Sandvik Cone Crushers Ch660-02 - Om - S223.626.en-02

operator’s manual Doc. no. S 223.
626 en
SANDVIK CH660:02
This document is valid for:
Serial no. / Machine no. Sign.
SANDVIK CH660:02
© Copyright 2010 Sandvik SRP AB.
All rights reserved. No parts of this document may be reproduced or copied in any form or by
any means without written permission from Sandvik SRP AB. All data and information in this
manual may be changed without further notice. Reservations for misprints.
Document number: S 223.626 en

Issue: 20100205
Version: 02
Sandvik SRP AB
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
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..................................................... 19
2.1.4 Mandatory signs..................................................... 19
2.2 Personnel............................................................................ 19
2.2.1 Personal protection ................................................ 20
2.3 General safety precautions................................................. 21
2.3.1 Machine safety guards........................................... 22
2.3.2 Machine access ..................................................... 22
2.3.3 Electrical safety...................................................... 22
2.3.4 Welding .................................................................. 23
2.3.5 Hydraulic system.................................................... 23
2.3.6 Lubrication system ................................................. 23
2.3.7 Lifting and moving loads ........................................ 24
2.3.8 Feed and jams ....................................................... 25
2.4 Emissions ........................................................................... 26
2.4.1 Dust........................................................................ 26
2.4.2 Noise...................................................................... 27
2.4.3 Radioactivity........................................................... 27
3. Technical data
3.1 General data ....................................................................... 30
3.2 Crusher motor..................................................................... 32
3.3 Drive system ....................................................................... 33
3.4 Lubrication system.............................................................. 34
3.4.1 Main lubrication system ......................................... 34
3.4.2 Pinionshaft lubrication system ............................... 35
3.5 Hydroset system ................................................................. 35
CH660:02 © 2010 Sandvik SRP AB – Doc. no. S 223.626 en Ver. 02 1

Table of contents
3.6 Oil cooling systems ............................................................. 36

3.6.1 Oil/water heat exchanger ....................................... 36
3.6.2 Oil/air heat exchanger ............................................ 36
3.7 Over-pressure dust exclusion system................................. 36
3.8 Corrosion protection............................................................ 37
3.9 Processing data .................................................................. 37
3.10 Noise levels and measuring conditions............................... 37
3.11 Tightening threaded fasteners ............................................ 38
3.11.1 Requirements for joints with threaded fasteners .... 38
3.11.2 Locking fluid for threaded fasteners ....................... 38
4. Starting up the cone crusher

4.1 General ............................................................................... 40
4.2 Running-in........................................................................... 40
4.2.1 Checking the setting with lead ............................... 41
4.2.2 Starting the main oil pump...................................... 42
4.2.3 Bleeding air from the Hydroset system .................. 42
4.2.4 Maximum load........................................................ 43
4.2.5 Starting a crusher in extremely low
ambient temperatures ............................................ 44
5. Using the cone crusher

5.1 Starting and stopping .......................................................... 46
5.1.1 Starting the crusher ................................................ 46
5.1.2 Stopping the crusher .............................................. 46
5.2 Checking the setting ........................................................... 47
5.3 Changing oil ........................................................................ 47
5.3.1 Normal operating conditions .................................. 47
5.3.2 Operation at elevated return oil temperatures........ 48
5.3.3 Operation in low ambient temperatures ................. 49
5.4 Checking the V-belt tension ................................................ 50
5.5 Accumulator ........................................................................ 50
5.6 Clearing out the crushing chamber ..................................... 50
2 © 2010 Sandvik SRP AB – Doc. no. S 223.626 en Ver. 02 CH660:02

Table of contents
6. Inspection and care

6.1 Routine inspection and care ............................................... 52
6.1.1 Daily ....................................................................... 52
6.1.2 Weekly ................................................................... 53
6.1.3 Monthly .................................................................. 54
6.1.4 Twice a year........................................................... 54
6.1.5 Yearly ..................................................................... 55
6.2 Bottomshell and mainshaft assembly ................................. 56
6.2.1 Dust seal ring ......................................................... 57
6.2.2 Scraper .................................................................. 57
6.3 V-belts................................................................................. 58
6.3.1 Direction of rotation................................................ 58
6.3.2 V-belt tension ......................................................... 59
6.4 Topshell assembly .............................................................. 60
6.5 Hydroset and lubrication systems....................................... 60
6.6 Over-pressure dust sealing................................................. 60
6.6.1 Dust sealing principles ........................................... 61
6.6.2 Blower .................................................................... 62
6.6.3 Regulator assembly for compressed air ................ 62
7. Lubricants
7.1 Lubricant requirements ....................................................... 64
7.1.1 Miscibility................................................................ 64
7.1.2 Low ambient temperatures .................................... 64
7.1.3 High ambient temperatures.................................... 65
7.2 Oil for lubrication system .................................................... 65
7.3 Oil for Hydroset system ...................................................... 66
7.4 Oil for pinionshaft lubrication .............................................. 68
7.5 Grease for spider bearing lubrication.................................. 69
8. Hydroset and lubrication systems

8.1 Overview............................................................................. 74
8.1.1 Tank unit................................................................. 74
8.1.2 Cabinet................................................................... 74

Table of contents
8.2 Main lubrication system ...................................................... 76

8.2.1 Dirt trap .................................................................. 77
8.2.2 Oil filter assembly ................................................... 77
8.2.3 Oil pump................................................................. 78
8.2.4 Pressure gauge...................................................... 79
8.2.5 Pressure drop indicator .......................................... 79
8.2.6 Temperature gauge ................................................ 80
8.2.7 Pressure relief valve............................................... 80
8.2.8 Return oil flow switch ............................................. 81
8.2.9 Oil strainer .............................................................. 82
8.2.10 Thermostats ........................................................... 82
8.2.11 Oil heating .............................................................. 84
8.2.12 Level indicator ........................................................ 84
8.3 Exchanging main lubrication oil .......................................... 85
8.3.1 Cleaning the tank ................................................... 85
8.3.2 Draining the main lubrication system ..................... 85
8.3.3 Cleaning the dirt trap.............................................. 86
8.3.4 Changing filter elements......................................... 87
8.3.5 Cleaning the return oil strainer and tank ................ 88
8.3.6 Cleaning the air/oil heat exchanger (option) .......... 89
8.3.7 Refilling the main lubrication system ...................... 89
8.4 Pinionshaft lubrication system ............................................ 90
8.4.1 Oil filter ................................................................... 90
8.4.2 Oil pump................................................................. 91
8.4.3 Pressure gauge...................................................... 91
8.4.4 Pressure drop indicator .......................................... 91
8.5 Water/oil heat exchanger (option) ....................................... 92
8.6 Air/oil heat exchanger (option) ............................................ 93
8.7 Hydroset system ................................................................. 93
8.7.1 Hydroset pump....................................................... 94
8.7.2 Oil filter ................................................................... 94
8.7.3 Dirt trap (magnetic plug)......................................... 94
8.7.4 Control valve .......................................................... 95
8.7.5 Pressure gauge...................................................... 96
8.7.6 Level indicator ........................................................ 96

Table of contents
9. Accumulators
9.1 General ............................................................................... 98
9.2 Flow regulator ..................................................................... 99
9.3 Charging kit (option) ........................................................... 99
9.3.1 Checking the gas pressure .................................. 100
9.3.2 Charging with nitrogen ......................................... 101
10. Topshell assembly

10.1 Exchanging the spider cap ............................................... 104
10.1.1 Removing the spider cap ..................................... 104
10.1.2 Spider cap removal checks .................................. 105
10.1.3 Installing the spider cap ....................................... 105
10.2 Inspection of crushing chamber........................................ 106
10.3 Spider bearing................................................................... 108
10.3.1 Inspecting the spider bearing............................... 108
11. Setting measurement

