.4.2 Assembling the flexible coupling

Place the outer member of the coupling over the inner member.
Attach the cover to the outer member. (See section 6.4.4 Bolting up flanges
for the correct torque).
Set the axial position of the outer member relative to the inner member so
that it projects the correct distance from the end of the motor shaft. See “C”-
dimension (shaft end gap) in section 6.4.4 Bolting up flanges for table and
figure.
The outer member should be centred relative to the inner member blades.

6.4.3 Fitting rubber elements

The PM 18 coupling has only one rubber block in each cavity.
Fit the rubber blocks in the sequence shown in the figure below.
Use silicone fluid as a lubricant to make the installation of the rubber

elements easier. Use a fluid which has a viscosity between 1000 and 3000 cSt
(such as Dow Corning 200 Fluid).
Brush each rubber block and the cavities of the coupling with the fluid before
inserting the rubber elements.
After fitting the blocks and before attaching the intermediate spacer to the
flexible coupling, it is essential that the blade tip clearance between inner and
outer members is checked to ensure that it is consistent all around the
coupling.

6.4.4 Bolting up flanges

Attach the intermediate spacer to the Safeset coupling and the flexible
coupling with the bolts supplied.
1 Cover screw
4 2
2 Flange bolts
3 Flange bolt 3 6 1
4 Shim plate
5 Cover plate
6 Intermediate spacer 5
C Shaft end gap
C
Don't forget to fit the shim plate (4) between the Safeset coupling and the
intermediate spacer.
NOTE! It will be easier to fit the bolts if their shanks are coated with an anti-seize
lubricant.
The spanner sizes are shown below. Tighten the bolts to the torque values
shown in the table below, using light oil or preservative type lubricant only.
Coupling size PM 18
Torque Screw Spanner size
Nm / (ft lbs) mm / (")
Cover Screw 1 220 / (162) M16 24 / (0.944)
Flange Bolt 2 & 3 220 / (162) M16 24 / (0.944)
Shaft end gap C 4 / (0.1575) mm / (")

6.4.5 Shaft alignment

The components should be aligned as accurately as possible, which will help
to prolong the life of the coupling. Misalignment should not exceed the
figures shown in the table.
Coupling size Max. radial Max.angular Max. axial misalignment
misalignment mm / (") misalignment mm / (") ± mm / (")
PM18 0.40 / (0.0157) 0.36 / (0.0141) 0.5/ (0.0196)
Before checking shaft alignment, the pressure in the Safeset-coupling must

be released so that the couplings can be rotated freely relative to the crusher's
pinionshaft (see section 6.3.3 Lowering the pressure).
Axial alignment
Use a rule or feeler gauge to check that the faces (A) and (B) are in line. The
shaft end gap “C” must then correspond to the figure in section 6.4.4 Bolting
up flanges.
Radial alignment
Mount a dial gauge on the shaft at (D), with the pointer at (E), as shown in
the figure below.
The difference between maximum and minimum readings on the dial gauge
for one complete turn of the drive should be less than twice the value shown
in the table above.
Angular alignment
Mount the dial gauge on the motor shaft at (D) with the pointer at (F), as
shown in the figure below.
The difference between maximum and minimum readings on the dial gauge
for one complete turn of the drive should be less than the value shown in the
table above.
For alignment with a laser device, see the instructions for the laser device.
E F
B
A
C D

6.4.6 Storage of flex elements

As with any elastomer or rubber material, the coupling's flex elements are
subject to aging effects. These effects can be minimised by careful selection
of storage conditions e.g.:
Temperature
The storage temperature should be less than 25°C / 77°F. For long-term
storage, a 15°C / 59°F maximum is recommended.
Humidity
Moist conditions should be avoided and no condensation should occur.
Light
All polymeric products should be protected against light, especially sunlight
or artificial light with ultraviolet content.
Oxygen and ozone
Where possible components should be protected from air circulation by
storage containers. Ozone is particularly damaging and for this reason, parts
should not be stored near electrical equipment where sparking is possible.
Deformation
Mouldings should be stored in a strain-free position.
Liquids
Mouldings should not be contaminated with liquids during storage.
Cleaning
If cleaning is required during storage, soap and water is relatively harmless.
The washed components should be allowed to dry at room temperature.
Storage time
When items have been stored for five years or more, a laboratory check on
quality must be carried out before use.

6.4.7 Speed monitor for direct drive

Fit a speed monitor to avoid the problems caused when the polyurethane flex
elements break up. It should be connected in such a way that the feed to the
crusher is stopped if the pinionshaft speed drops by 5%.
5 mm / 0.1969"
-SM1
6.4.8 Drive guard

When all adjustments are finished, install the guard.
CAUTION! Do not start the motor/crusher before the drive guard has been correct-
ly installed.

6.5 Motor and V-belt drive (alt. 2)

6.5.1 Installing V-belt drive motor
a) Position the hook(s) of a crane vertically above the electric motor (4) and
connect the hook(s) to the lifting eyes on the motor (4).
b) Take up the slack in the lifting tackle.
Hanging load
An electric motor weighs up to 4 000 kg. Handle the motor with care.
The tackle should now be tight but not lifting the motor.
c) Lower the motor (4) on to the motor frame (2).

d) Mount the washers and the nuts on the T-bolts. Do not tighten.
e) Align the motor (4) and crusher (5) as described in section
6.5.2 Installing V-belts.
5
2 9
9 3
1 4
1 V-belt guard
2
2 Motor frame
3 Inspection door
4 Motor
5 Cone crusher
2
9 Sub-frame
V-belt drive, right-hand layout. The entire drive

assembly can also be mounted on the left.

6.5.2 Installing V-belts

a) Push the motor with the V-belt pulley (6) towards the pulley of the
crusher (5) on the motor frame (2).
b) Install the 12 V-belts (7) on the pulleys (6).
c) Push the motor away from the crusher to tension the belts (7).
d) Check the tension of the V-belts (7) and align the crusher pulley and the
motor pulley (tolerance) with the screws. See OM for further
information.
2 Motor bracket 5
5 Crusher 7 6 8
6 Pulley
7 V-belt
8 Spacer 2
6.5.3 Speed monitor for V-belt drive

Fit a speed monitor, to avoid the problems caused by slipping or broken V-
belts. It should be connected in such a way that the feed to the crusher is
stopped if the pinionshaft speed drops by 5%.
7mm / 0.275"
-SM1

6.5.4 Coupling and V-belt guards

When all adjustments are finished install the guards.
a) Install the guard sections (10) over the V-belt drive.
CAUTION! Do not start the motor/crusher before the V-belt guards have been cor-
rectly installed.
10 V-belt guard 10
10
V-belt drive, right-hand layout. The entire drive assembly can

also be mounted on the left.

6.6 Crusher assembly

6.6.1 Install feed hopper
Install the feed hopper according to this figure. The process material (arrow)
must enter aligned with the spider arm.
a) Position the hooks of a crane vertically above the feed hopper.

b) Put lifting hooks to the lifting eyes (1). Connect the lifting hook to the
lifting gear.
c) Take up the slack in the lifting tackle.
Hanging load
A feed hopper weighs up to 850 kg. Handle the feed hopper with care.
The tackle should now be tight but not lifting the topshell.
d) Carefully lift the feed hopper (7001-0) onto the rim of the topshell.
e) Install the screws, washers and lock nuts (7004-0, -2, -3) to attach it to
the topshell.
7001-0
7004-0, -2, -3
1 Lifting eye
7001-0 Feed hopper
7004-0 Screw
7004-2 Washers
7004-3 Lock nut

6.7 Hoses and pipes - General

NOTE! Piping and hoses are not included in Sandvik's supply.
See drawings in appendix A: CH660:01 Installation drawings.

Route all pipes and/or hoses to and from the crusher along the same path.
The inclination of return lines is critical. See section 6.8.1 Oil tank unit. and
section 6.8.2 Water/oil heat exchanger (alternative).
There is a description of hoses and pipes in appendix A: Mechanical
drawings.
NOTE! When starting the crusher the first time, make sure there are no leakages. If
there are leakages use a suitable compound to seal.
6.8 Hydroset and lubrication systems

Lubrication oil is supplied to the crusher through two lines - one to the
Hydroset cylinder and the other to the pinionshaft housing. The lubrication
oil drains back to the oil tank unit through two return lines, one from the
bottomshell and one from the pinionshaft housing. There are three Hydroset
lines, connected to the bottom of the Hydroset cylinder.
For more information on placement of the Hydraulic system, please read
section 4.4 Placement.