11.1 General ............................................................................. 112
11.1.1 Checking the setting with lead ............................. 112
12. Troubleshooting
12.1 Faults and suggested corrective actions .......................... 114
Appendix A: Inspection

Table of contents

1. Introduction
OM Sandvik CH660:02 7
OM Sandvik CH660:02 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 SRP
AB will not accept any liability for damage to equipment or injury to
personnel caused by unauthorized or improper use or modification of this
equipment.
Manufacturer
This Sandvik equipment has been manufactured by:
Sandvik SRP AB
Stationsplan
SE-233 81 Svedala
Sweden
www.sandvik.com
For maintenance
Contact the nearest Sandvik 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 © 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02

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
6 Manufacturer 8
7 Year of manufacture 7
8 CE mark
Type:
9 Type and size of crusher
10 Crushing chamber (concave ring) 1 2 3 4 5 6
11 Mantle
12 Filler ring CH660-M/B/M-36/40/44/32:1
13 Eccentric throw (mm)
14 Mark number
9 10 12 13 14
11
Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB 9

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.
15 Type
16 Part number
17 Serial number 22
18 Mass (kg)
21
19 Order number
20 Manufacturer
21 Year of manufacture
22 CE mark
15 16 17 18 19 20
CE marking
This equipment complies with the basic health, environment and safety
regulations of the European Union and European Economic Area. Sandvik
will not take responsibility for this compliance when customers modify the
cone crusher in any aspects.

1.1.1 Document information

Purpose of this Operator’s manual
The purpose of this Operator’s manual is to provide the operator with
information on how to handle and operate this Sandvik equipment.
It is important to:
• keep the manual for the lifetime of the equipment
• pass the manual on to any subsequent holder or user of the equipment
Document compliance
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Sandvik
manufacturing plant.
Technical publications
Technical publications related to the installation and operation of this
equipment are:
• Installation manual (IM)
• Operator’s manual (OM)
When ordering technical publications, always specify the language and quote
the machine identity number.
Technical publications related to the 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 122 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

1.2 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 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 of which this wear occurs depends on the
characteristics of the process material. Read more in section 10.2 Inspection
of crushing chamber.
1
2
3
1 Spider bearing 4
2 Topshell
3 Concave ring 5
4 Mantle 6
5 Eccentric assembly
6 Mainshaft

Setting adjustment
Due to the need to compensate for wear and the need to produce different
product sizes the crusher has a control system, named Hydroset system. It
basically consists of a robust hydraulic jack, 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 11. Setting measurement.
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 section 8.2 Main lubrication system. The pinionshaft
lubrication system is described in section 8.4 Pinionshaft lubrication system.

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 – sectional view
1 Spider cap
2 Spider bushing
1
3 Head nut
4 Mantle 2
5 Concave ring
6 Mainshaft with
headcentre
7 Eccentric wearing plate
3
8 Bottomshell bushing 4
9 Eccentric 5
10 Eccentric bushing 19
11 Step bearing 6
12 Hydroset piston
18
13 Pinionshaft housing
7 17
14 Pinionshaft 16
15 Dust collar 8
16 Locating bar 15
17 Dust seal ring 20
18 Bottomshell
19 Topshell
20 Accumulator
9 14
10 13
11
12

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


2. Safety precautions
To ensure maximum safety, always read this section carefully before carry-
ing out any work on the equipment or making any adjustments.
OM Sandvik CH660:02 2. Safety precautions
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!
18 Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB

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 SRP AB. 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 SRP AB as belonging to one of three categories – work roles –
based on different competence profiles. These three work roles are:
• Installation
• Operation
• Maintenance
© 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02 19

Sandvik SRP AB provides technical documentation appropriate to all three

work roles:
• Installation manual
• Operator’s manual
• Maintenance manual and Spare parts catalog
Sandvik SRP AB can provide adequate training for all three work roles and
can carry out authorization of trained personnel.
The technical documentation from Sandvik SRP AB 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 SRP AB declines all responsibility for injury or damage resulting
from non-compliance with the instructions in this manual.
2.2.1 Personal protection

Sandvik SRP AB strongly recommends that personal protective equipment is
always worn when working in the vicinity of the equipment.
Sandvik SRP AB strongly recommends to use a safety harness when
working above, inside and under the equipment.
The Sandvik SRP AB 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.
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 SRP AB 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 SRP AB.)
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 service
personnel must be consulted.
CAUTION! Only welders qualified according to European Standard EN 287 or

similar 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 system

CAUTION! Only personnel certified in hydraulics are permitted to perform
maintenance 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. Equipment and hoses/pipes
WARNING! containing hydraulic oil may be hot on surface.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired
and replaced before starting the equipment.
2.3.6 Lubrication system

CAUTION! Equipment and hoses/pipes containing lubrication oil may be hot on
surface.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired
and replaced before starting the equipment.
CAUTION! Always remove oil stains to avoid skidding risk.

2.3.7 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.

2.3.8 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 SRP AB 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
Since Sandvik’s crushers are used for handling and/or processing of minerals
or other materials which can give rise to health risks for human beings and
animals, it is the responsibility of the user to follow the relevant rules and
regulations intended to prevent health risks for example specific regulation
applying to dust emission, asbestos, quartzite, radon etc.
2.4.1 Dust
Health hazard
Breathing or inhaling dust particles will cause death or severe injury.
Always wear approved respirator.
DANGER!
Always work with a respirator approved by the respirator manufacturer
for the job you are doing. It is essential that the respirator that you use
protects you from the tiny dust particles which cause silicosis and
which may cause other serious lung diseases. You should not use the
equipment until you are sure your respirator is working properly. This
means the respirator must be checked to make sure that it is clean,
that its filter has been changed, and to otherwise make sure the
respirator will protect you in the way it is meant to.
Make sure the dust suppression system in your equipment is working

properly. If the dust suppression system is not working properly, stop
working immediately.
Always make sure dust has been cleaned off your boots and clothes
when you leave your shift.
The smallest particles of dust are the most harmful. They may be so
fine that you can not see them.
Remember, you must protect yourself from the danger of breathing or

inhaling dust.
Sandvik SRP AB 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 SRP AB 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!
Refer to OM - Technical specifications for measured noise levels and
measurement conditions.
Rubber compression mountings and dust encapsulation result in lower noise
levels.
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 SRP AB 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
OM Sandvik CH660:02 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 CH660:02
Type Cone crusher
Application Mineral processing
Usage Outdoors/Indoors
Total mass 25 565 kg (56 360 lb.)
Length (with motor cradle) 5.40 m (212.6”)
Width 2.10 m (126")
Height 4.25 m (209")
Max. motor power 315 kW 422 Hp
Installed power 139-315 kW
Available crushing chambers 8 (EC, C, CX, MC, M, MF, F and EF)
Close Side Setting (CSS) Approx. 10-55 mm depending on crushing chamber and eccentric
throw
Open Side Setting (OSS) Max. depends on chamber, Min. = CSS + ECC
CSS and ECC
Pinionshaft speed 1188 rpm / 50 Hz 1195 rpm / 60 Hz
Feed hopper Mass 570 kg (1 257 lb.)
Material Steel
Thickness 8 mm, 50 mm incl. rubber lining
Height 1200 mm (47.24")
Inner diameter Ø 1950 mm (110.2”)
Capacity 10.8 ton with B.D = 1.6 ton/m3
Topshell Mass 6 859 kg (15 120 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 74 kg (163 lb.)
Material Manganese steel
Backing material No
Securing method Welding
Spider cap Mass 340 kg (748 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 50 mm (1.97”)
Bottomshell liners Number of liners 10
Different shapes 6
Material Rubber
Securing method Bolts
Bottomshell arm liners Material PU
Min. thickness 30 mm (1.18”)
Max. thickness 40 mm (1.57”)
Number of liners 5
Different shapes 2
Mass of heaviest liner 17 kg (37,5 lb.)
Securing method Bolts
30 © 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver.02