6.8.1 Oil tank unit

Hanging load
Keep clear of hanging loads. See section 2. Safety precautions.
The oil tank unit weighs approximately 520 kg (1150 lb.).
WARNING! Make sure that the SWL (Safe Work Load) of the lifting equipment is
sufficient for the load.
a) Install the main oil tank unit in a suitable location.

See also section 4.4 Placement
NOTE! The main oil tank 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 oil tank unit.

NOTE! Connections are already fitted to the crusher. However, other hoses, pipes
and pipe fittings are not included in Sandvik's supply.
– 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.
1 Lifting lugs
1

6.8.2 Water/oil heat exchanger (alternative)

Minimum water flow 60 l/min (15.85 gal/min)
Maximum water temperature 30°C (86°F)
See the drawing in appendix A: CH660:01 Installation drawings.
1 Water in
2 Water out 2
NOTE! Water hoses, pipes, water pump and pipe fittings are not supplied by
Sandvik.
a) 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!
b) Set the thermostatic valve (TG2) to correct value according to the table
in OM section 8.2.10 Thermostats.
TG2

6.8.3 Air/oil heat exchanger (alternative)

See the drawing in appendix A: CH660:01 Installation drawings.
CAUTION! If the crusher is installed at high altitude and/or extremely high or low
ambient air temperature, 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 tank unit or in a
suitable place close to it. Piping and hoses can be used to connect to the 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
1
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 hose to the heat exchanger.
c) Connect piping or hose to the tank unit.

6.9 Over-pressure system

Minimum and maximum length of hoses 2-15 m
Minimum and maximum pressure 600-1000 Pa
The cone crusher and the main oil tank 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 hoses. Two hoses are needed:
One from the blower and one from the oil tank. They are joined to a T-pipe.
The lengths of the individual hoses depend on the position of the blower,
tank and T-pipe.
NOTE! As an alternative to the blower installation, a connection can be made to a
compressed air system, using a regulator and a filter. When using a
compressed air system, read “regulator” instead of “blower” in the following
instruction. If possible, the regulator and filter should be installed in a heated
space.
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 dust free environment. Dust will
damage the blower and result in malfunction of the cone crusher.
a) Install the blower (3) in a dust-free environment. The blower (3) can be
mounted either horizontal or vertical (but the regulator (4) assembly
must be installed horizontal). When connecting up 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 at least 0.5 m above the pinionshaft. This will ensure that
oil cannot run back to the blower.
b) Measure the hose lengths required and cut the appropriate lengths from
the hose coil supplied with the crusher.
c) Connect one hose between the T-pipe and the hose coupling (1) on the
blower. Use hose clips (2).
d) Connect a hose second hose between the T-pipe and the hose coupling
(1) on the main oil tank. Use hose clips (2).
e) Install the over-pressure air connection on the bottomshell.
f) Connect the hose between the hose coupling (1) and the T-pipe. Use hose
clips (2).

g) Set the pressure valve on the blower (5) between 600-1000 Pa.
5 4 3
1 Hose coupling
2 Hose clips
3 Blower
4 Regulator
5 T-pipe
2 1
6.10 Guards, platforms and covers

6.10.1 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 4.7.7 Guards for further information.
6.10.2 Platforms
Sandvik recommends installing platforms so they are located at least 50 mm
away from the crusher to avoid contact. Allowance must be made for
this.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. During normal operation the crusher will oscillate
horizontally up to ±15 mm. During starting and stopping the movement is
greater - up to ±50 mm.
See section 4.7.8 Platforms and guard rails for further information.
6.11 Lubricants
Fill the required amounts of oil into the tanks. See OM for further
information.


This section describes how to carry out the electrical installation of the cone
crusher. Full electrical drawings are found in appendix A: CH660:01
Installation drawings.

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 those aspects of the operation of the cone crusher that
are not controlled by ASRi (option). See the ASRi documentation for further
information on the ASRi installation.
Full electrical drawings are collected in appendix A: CH660:01 Installation
drawings.
7.3 Motors and heating elements

Starting equipment for the drive motor, auxiliary motors and heating
elements are normally not a part of the of supply from 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 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 main
lubrication pump, (M2) is in operation.

7.3.2 M2 - Main 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 heat exchanger in the lubrication system.
Sometimes, a water/oil heat exchanger is used, sometimes it is preferable to
use an air/oil heat exchanger. If the main oil tank is supplied with one or two
air/oil heat exchanger(s), the power supply to each motor must incorporate
the necessary fuse, relay and motor protection built into an appropriate
switchgear cabinet.
The temperature is controlled by a thermostatic valve (TG5) See OM, Heat
exchanger for further information.
7.3.4 M6 - Hydroset pump

Starting and control equipment is included in the supply and is normally
delivered by Sandvik. The delivered electrical cabinet L3 contains fuses,
relays and motor protection for operation of the Hydroset pump.
Electrical cabinet L3 must be supplied with 3-phase current.
7.3.5 E7 - Oil heaters

The power supply to the heaters must incorporate the necessary fuse, relay
and motor protection built into 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 appropriate switchgear
cabinet. M9 - Pinionshaft pump
The power supply to the motor must incorporate the necessary fuse, relay
and motor protection, all installed 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 support struc-
ture
3 The discharge system is sufficient and connected/positioned
4 The feed arrangement is connected/positioned
5 The drive arrangement have been correctly installed.
6 All transport and packing materials have been removed from
parts
8.1.1 Lubrication system and Hydroset checks

No. Checks Done
1 Brand name and type of oil and grease are recorded
2 Main oil tank is placed in relation to cone crusher according to
instruction and installed properly.
4 The Hydroset and lubrication systems are correctly installed
5 Hydroset tank is placed in relation to cone crusher according to
instruction and installed properly.
6 Heat exchanger/s is/are installed properly.
7 Piping and hosing has been installed according to recommenda-
tion in 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 Make sure that the rotation directions of the motors are correct
3 Check the PG2 sensor (see below)
4 ASRi is installed properly (option)

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
2 Pressure drop sensor (PG2) 1
3 Oil filter assembly
2
3
8.3 Safety checks
No. Checks Done

1 Make sure that all accessible moving parts are correctly protected
by guards
2 Make sure that any Emergency stop buttons engage and
release correctly.
3 Check that all threaded fasteners have been tightened to the cor-
rect torque values.
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 functioning of the individual machine. A

line performance test is required to check the functioning of the cone crusher
as part of a complete production line. Check with 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 have
been 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 pur-
poses
9.3 Supply value checks

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

9.4 Function checks

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

1 There are no unusual noises which could indicate
misaligned parts or faults
2 Hydroset pressure remains within limits.
4 Oil heating elements operate correctly
5 Return lubrication oil temperature stays within limits
6 Over-pressure dust exclusion system functions correctly.
7 There is 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
a) 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 and
removal

10.1 Draining the cone crusher

If the crusher is to be transported, or not to be used for a longer time it
is necessary to drain the oil and water circuits.
NOTE! If the water/oil heat exchanger is to be stored a longer time, make sure that it
is dry or the remaining liquid is a water-soluble anti-rust agent.
The crusher cannot be moved without being drained.
10.1.1 Draining procedure

To drain the oil circuits, follow the instructions Draining the main
lubrication system and Draining the pinionshaft oil system in the OM.
It is important to drain the water/oil heat exchanger. Drain the water circuit at
the lowest point. See OM, Water/oil heat exchanger for further information
10.2 Moving the cone crusher

10.2.1 Short moves and short-term storage
Risk of electrocution!
High voltage. Follow the safety precautions when disassemble the
parts.
WARNING!
Preparation for moving
a) Shut off utilities connected to the cone crusher:
– Electrical power
– Process material
– Water
b) Disconnect the following connections:
– Electrical power
– ASRi (option)
c) Plug or protect all open connections

d) Drain according to section 10.1.1 Draining procedure.