Mantle Types A, B, D, 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), CX, (MC), (M), MF F, EF
Min. thickness 30 mm
Max. thickness 90 mm
Inner diameter at bottom Ø 1400 mm
Material Manganese alloyed steel
Mass of heaviest concave 1300 kg (2866 lb.)
Backing material Yes
Securing method Clamping ring, filler ring
Mainshaft Max. mainshaft travel 340 mm
Mainshaft position sensing Yes
Mass 5 891 kg (12 990 lb.)
Length 2186 mm (86.06")
Eccentric Adjustable throw Yes
Standard eccentric throws 18, 20, 24, 28, 32, 36, 40, 44, 48,
50,
Eccentric speed 290 rpm
Balancing Yes
Eccentric assembly mass 1124 kg (2 478 lb.)
Eccentric bushing mass 460 kg (1 014 lb.)
Pinion Mass pinion 70 kg (50 Hz)
45 kg (60 Hz)
Pinionshaft housing assembly 408 kg (899.5 lb.)
mass
Pinionshaft bearing mass 18 kg
Bevel gear mass 300 kg (50 Hz)
380 kg (60 Hz)

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 CH660:02
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 CH660:02

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.)

3.4 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

3.4.2 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

3.6 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/min (10.59 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

3.8 Corrosion protection

Paint system CH660:02
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 Noise levels and measuring conditions

Machine Test running in the Typical values when
factory (without crushing
material) dB(A)
dB(A)
CH660 Hydrocone 95 95 - 106
The values given above are equivalent continuous sound levels (Leq)
measured during a period of 60 seconds with an integrating sound level
meter. The values are measured at a distance of approx. 1 m from the
machine and approx. 1.6 m above ground level or above a platform alongside
the machine.
The sound levels given are approximate values. The sound level depends on
many factors, e.g. whether or not the crusher has dust encapsulation, how the
equipment is installed, how the feed arrangement is designed, the size and
impact strength of the feed material, the size of the drive motor, etc.

3.11 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)
3.11.1 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%.
3.11.2 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.

4. Starting up the cone crusher
This section describes how to start up the cone crusher.
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.
OM Sandvik CH660:02 4. Starting up the cone crusher
4.1 General
Each cone crusher delivered by Sandvik has been assembled, test run and
checked in our factory before shipping. The test run is carried out without
load to discover any mechanical faults.
4.2 Running-in
The appropriate parts of this section apply also after repair work and the
fitting of new parts.
a) Start the main lubrication oil pump and pinionshaft oil pump.
b) When the “Ready for start” signal is obtained, start the crusher’s drive
motor.
c) Check and adjust the setting. See section 4.2.1 Checking the setting with
lead.
d) Make sure that the mainshaft is in the bottom position. Bleed the
Hydroset system. See section 4.2.3 Bleeding air from the Hydroset
system.
e) Start the feed to the crusher. Feed the crusher carefully and gradually
increase the load rate until it reaches 75% of the maximum level for
power draw or Hydroset pressure. See section 4.2.4 Maximum load. The
load is altered by changing the setting.
CAUTION! If possible the crushing chamber should be full. The crusher will not be
run-in by idling. The crusher is normally run-in after approximately
16 hours operating at 75% load. Thereafter increase the load gradually
up to full load. Depending on the availability of material, and for other
process engineering reasons, running-in can take longer. It is important
that items e–g are followed carefully during the entire running-in
procedure.
f) Check the return oil temperature regularly. This temperature should

normally lie between 40°C (104°F) and 45°C (113°F).
g) Check that the cooling system cuts in and out at the correct oil
temperatures, see section 8.2.10 Thermostats.
NOTE! If operating conditions differ from normal (Oil = ISO VG 150 viscosity), set
the thermostats according to section 8.2.10 Thermostats and section
8.2.11 Oil heating.
h) Inspect and clean the oil strainer regularly, see section 8.2.9 Oil strainer.
Quite often, a small quantity of fine steel and bronze particles can be
found on the oil strainer during the initial running-in period.
(Continued)

i) Check that there is no movement between the topshell and bottomshell.

Put a finger between the topshell and bottomshell to feel possible
vibrations.
j) Check that there are no oil leaks from the lubrication and Hydroset lines.
k) Check that the indicating pointer of the Hydroset pressure gauge moves
steadily. See section 8.7.5 Pressure gauge.
l) Check the temperature outside the pinionshaft housing with a suitable
thermometer, e.g. infrared camera. The normal temperature is 50–60°C
(122–140°F).
m) Check that the feed is correctly distributed around the crushing chamber.
See the Installation manual.
n) Check the power consumption and Hydroset pressure. See section
4.2.4 Maximum load and section 8.7.5 Pressure gauge.
o) Check and record the main lubrication oil pressure, see section 8.2 Main
lubrication system. Also check and record the pinionshaft oil pressure,
see section 8.7 Hydroset system.
p) Check for a ringing sound during crushing, it can indicate a loose mantle
or concave ring.
q) Check that there are no grease leaks from the spider bearing.
r) After running-in is completed, check the tightness of all bolts and re-
tension the V-belts. See section 6.3.2 V-belt tension.
s) After a few hours of operation, bleed the Hydroset system again. See
section 4.2.3 Bleeding air from the Hydroset system.
4.2.1 Checking the setting with lead

The CSS (Closed Side Setting) can easily be checked by using a lump of lead
fastened to a steel wire and lowering it slowly into the discharge area of the
crushing chamber. The lead lump will be squeezed and its thickness will then
correspond to the setting. Make sure the lead lump is large enough to get a
proper thickness measurement.
The CSS should occasionally be checked at 4 points, evenly spaced around
the crushing chamber. This will enable you to detect uneven wear, which
indicates an unsatisfactory feed arrangement. See section 11. Setting
measurement.
CAUTION! The setting must never be so small that the power drawn by the crusher
or the Hydroset pressure exceeds the limits given in section
4.2.4 Maximum load.

4.2.2 Starting the main oil pump

Before the main oil pump is started check the oil level. When the pump is
started, the oil tank must be full of oil so that the pump does not operate dry.
4.2.3 Bleeding air from the Hydroset system
1 Measuring nipple
2 L1 push button box
a) Prepare to attach the air-bleed hose to the measuring nipple on the throat
of the accumulator.
b) Position the free end of the air-bleed hose in a suitable receptacle.
Oil pressure
The oil in the Hydroset system can be under pressure. See section
2.3.5 Hydraulic system for further information.
WARNING!
c) Screw the hose onto the measuring nipple (1). The non-return valve in
the measuring nipple will automatically open when the hose is screwed
on.
d) When bubble-free oil comes out of the air-bleed hose, raise the
mainshaft a few millimetres (mm) by using the L1 push button box (2),
which is located in the vicinity of the cone crusher. Lower the mainshaft
again.
e) Repeat the air bleeding procedure 2-3 times until completely bubble-free
oil flows out.
f) Unscrew the hose from the measuring nipple (1). The non-return valve in
the measuring nipple will automatically close.

4.2.4 Maximum load

The power drawn by the crusher and the Hydroset pressure during operation
are dependent on the crushing chamber, the eccentric throw, the crusher’s
setting and the feed material’s crushability, size analysis, moisture content,
etc.
• The maximum average power drawn by the crusher must not exceed
315 kW.
• The maximum average Hydroset pressure measured on the pressure
gauge must not exceed the following values.
Crushing chamber Average pressure
EF, F, 3.6 MPa (522 p.s.i.)
MF, M 3.4 MPa (493 p.s.i.)
MC 3.2 MPa (464 p.s.i.)
C, Cx 3.0 MPa (435 p.s.i.)
EC 2.8 MPa (406 p.s.i.)
NOTE! These values are not valid if the crusher is regulated with the ASRi system.
Average power
The following are typical values for the average power draw measured on the
motor shaft, depending on eccentric throw and crushing chamber. The
average power draw can be higher if it is even and without peaks, but the
values above for maximum average power and maximum average Hydroset
pressure must not be exceeded.
Power (kW) Crushing chamber

Throw EF F MF M MC C Cx EC
18 mm 139 145 148 152
20 mm 151 158 162 165
24 mm 167 176 184 189 193
28 mm 180 190 200 211 216 221
32 mm 190 202 213 225 237 243 248
36 mm 197 211 224 237 250 263 269 276
40 mm 216 231 245 260 275 289 296 304
44 mm 235 251 267 283 299 315 323
48 mm 254 272 289 307
50 mm 264 282 300 315

4.2.5 Starting a crusher in extremely low ambient

temperatures
In extremely low ambient temperatures it may be found that lubrication oil
overflows over the dust collar when the main lubrication pump is started
(before normal operating temperature is reached).
a) Start and stop the oil pump repeatedly at 10 second intervals until the
“Ready for start” signal is obtained. Then start the crusher and allow it to
run idle. Check that the oil flow is normal.
• For more information about avoiding problems when operating in low
temperatures, see the Installation manual – Operating in low
temperatures.

5. Using the cone crusher
This section describes basic procedures when using the cone crusher.
OM Sandvik CH660:02 5. Using the cone crusher
5.1 Starting and stopping

Normally, the crusher is controlled by a control system which restricts the
ways in which it can be started. Read complementary information from the
manufacturer of the control system. Nevertheless, follow or check that the
control system follows the start and stop procedures below.
NOTE! Regarding running-in and after repair work or the fitting of new parts, see
section 4.2 Running-in.
NOTE! Follow the routine inspection and care procedures described in section
6.1 Routine inspection and care, e.g. the items under section 6.1.1 Daily.
5.1.1 Starting the crusher

NOTE! For starting the crusher in extremely low ambient temperatures, see section
4.2.5 Starting a crusher in extremely low ambient temperatures and the
Installation manual.
a) Start the main lubrication oil pump and the pinionshaft oil pump.
b) When the “Ready for start” lamp lights up, start the crusher’s drive
motor.
c) Check and adjust the setting. See section 4.2.1 Checking the setting with
lead.
d) Start the feeder. The crusher should be choke fed without segregation.
CAUTION! The setting must never be so small that the power drawn by the crusher
or the Hydroset pressure exceeds the limits given in section
4.2.4 Maximum load.
5.1.2 Stopping the crusher

a) Stop the feeder, but let the crusher run until the crushing chamber is free
of processing material.
b) Stop the crusher’s drive motor.
c) Stop the main lubrication oil pump and pinionshaft oil pump.
NOTE! The oil heating should run for 24 hours a day. The heating elements are
automatically controlled by the oil heating thermostat.

5.2 Checking the setting

The procedure for checking the CSS setting is described in section
4.2.1 Checking the setting with lead. See also section 11. Setting
measurement.
5.3 Changing oil

Risk of fire and toxic gases
Oil products present environmental and fire risks and can cause injury
if inhaled or brought into contact with the skin. Follow your lubricant
WARNING! supplier’s instructions and safety directions when handling oils and
greases.
NOTE! Never mix different brands or types of lubricants. A bad mixture may cause
precipitation and lose its lubricant characteristics. Consult your lubricant
supplier.
Normally the old lubricant must be flushed out very carefully before a
change is made. The lubricant manufacturer(s) can provide information on
whether mixing can take place.
5.3.1 Normal operating conditions

Normal operating conditions
Ambient air temperature Max. 32°C (90°F)
a) Choose a main lubrication oil for normal operating conditions according

to section 7.2 Oil for lubrication system.
b) Exchange the main lubrication oil according to section 8.3 Exchanging
main lubrication oil. Also change the filter elements section
8.3.4 Changing filter elements and clean the dirt trap section 8.2.1 Dirt
trap, return oil strainer section 8.3.5 Cleaning the return oil strainer and
tank, tank and air/oil heat exchanger section 8.3.6 Cleaning the air/oil
heat exchanger (option).
c) Choose a Hydroset oil according to section 7.4 Oil for pinionshaft
lubrication and exchange the oil in the Hydroset system. Also change the
filter element and clean the dirt trap, see section 8.7.2 Oil filter and
section 8.7.3 Dirt trap (magnetic plug).
d) If thermostats TG 1, TG 2 and TG 3 are not already set for normal
operating conditions, reset them according to section 8.2.10 Thermostats
and section 8.2.11 Oil heating.

5.3.2 Operation at elevated return oil temperatures

Operation at elevated return oil temperatures
Ambient air temperature Max. 40°C (104°F)
If the ambient temperature is so high that the cooling system cannot keep the
return oil temperature below 50°C (122°F), it may be necessary to permit
operation at an elevated return oil temperature. In such a case, contact
Sandvik. At the same time, a change must be made to a lubricating oil with
higher viscosity:
a) Choose a main lubrication oil for operation at elevated return oil
temperature according to section 7.2 Oil for lubrication system.
main lubrication oil. Also change the filter elements section
8.3.4 Changing filter elements and clean the dirt trap section 8.2.1 Dirt
trap, return oil strainer section 8.3.5 Cleaning the return oil strainer and
tank, tank and air/oil heat exchanger section 8.3.6 Cleaning the air/oil
heat exchanger (option).
lubrication and exchange the oil in the Hydroset system. Also change the
section 8.7.3 Dirt trap (magnetic plug).
d) If thermostats TG 1, TG 2 and TG 3 are not already set for operation at
return oil elevated temperature, reset them according to section
8.2.10 Thermostats and section 8.2.11 Oil heating.

5.3.3 Operation in low ambient temperatures

Operation in low ambient temperatures
Ambient air temperature Below 0°C (32°F)
The oil’s viscosity increases at low temperature, but normally it’s not
necessary to change to a thinner oil during the winter as the oil tank is
equipped with heating elements. Furthermore, there are several other ways to
reduce the risk of freezing, including insulation and extra heating. See the
Installation manual and consult Sandvik.
Nevertheless, in extremely low ambient temperatures it can sometimes be
advisable to change to a less viscous oil:
a) Choose a main lubrication oil for operation in low temperatures
according to section 7.2 Oil for lubrication system.
main lubrication oil. Also change the filter elements and clean the dirt
trap, return oil strainer, tank and air/oil heat exchanger.
lubrication and exchange oil in the Hydroset system. Also change the
section 8.7.3 Dirt trap (magnetic plug). It is normally unnecessary to
change to a different grade of Hydroset oil. However, if conditions are so
extreme that a less viscous oil or a heater in the Hydroset tank is needed,
consult Sandvik .
d) For operation in extreme ambient temperatures, consult the lubricant
supplier regarding grease for spider bearing lubrication, see section
7.5 Grease for spider bearing lubrication.
e) If thermostats TG 1, TG 2 and TG 3 are not already set for operation in
low ambient temperatures, reset them according to section
8.2.10 Thermostats and section 8.2.11 Oil heating.