e) Disassemble the crusher to the extent necessary for the planned
transport/storage. See relevant parts of IM and MM for information on
how to disassemble.
f) Move the cone crusher to the cone crusher’s new position according to
section 5.4 Moving and Storage.
CAUTION! Protect the sensitive machined parts surfaces. Treat them with anti rust
agent.
g) Level the cone crusher roughly.
h) Cover the cone crusher with suitable protective covering.
i) Store the cone crusher according to section 5.4.2 Storage of a non-
assembled crusher.
10.2.2 Long moves and long-term storage

a) Perform the instructions (a) to (g) listed in section 10.2.1 Short moves
and short-term storage.
b) Wrap all loose components in bubble wrap or other suitable wrapping to
prevent damage.
c) Pack the equipment in suitable packing, crates and transport platforms.
Use original packing, crates and transport platforms if possible. Make
sure that all parts are adequately protected.
d) Fix small boxes to each other to prevent them from moving during
transport.
e) Perform the instructions (h) to (k) listed in section 10.2.1 Short moves
and short-term storage.

10.3 Storage of an assembled crusher

If an assembled crusher is taken out of operation for a period of more than 30
days, carry out the following:
a) Use the crusher's oil system to fill the bottomshell with oil through the
hole (2) with lubricating oil until a little oil overflows over the dust
collar (1).
1 2
1 Oil level = top of dust collar

2 Over-pressure air connection
b) Plug the oil return line so that the oil cannot run out from the crusher.
c) Close the valve(s) between the tank and the pump to prevent oil running
back from the crusher through the pump.
d) Plug the connection hole for over-pressure air (2).
e) Fill the pinionshaft housing with oil and plug the inlet and outlet holes.
f) Fill the spider bushing with grease to prevent condensation on bearing
surfaces. See Lubricants in OM for further instructions.
NOTE! Before putting the crusher into operation, check that the ventilation hole and
the breather are not blocked with grease.
g) Coat the exposed part of the mainshaft sleeve (between the spider and
the head nut - see arrows) with grease. Make sure that this area is
protected from contamination.
h) If the lubrication and Hydroset oil tank unit is stored separately from the
crusher, fill the pumps with oil.
i) Rotate the crusher pulley/drive shaft by hand through at least four
revolutions every 14th day.

10.4 Return to the manufacturer

a) Prepare the equipment for transport, see section 10.1 Draining the cone
crusher.
b) Contact the local service organization for further instructions on
arranging transport.
10.5 Disposal
If the cone crusher is to be permanently disposed of, follow the sequence
below.
a) Drain the cone crusher, see section 10.1 Draining the cone crusher.
b) Carry out steps (a) to (g) listed in section 10.2.1 Short moves and short-
term storage.
Toxic gases
When dismantling and scrapping the crusher it can be necessary to
cut certain parts. This process can certain create toxic gases that
WARNING! contain hexavalent chromium, manganese, nickel, lead etc. It is
important to provide good ventilation and use breathing apparatus.
c) Disassemble the equipment as far 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

Environmental hazard
Long-term storage of disposed crusher parts can leach lead, copper,
chromium, manganese etc. into subsoil water and soil. Sandvik
WARNING! recommends recycling all material and components in compliance
with local regulations.
d) Recycle or dispose of all material and components in compliance with

local regulations.

Doc. no. 223.522 en
Appendix A: CH660:01
Appendix A: CH660:01 Installation drawings
A.1 General
The drawings in this appendix are divided into two main installation
alternatives: With direct drive and with V-belt drive. The V-belt drive can be
installed either on the left side or on the right side of the crusher.
The following drawings show machine dimensions, connection positions and
dimensions, and access dimensions. All dimensions must be respected and
all dimensions are in millimetres with inch dimensions in brackets. Reverse
V-belt drive dimensions for installation on the left side.
A.1.1 Mechanical drawings