5.4 Checking the V-belt tension

The procedure for checking the V-belt tension is described in section 6.3.2 V-
belt tension.
5.5 Accumulator
Checking the gas pressure and charging is described in section 9.3 Charging
kit (option).
5.6 Clearing out the crushing chamber

If the crusher stalls with the crushing chamber full of material, clear it out as
follows:
a) Make sure that the crusher’s feeding arrangement is switched off.
b) If there is material in the discharge chute beneath the crusher, remove the
material.
NOTE! If there is an ASRi system, switch it off. The ASRi system must be
disconnected to prevent an automatic raising or lowering of the mainshaft.
c) Fully open the damping valve in the line to the Hydroset pressure gauge,
see section 8.7.5 Pressure gauge.
d) Use the L1 push button box to lower the mainshaft, keeping an eye on
the Hydroset pressure.
e) If the Hydroset pressure drops below 0.3 MPa, then raise the mainshaft
again until the pressure gauge displays at least 0.5 MPa. (The mainshaft
step may lose contact with the step washer if the pressure goes below
zero.)
f) Start the crusher.
NOTE! Check for material build-up on the bottomshell arms. If damp, wet feed is
causing packing, operate at a larger setting.
NOTE! Check the interlocking between the feeding arrangement and discharge
system. There must be room beneath the crusher for all of the material in the
crushing chamber and the feed hopper, in case the discharge system stops.
CAUTION! Do not start the crusher if it has stalled because of uncrushable material
(metal, wood etc.). Empty the crusher manually or unbolt the topshell so
that all material can leave the crushing chamber, see Maintenance
manual.
CAUTION! Never start the crusher with a loose topshell.

6. Inspection and care
This section describes the routine inspection and care instructions for the
cone crusher.
OM Sandvik CH660:02 6. Inspection and care
6.1 Routine inspection and care

Every cone crusher must be subjected to regular systematic checks. This will
result in fewer and smaller repairs, less downtime and thus lower overall
running costs.
NOTE! A new crusher must be inspected often during the initial operating period.
The intervals between inspections can then be increased until a suitable
frequency is found.
Keep a written log including the crusher’s operating conditions and loads,
important data and details of adjustments made and any repairs carried out.
An example of such a record sheet can be found in appendix A: Inspection.
Since crushers operate under widely differing conditions, it is impossible to
recommend an inspection and care schedule applicable to all crushers.
However, regular inspections are necessary. The following table describes an
example.
6.1.1 Daily
The operator’s role includes responsibility for these inspections daily or after
every 8 hours of operation.
Action When See section
Check the oil level in the lubrication tank. Before starting the crusher 8.2.12
Check the oil level in the Hydroset tank. Before starting the crusher 8.7.6
Check that the shut-off valves between the tanks and pumps Before starting the pumps and –
are fully open. crusher
Check that no material has built up on the bottomshell arms. Before starting the crusher –
Check that lubricating returns to the tank and that the oil is After starting the lubrication 8.2.9
clean. pump
Check that the oil lines do not leak. After starting the pumps –
Check that the pinionshaft lubrication circuit is operating cor- Running idle 8.4.2, 8.4.3
rectly.
Check the CSS. Running idle 4.2.1
Check that material has not jammed in the feed hopper and Running idle –
blocked the feed opening.
Listen for abnormal noises in the crusher. While crushing –
Listen for abnormal noises in the lubrication pump. While crushing and before –
Check the return oil temperature. While crushing 8.2.6
Check the drive motor current or power consumption. While crushing 4.2.4
Check the Hydroset pressure and that the pressure gauge While crushing 8.7.5, 4.2.4
damping is correct.
Check the temperature of the pinionshaft housing. Use an While crushing –
infrared camera or feel above the housing. If it’s too hot to
touch, then the temperature is too high. Normal temperature is
50–60°C (122–140°F).
Check the oil pressure in the main lubrication system and pin- While crushing 8.2.4, 8.4.3
ionshaft lubrication system at normal operating temperature.


Check that there is no oil leakage. While crushing –
Check that no bolts have come loose. While crushing –
Check that the oil heaters are working. With crusher stopped 8.2.11
Check the distance between the head nut and the underside of With crusher stopped 10.2
the spider (i.e. the A-dimension).
Check that there is no contamination increase or change on With crusher and lubrication 8.3.5
the return oil strainer, e.g. an abnormal amount of metal parti- pump stopped
cles.
6.1.2 Weekly
The operator’s role includes the responsibility for these inspections weekly
or after every 40 hours of operation.
Inspect the oil filters (check if the red button on the pressure With crusher and lubrication 8.2.2, 8.3.4,
drop sensor protrudes) of the main and pinionshaft lubrication pumps stopped 8.7.2
systems.
Inspect the crushing liners for wear and damage. With crusher stopped 10.2
Measure the setting at four points around the crushing cham- Running idle 4.2.1, 11.1
ber to check for uneven wear.
Check the pumps for abnormal noise. While crushing. 8.2.3, 8.7.1
Check wear and tension of the V-belts. With crusher stopped 6.3.2
Check the cooler core of the air/oil heat exchanger (option). With crusher and lubrication 8.6
pump stopped
Clean the damping valve for the Hydroset pressure gauge. With crusher stopped 8.7.5
Check the air pressure (blower running or regulator working) Running idle 6.6
the over-pressure dust sealing system.
Check the hose and filter of the over-pressure dust sealing With crusher stopped 6.6.1
system and that the covers on the tank unit are air tight.

6.1.3 Monthly
These inspections should be carried out monthly or after every 160 hours of
operation. The crusher must be stopped.
Action Responsible See section
Check the dust seal ring for wear. Operator 6.2.1
Clean the dirt trap and inspect the oil tank of the main lubrica- With crusher and lubrication 8.3.1, 8.2.1,
tion system. pump stopped 8.3
Check the condition of the scraper which rotates above the Operator 6.2.2
dust collar.
Check the tightness of all bolts. Operator –
Check the play between the mainshaft sleeve and the spider Operator 10.1, 10.3
bushing.
Check the grease level in the spider bearing. Operator 7.5
Clean the air vent passages in the spider cap and topshell. Operator 10.1
Check the condition of the lubrication oil. Operator 7.2
Check the function of the return oil flow switch. Operator 8.2.8
Check the backlash in the pinion and eccentric gear. Service personnel See MM
Check – using feeler gauges – between the headcentre and Service personnel See MM
the mantle and between the topshell and the concave ring.
Check the spider bearing grease seal for wear. Service personnel See MM
6.1.4 Twice a year

These inspections should be carried out twice a year or after every
1000 hours of operation. The crusher must be stopped.
Check the gas pressure in the accumulator. Operator 9.3
Clean the drain plug on the pinionshaft housing. Operator 7.4
Clean out the oil tank. Operator 8.3.1, 8.3.5
Change the oil filter element and clean the dirt trap in the Operator 8.7.2, 8.7.3
Hydroset system.
Check the play in the spider bearing. Operator 10.1, 10.3

6.1.5 Yearly
These inspections should be carried out yearly or after every 2000 hours of
operation. The crusher must be stopped.
Check the topshell and bottomshell for wear. Service personnel See MM
Check the chevron packing for wear. Service personnel See MM
Check the tapered contact faces of the topshell and bottom- Service personnel See MM
shell.
Check the mainshaft sleeve for wear and pitting. Service personnel See MM
Check the inner seal ring for wear. Service personnel See MM
Check the play between the locating bar and the gear hub. Service personnel See MM
Check the eccentric bushing for wear and scratches. Service personnel See MM
Check the eccentric for wear and scratches. Service personnel See MM
Check the eccentric wearing plate for wear. Service personnel See MM
Check the bottomshell bushing for wear and scratches. Service personnel See MM
Check the thickness of the step bearing assembly. Check for Service personnel See MM
wear and scratches.
Check the gears for wear. Service personnel See MM
Check the Hydroset cylinder bushing for wear and scratches. Service personnel See MM
Check the function of the temperature gauge. Operator 8.2.6
Check the function of the protective thermostat (TG 1), and the Operator 8.2.10
thermostat for oil heating control (TG 3) and the thermostat for
oil cooling control (TG 2)

6.2 Bottomshell and mainshaft assembly

There are two inspection holes in the bottomshell, through which the dust
seal ring and dust collar can be inspected and checks can be made on liner
condition and oil leakage.
Do not remove covers/guards

Do not open the covers while the machine is crushing. Never put
hands inside while the crusher is running.
PROHIBITION!
1 Cover / inspection hole

6.2.1 Dust seal ring

The dust seal ring (3), which is supported beneath the headcentre, is free to
move and has an easy sliding fit on the dust collar (4). It is the most
important seal for the crusher’s oil system. The dust seal consists of the dust
seal ring (3) and a retaining ring (2). The retaining ring (2) is screwed on the
headcentre.
2
3 5
4
2 Retaining ring
3 Dust seal ring
4 Dust collar
5 Scraper
Use feeler gauges to check the play between the dust seal ring and the dust
collar.
Max. permissible play between dust seal ring and dust collar
mm/(inches)
1.9/(0.0748)
6.2.2 Scraper
To prevent the accumulation of dust and material etc. on the outside of the
dust collar (4), the crusher has a scraper (5) mounted on the underside of the
retaining ring (2). The scraper consists of a rubber flap and a retaining plate
which is bolted to the bottom of the retaining ring.
The scraper (5) ensures that there is always room for the downward
movement of the mainshaft assembly, e.g. if tramp iron enters the crusher.
Check the condition of the scraper (5) at regular intervals. If necessary, clean
out the area around the dust collar and the bottomshell arms.

6.3 V-belts
Do not remove fixed guards
Never operate the cone crusher unless the fixed guards around its
moving parts are mounted.
PROHIBITION!
6.3.1 Direction of rotation

CAUTION! The crusher’s V-belt pulley must rotate in the direction indicated by the
arrow on the bottomshell. This is necessary for the self-tightening
action of the head nut.

6.3.2 V-belt tension

During the first few days of operation, the belt tension must be checked
frequently since new belts stretch. If the belts are not tensioned sufficiently,
slipping can occur and belt life will be reduced considerably.
Proper belt tension can be determined with the help of the deflection load.
Check the deflection load with a spring balance or a special instrument, a
tensiometer or its equivalent.
Recommended deflection load (F)

F, kp/belt (lbf/belt)
Belt profile Normal Max. (newly fitted belts)
SPC 7 (15.4) 12.0 (26.5)
8V 9 (19.8) 14.0 (30.9)
Checking the deflection load with a tensiometer:

a) Measure the belt span (W) in meters, as shown below.
b) Multiply the span by 1.5, to give the belt deflection (D) in cm.
c) Set the top side of the lower O-ring to the correct deflection in cm on the
meter’s lower scale.
d) Push the upper O-ring up against the lower edge of the outer sleeve.
e) Press the meter against the belt in the middle of the span and press
sufficiently hard to bring the top side of the lower O-ring level with the
belt alongside.
f) Remove the meter and read off the load (F) in kp (lbf) at the top side of
the upper O-ring. The correct load is obtained from the table above,
which should be reproduced on the meter.
g) If the average load is too low or too high, tighten or slacken the belts. If
one or two of the belts is slack, change all of the belts. See MM.
1 F-scale
2 D-scale F
2
D = deflection 1
6
6 14 12 10 8
W
W = belt span
F = deflection load D
5
F
4
2
3
2
D
1

6.4 Topshell assembly

For further information about inspection and care of the topshell assembly,
see section 10. Topshell assembly.
6.5 Hydroset and lubrication systems

For further information about inspection and care of the Hydroset and
lubrication system, see section 8. Hydroset and lubrication systems.
6.6 Over-pressure dust sealing

The crusher has a dust seal ring (4305-0) to keep out dust, but air must be
introduced into the crusher at a small over-pressure. This is because a slight
under-pressure can otherwise occur inside the crusher when aerated
lubricating oil runs back to the tank. The resultant under-pressure will draw
dust into the crusher and a film of dust will collect on the inside of the dust
collar (1400-0).
The lubricating oil will transport this dirt and dust around the lubrication
system. This will result in rapid blockage of the filters, accelerated wear on
the step bearing components and sedimentation in the oil tank. Other
components inside the crusher will also be subjected to unnecessarily heavy
wear.
The over-pressure air (white arrows) can be provided by a blower (as
described in section 6.6.2 Blower) or from a compressed air system (as
described in section 6.6.3 Regulator assembly for compressed air).
1400-0 Dust collar

1450-0 Inner dust seal ring 1400-0
4305-0 Dust seal ring
4350-0 Retaining ring
1450-0
4355-1 Scraper 4305-0
1 Dust
4350-0
1
4355-1

6.6.1 Dust sealing principles

The condition of the dust seal ring (4305-0) is of decisive importance for the
function of the seal against the dust collar (1400-0). A worn or oval dust seal
ring gives a large gap to the dust collar and increases the possibility of dust
and dirt entering the crusher.
A plastic hose is connected between the crusher and tank unit to provide
pressure equalization. One end is connected to the T-connector (2) mounted
on the crusher, just above the pinionshaft housing. The other end is
connected to the sleeve (5) welded to the end wall of the tank, above the oil
level.
2 4 5
2 T-connector
4 Blower
5 Sleeve
NOTE! The covers on the tank unit must be air tight. Adjust or replace the sealing
strips if necessary.
Dust is prevented from entering the crusher by creating an over-pressure

inside the crusher and tank. This over-pressure is created by introducing air
with the help of a blower or a regulator assembly for compressed air. See
section 6.6.2 Blower and section 6.6.3 Regulator assembly for compressed
air respectively. The over-pressure air is introduced through the same
T-connector (2) on the crusher as is used for the pressure equalization hose to
the tank.
Check
When the crusher is operating, the air pressure – measured at the entry to the
crusher – must be 600–1000 Pa (60–100 mm w.g.)

6.6.2 Blower
The blower capacity at a pressure of 600 Pa (60 mm w.g.) must be at least
0.3 m3/min.
Check
The blower (4) has an air filter (6) with a replaceable paper element. Inspect
the filter element at regular intervals and change it when necessary.
6
4 Blower
6 Filter
6.6.3 Regulator assembly for compressed air

The regulator assembly includes a pressure gauge (3) which measures the
over-pressure at the entry to the crusher.
3 Pressure gauge
7 Air regulator
8 Filter
9 Compressed air connection
3 7 8 9

7. Lubricants
This section describes the requirements that must be put on the lubricants
used in the cone crusher.
OM Sandvik CH660:02 7. Lubricants
7.1 Lubricant requirements

If the crusher is to be utilized optimally, stringent demands must be made on
the lubricants that are used.
NOTE! Lubricants which do not meet Sandvik's requirements must not be used
during the warranty period.
Risk of fire and toxic gases

Oil products present environmental and fire risks and can cause injury
if inhaled or brought into contact with the skin. Follow your lubricant
WARNING! supplier's instructions and safety directions when handling oils and
greases.
Check
A change in oil colour may indicate the presence of water or dirt. Change the
oil.
7.1.1 Miscibility
NOTE! Never mix different brands or types of lubricants. A bad mixture may cause
precipitation and lose its lubricant characteristics. Consult your lubricant
supplier.
Normally the old lubricant must be flushed out very carefully before a
change is made. The lubricant manufacturer(s) can provide information on
whether mixing can take place.
7.1.2 Low ambient temperatures

As the oil’s viscosity changes at low temperatures, the oil tank is equipped
with heating elements so that a change to a thinner oil is normally not
necessary during the winter.
In extremely low ambient temperatures, it can sometimes be advisable to
change to a less viscous oil – If such a change is made it is necessary to
change the temperature settings in the TIMS. See the tank manual.
NOTE! When a change is made back to the normal oil, the temperatures settings
must be changed back again.