Drawing name Drawing no. Note
Installation, general, V-belt drive 442.9864
Installation, general, Direct drive 452.0331
Installation, oil tank 442.8947
Oil connections, standard 442.9828
Oil connections, USA 442.9827
Foundation loads, V-belt drive 442.9865
Foundation loads, Direct drive 452.0330
A.1.2 Electrical drawings

Drawing name Drawing no. Note
Piping and Instrumentation diagram 194.0436
Cable list 195.0999
Connection diagram 194.0446
Circuit diagram 194.0447
Instrument list 195.0622
Sensor list 195.1478
Apparatus list 194.0448
Operating in low temperatures
Modification of return oil flow switch 194.0190
Connection of extra heating elements 194.0191
Connection of heating table 190.3592
Connection of heater for Hydroset oil 190.3590
A-2 © Sandvik SRP AB – Doc. no. 223.552 Ver. 1 CH660:01

A.1.3 Foundation loads

On the installation drawings you will find information on the forces
transmitted to the foundation or supporting structure via the crusher's
mounting points. Vz = Vertical load, positive downloads. H = Horizontal
load, (all horizontal directions)
Installation drawing for direct drive 442.0330
Forces on foundation at each attachment point (6x) (kN).
CH660 Foundation A1 A2 B1 B2 C1 C2
Static load Machine Vz 80 80 35 35 35 35
Static load Material Vz 22 22 6 6 6 6
Dynamic load during H 3 3 2 2 2 2
normal operation 4.8Hz
Vz ±10 ±10 ±5 ±5 ±5 ±5
start/stop
Vz ±40 ±40 ±20 ±20 ±20 ±20
Installation drawing for V-belt drive 452.9865 - crusher with

subframe and on rubber dampers
CH660 Foundation A2 A3 B1 B4 C1 C4
Static load Machine Vz 80 80 35 35 35 35
Static load Material Vz 22 22 6 6 6 6
Vz ±10 ±10 ±5 ±5 ±5 ±5
start/stop
Vz ±40 ±40 ±20 ±20 ±20 ±20
Installation drawing for V-belt drive 452.9865 - crusher on rubber

dampers
CH660 Foundation D1 D2 E1 E2
Static load Machine Vz 60 60 60 60
Static load Material Vz 16 16 16 16
Dynamic load during H 3 3 3 3
Vz ±10 ±10 ±10 ±10
start/stop
Vz ±40 ±40 ±40 ±40
Installation drawing for V-belt drive 452.9865 - fixed crusher

CH660 Foundation F1 F2 G1 G2
Static load Machine Vz 60 60 60 60
Static load Material Vz 16 16 16 16
Vz ±45 ±45 ±45 ±45
CH660:01 © Sandvik SRP AB – Doc. no. 223.552 Ver. 1 A-3

A.1.4 Reference letters

These letters stated on the installations drawings:
Letter Denomination
A Crusher complete with feed hopper and feed distributor
B Crusher and motor on sub-frame with rubber compression mountings on a concrete foundation
or beam frame.
C Concrete foundation
E V-belt drive
F Diameter of discharge opening
G Reference level = highest floor level for dismantling of Hydroset cylinder components.
NOTE! Applies for C:

Foundation bolts and anchor plates for embedding in the concrete foundation
are not supplied.
A.1.5 Mechanical connections

The drawings show the points on the crusher and tank unit where
connections are made, and also show the hoses that are supplied.
This overview shows general information about the connections for the cone
crusher and its accessories.
Drawing no. 442.9828 (standard)
Tank unit Dimension Max. pressure
(MPa/PSI)
E Oil to air heat exchanger G 1½" 1.0 / 145
F Oil from air heat exhanger G 1½" 1.0 / 145
L1 Lubrication oil to crusher Rp 4" INT 1.0 / 145
N Hydroset Rp ¾" INT 20 / 2900
M1 Lubrication oil from crusher Rp 4"INT 1.0 / 145
P Over-pressure air Rp ¾" INT 0.1 / 14.5
Q Pinionshaft housing lubrication outlet BSP 1½" B EXT 20 / 2900
Crusher
L2 Lubrication oil from tank G 2" B EXT 1.0 / 145
N Hydroset G¾B 20 / 2900
M2 Lubrication oil to tank R 4" EXT 1.0 / 145
P Over-pressure air Rp ¾" EXT 0.1 / 14.5
Water–oil heat exchanger