7.1.3 High ambient temperatures

If the ambient temperature is so high that the cooling system cannot keep the
return oil temperature below 50°C (122°F), it may be necessary to permit
operation at an elevated return oil temperature. In such a case, contact
Sandvik. At the same time, a change must be made to a lubricating oil with
higher viscosity. See “Operation at elevated temperatures” in the table
below.
7.2 Oil for lubrication system

Requirements specified
The lubrication oil must be of “good quality” and be designed for circulation
lubrication and contain anti-wear additives (not EP-type). This oil can be
used for all the crusher’s lubrication needs. Its necessary to have three types
viscosity values to meet the different operating conditions. Pre-heating is
necessary at cold start conditions at ambient air temperatures below 0°C
(32°F).
The table below specifies lubricating oil types for use under different
operating conditions.
Oil requirements for different operating conditions
Characteristics Operating conditions Testing method
Operation in low Normal Operation at elevated
temperatures temperatures
Ambient air temperature –30 to 10°C –20 to 35°C –10 to 25°C
(–22 to 50°F) (-4 to 95°F) (14 to 77°F)
Tank temperature 10 to 25°C 15 to 40°C 15 to 35°C
(oil to crusher) (50 to 77°F) (59 to 104°F) (59 to 95°F)
Oil viscosity 100 150 220 ISO VG
Base oil type mineral or PAO
Base oil viscosity at (cSt)@ 100 150 220 ASTM D-445
40°C(104°F)
Viscosity index base oil ≥ 95 ASTM D-2270
natural
Base oil specified weight ≥ 870 ≥ 870 ≥ 870 ASTM D-1298
kgm3@ 15°C (59°F)
Flash point COC ≥ 200°C (392°F) ASTM D-92
Lowest pour point ≤ –20°C (-4°F) ≤ –15°C (5°F) ≤ –5°C (23°F) ASTM D-97
Greasability FZG, step ≤ 12 DIN 51 354
Copper corrosion 1A ASTM D-130
Rust test Approved ASTM D-665
Oxidation resistance ≤ 1 500 ASTM D-943
TOST, hours
The tank temperature is foreseen as the oil temperature to the crusher. The
ambient air temperature is the temperature in which the equipment is
positioned.
For safety's sake, check with your supplier that the selected lubricant
complies with the requirements in question.

Oil quantity
The capacity of the lubrication oil tank is 800 litres (211.3 US gal.).
When the crusher is running, the oil level must be above the minimum level
mark. See the oil level indicator in the tank unit.
When the crusher stops, a certain amount of oil will be trapped in the crusher
and the oil supply lines. The tank should therefore be topped up after test-
running. To prevent flooding over the strainer when oil drains back to the
tank after the crusher has been stopped, be very restrictive with topping-up if
the oil lines between the tank and the crusher are long.
CAUTION! Make sure that the heating tubes and the temperature transmitter (-TT3)
are always covered with oil during operation. This is to avoid
overheating in the heating elements.
Oil changes
To keep a check on the condition of the oil, it is advisable to send an oil
sample to the oil supplier each month so that suitable oil change intervals can
be established in cooperation with the supplier.
When oil is to be changed to a different brand or type, all of the oil must be
changed. This is especially important if the change is from an oil with a lead
additive to an oil with sulphur/phosphorus additives. The oil which is trapped
in the crusher must be drained out by breaking the supply line at a suitable
point between the crusher and the lubrication oil tank unit. When this is
done, the mainshaft must be raised to its highest position so that the
lubricating oil in the Hydroset piston runs out.
7.3 Oil for Hydroset system

Requirement specified
Use a high quality R&O oil containing AW and designed for circulating
system (Turbine grade). Pre-heating is necessary under start-up in low air
temperature conditions.
Oil change
Oil change according to routine oil samples every 1000 hours of operation.
The oil must comply with ISO VG 46.

Requirements for the Hydroset oil

Properties Requirement Test method
Viscosity grade 46 DIN 51 519
Type of base oil mineral or PAO
Viscosity - nominal, cSt@ 46 DIN EN ISO 3104,
40°C ASTM D-445
Viscosity index - natural ≥ 95 DIN ISO 2909,
ASTM D-2270
Specific gravity, ≥ 870 DIN 51 757,
kg/m3 @ 15°C ASTM D-1298
Flash point COC, °C ≥ 200 DIN 51 376,

ASTM D-92
Pour point, °C ≤ - 30 DIN ISO 3016,
ASTM D-97
FZG test, load ≥ 12 DIN 51 354
Oxidation stability TOST, ≥ 1 500 DIN EN ISO 4263,
hours ASTM D-943
Corrosion copper 1A DIN 51 811,
ASTM D-130
Rust preventing Pass DIN 51 585,
ASTM D-665
NOTE! Check with your supplier that the selected oil complies with the requirements
in question.
Oil quantity
When the Hydroset oil tank is filled, the mainshaft must be in its lowest
position. If the tank is filled when the mainshaft is in its highest position,
there may not be sufficient room in the tank for all of the oil when the
mainshaft is lowered.
The capacity of the Hydroset oil tank is 300 litres (79.25 US gal.).
Oil changes
The oil in the Hydroset system should be changed when the lubricating oil is
changed. See section 7.2 Oil for lubrication system - Oil changes.

7.4 Oil for pinionshaft lubrication

The pinionshaft bearings are lubricated by a separate circulatory system. A
small flow of oil is bled off from the main lubrication system and is pumped
to the oil inlet in the top of the pinionshaft housing.
Oil quantity
Oil quantity
Pinionshaft housing 3.0 litres / (0.8 US gal.)
The volume in the pinionshaft housing is limited by a level tube (1) and
excess oil returns to the main lubrication tank by gravity.
1 Level tube 2 3575-0

2 Oil level
3575-0 Level tube
3590-0 Drain plug
1 Level tube
2 Oil level
3575-0 Level tube
3590-0 Drain plug 1
3590-0
Cleaning
Remove the drain plug (magnetic plug) and clean it at least twice a year. This
will also drain out any sediment from the pinionshaft housing.

7.5 Grease for spider bearing lubrication

The motion of the mainshaft in the spider bearing is both gyratory and rotary.
The speed is relatively low and the pressure is high. It is important that the
correct grade of lubricant is used so that the grease can penetrate to the
bearing surfaces.
Requirement specification
The grease must comply with the demands in the table below in order to
guarantee lubrication of the spider bearing for long periods, under conditions
of vibration and extremely high loads. In addition, the grease must provide
good protection against corrosion. The spider bearing contains components
of alloyed steel, cast iron and nitrile rubber. The grease must therefore be
harmless to these materials.
Requirements for spider bearing grease
Properties Requirements Test method
Consistency 0 or 00 NLGI
Base oil viscosity at 40°C ≥ 400
(104°F) in mm2/s (cSt)
Thickening agent Lithium or sodium
Drop point ≥ 140°C (284°F) DIN ISO 2176
Corrosion protection Approved DIN 51 802 SKF Emcor
Other properties:
– Must contain EP additives
– Must be pumpable
The recommended operating temperature range is –10°C to +100°C (14°F to
212°F). For operation in extreme ambient temperatures, contact the lubricant
supplier.
(Continued)

Examples of greases
The examples listed below are greases which – according to the respective
manufacturer – comply with Sandvik’s requirements.
Local variations can occur in different countries. For safety’s sake, check
with your supplier that the selected grease complies with the requirements in
question.
In addition to the greases listed, a number of other brands and qualities meet
Sandvik’s requirements and are accordingly also usable.
Mobil Mobilith SHC 007 (643569) Statoil GreaseWay LiCaX90
Molub-Alloy Tribol 3020/1000-00 Texaco Marfak 00 (01907)
Grease quantity
Grease quantity
Spider bearing 7–9 kg / (15.4–19.8 lbs.)
The spider bearing must be filled with grease up to the correct level (2). This
corresponds to approximately the amount given in the table above. When the
spider bearing is being greased, the mainshaft must be in its lowest position.
Grease is normally added straight from the drum. For topping up, grease can
be pumped in through a pipe (1) inside one of the topshell spider arms.
1 Grease pipe
2 Grease level 1 5
3 Observation hole
4 Spider bearing seal
5 Air vent line
2 4
3