H Water outlet G 1½" B 3.0 / 435.1
J Water inlet Rp ¾" 3.0 / 435.1
Air–oil heat exchanger

E Oil inlet G 1½" 1.0 / 145
F Oil outlet G 1½" 1.0 / 145

Drawing no. 442.9827 (USA)

Tank unit Dimension Max. pressure
(MPa/PSI)
E Oil to air heat exchanger JIC 1 7/8 -12/74° EXT 1.0 / 145
F Oil from air heat exhanger JIC 1 7/8 -12/74° EXT 1.0 / 145
L1 Lubrication oil to crusher 4" NPT EXT 1.0 / 145
N Hydroset JIC 1 7/8 -12/74° EXT 20 / 2900
M1 Lubrication oil from crusher 4" NPT EXT 1.0 / 145
Q Pinionshaft housing lubrication outlet JIC 1 7/8 -12/74° EXT 20 / 2900
Crusher
L2 Lubrication oil from tank 4" NPT EXT 1.0 / 145
N Hydroset JIC 1 7/8 -12/74° EXT 20 / 2900
M2 Lubrication oil to tank JIC 1 7/8 -12/74° EXT 1.0 / 145
Water–oil heat exchanger

H Water outlet JIC 1 7/8 -12/74° EXT 3.0 / 435.1
J Water inlet JIC 1 7/8 -12/74° EXT 3.0 / 435.1
Air–oil heat exchanger

E Oil inlet JIC 1 7/8 -12/74° EXT 1.0 / 145
F Oil outlet JIC 1 7/8 -12/74° EXT 1.0 / 145
Mechanical connections overview

E
J
P
H
P F
Q
L2 L1
Q
M2 N, P
N M1
F E
CH660:01 © Sandvik SRP AB – Doc. no. 223.552 Ver. 1 A-5


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installation manual Doc. no. S 223.

3. Select one Document type and one Machine category to be shown.

4. Set document variables (Edit User Variables) and import them to

Serial no. / Machine no. Sign.

CH660:01 © Sandvik SRP AB – Doc. no. 223.522 en Ver. 1 i

3.6 Oil cooling systems ............................................................. 33

ii © Sandvik SRP AB – Doc. no. 223.522 enVer. 1 CH660:01

4.8 Operating in low temperatures............................................ 58

CH660:01 © Sandvik SRP AB – Doc. no. 223.522 en Ver. 1 iii

6. Mechanical installation and connections

iv © Sandvik SRP AB – Doc. no. 223.522 enVer. 1 CH660:01

6.8 Hydroset and lubrication systems..................................... 102

8. Final installation checks

9. Preparations for commissioning

CH660:01 © Sandvik SRP AB – Doc. no. 223.522 en Ver. 1 v

10. Disassembly and removal

vi © Sandvik SRP AB – Doc. no. 223.522 enVer. 1 CH660:01

CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 7

1.1 Equipment information

8 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 CH660:01

CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 enVer. 1 9

Tank unit identification

10 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 CH660:01

1.1.1 Document information

Figures in this manual

CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 enVer. 1 11

1.2 Operating principles of a cone crusher

12 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 CH660:01

Auxiliary lubrication systems

CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 enVer. 1 13

14 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 CH660:01

Cone crusher – side view

Tank unit and auxiliary equipment

CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 enVer. 1 15

16 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 CH660:01

CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 17

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

18 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 CH660:01

CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 enVer. 1 19

2.2.1 Personal protection

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or breathing

2.3 General safety precautions

20 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 CH660:01

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

2.3.1 Machine safety guards

CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 enVer. 1 21

2.3.2 Machine access

2.3.3 Electrical safety

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

22 © Sandvik Rock Processing AB – Doc. no. 223.522 en Ver. 1 CH660:01

2.3.5 Hydraulic systems

2.3.6 Lifting and moving loads

CH660:01 © Sandvik Rock Processing AB – Doc. no. 223.522 enVer. 1 23

2.3.7 Feed and jams