Checking and changing the grease

During the first few weeks of operation, the grease level should be checked
daily by unscrewing the plug in the spider cap.
Checking the grease level in the spider cap:
a) Stop the crusher.
b) Unscrew and remove the plug in the spider cap.
c) Examine the grease level by sticking a finger into the observation hole
and feeling the grease level, alternatively shine a flashlight into the hole
and observe the level.
If an unusually large quantity of grease is observed on the mainshaft beneath
the spider bearing, it is possible that the spider bearing seal has been
damaged. It is important to keep the mainshaft free of grease and stone dust
accumulations to prevent such contamination being pressed into the spider
bearing through the spider bearing seal (4) each time the mainshaft is raised.
The grease level (2) should be checked frequently and new grease should be
added when necessary. If it is damaged, the spider bearing seal (4) must be
replaced as quickly as possible. See the Maintenance manual.
Alongside the grease nipple on one of the topshell arms there is a decal
which shows the type of grease pumped into the spider bearing before
delivery. Do not mix different types of greases.
When a new mantle and/or concave ring is fitted, the spider bearing and seal
should be carefully cleaned and then filled with new grease. To avoid
unscheduled stoppages, it is recommended that the spider bearing seal (4) is
changed each time the liners are changed.


8. Hydroset and lubrication
systems
This section describes the care procedures for the Hydroset and lubrication
systems of the cone crusher.
OM Sandvik CH660:02 8. Hydroset and lubrication systems
8.1 Overview
8.1.1 Tank unit
The tank unit consists of a cabinet containing the motor-driven pumps, filters
etc. and at the rear lubrication and Hydroset oil tanks.
1
2
1 Hydroset tank cover
3
2 Lubrication tank cover
3 Identification plate
4 Cabinet 4
8.1.2 Cabinet
The cabinet contains components of the main lubrication system, pinionshaft
lubrication system and Hydroset system.

In subsequent figures, the interior of the cabinet is divided into different

views:
Main lubrication system Pinionshaft lubrication system
Hydroset system Thermostats and heaters

8.2 Main lubrication system

In the main lubrication circuit, oil is pumped from the tank through the filter
(7) and heat exchanger to the crusher’s main oil inlet. Oil entering the
crusher is pressed through the step bearing, up between the eccentric bushing
and the mainshaft, and between the bottomshell bushing and the eccentric to
lubricate these bearings. The oil lubricates the wearing plate and the bevel
gears before running back to the tank unit by gravity.
1
2 10
3
1 Pressure drop lamp
4 11
2 Temperature gauge 5 9
3 Pressure gauge 6 8
4 Lubrication oil pump unit 7 16
5 Pressure gauge connection
6 Pressure drop sensor 17
7 Oil filter
8 Dirt trap
9 Shut-off valve
10 Pressure relief valve
11 Shut-off valve
12
12 Oil inlet (return from crusher)
13 Oil outlet (to crusher)
16 Oil inlet (return from heat exchanger)
17 Oil outlet (to heat exchanger)
13

8.2.1 Dirt trap

The dirt trap (8) protects the oil pump (4) and is mounted ahead of it.
CAUTION! Clean the dirt trap regularly. If it is allowed to clog, cavitation will occur
in the pump, which can result in pump breakdown. See section
8.3.3 Cleaning the dirt trap.
CAUTION! The gauze element (19) must not, under any circumstances, be left out
or replaced by another with a different mesh.
18 Gauze element
19 Plug
18
19
8.2.2 Oil filter assembly

The filter assembly has four filter elements, which are of throw-away type.
The type of oil filter used is full-flow, which means that all oil pumped to the
crusher is filtered. See section 8.3.4 Changing filter elements.
The filter elements must be changed when the pressure drop across the filter
exceeds 0.22 MPa (32 psi) at normal operating temperature.
There is a by-pass valve on the filter assembly. It opens when the pressure
drop across the filter assembly exceeds 0.35 MPa (51 p.s.i.). When the valve
is open, part of the oil flow by-passes the filter assembly and is thus not
filtered.
NOTE! If filter elements have to be changed often, the crusher’s dust sealing system
must be checked.

8.2.3 Oil pump

Normally the lubrication oil pump (4) requires no special attention. Wear
can, however, be considerable if the oil contains stone dust or similar
contaminants. The most usual sign of pump wear is a reduction in oil flow.
CAUTION! When the pump is started, the oil tank must be full of oil so that the
pump does not operate dry. Before starting the pump, check that the
shut-off valve (9) ahead of the dirt trap (8) is open.
Exchange
The pump’s capacity at normal operating temperature and pressure is shown
in the table below. (If the motor is connected to a 60 Hz supply instead of a
50 Hz supply, the pump speed will be 20 % higher and the flow will
increase).
Exchange the oil pump when the flow has dropped below the minimum
value in the table below.
Lubricant flow l/min US gal./min
Supply frequency 50 Hz Normal capacity 120 31.7
Min. capacity 100 26.4
Supply frequency 60 Hz Normal capacity 144 38.0
Min. capacity 100 26.4
Check
Check oil delivery by measuring the return oil flow. Position a bucket with a
known volume beneath the opening in the return oil chamber and measure
the time taken to fill the bucket.
Example: It takes 5 seconds to fill a 10 litre bucket. The oil flow is thus:
(10×60)/5 = 120 l/min.

8.2.4 Pressure gauge

The pressure gauge (3) gives the pressure measured by the pressure gauge
connection (5) between the oil pump (4) and the filter assembly (7).
Check
Check the pressure at regular intervals and keep a record of the readings. At
operating temperature, the pressure in the main system is normally 0.15–
0.5 MPa (21.8–72.5 p.s.i.), depending on tank installation. If the pressure
ahead of the oil filter assembly rises, this is a sign that the filter elements
should be changed. An abnormally low pressure can mean that the pump is
worn, or that the dirt trap is choked.
2 Temperature gauge 1
3 Pressure gauge 2 10
4 Lubrication oil pump unit
3
6 Pressure drop sensor
4 11
7 Oil filter assembly 5 9
8 Dirt trap 6 8
9 Shut-off valve 7 16
17
8.2.5 Pressure drop indicator

The pressure drop sensor (6) monitors the pressure drop across the filter
assembly and gives a signal when the pressure drop exceeds 0.22 MPa (32
p.s.i.). This signal indicates that the filter elements should be changed.
The signal is given both electrically – to a pressure drop lamp (1) on the
outside of the tank unit – and in the form of a red button which protrudes
(about 4 mm) from the top of the sensor.
NOTE! During a cold start, the indicator can incorrectly give a signal due to higher
oil viscosity.
The electrical signal will automatically be reset when working temperature
has been reached, but the mechanical signal (the red button) must be reset
manually. If the red button jumps out again immediately, or if the lamp does
not go out when working temperature has been reached, the filter elements
must be changed.

8.2.6 Temperature gauge

A temperature gauge (2) monitors the return oil temperature. The return oil
temperature is affected by the load on the crusher, the ambient air
temperature and the viscosity of the lubricating oil. See section
8.2.10 Thermostats.
Check
Check the gauge once a year against a reference thermometer to ensure that it
reads correctly. Carry out this check at an oil temperature of 40–50°C (104–
122°F).
8.2.7 Pressure relief valve

A pressure relief valve (10) is fitted between the oil filter assembly (7) and
the heat exchanger. Its duty is to decrease the pressure over the pump (4) and
heat exchanger if the crusher is started at low temperature when the oil is
more viscous.
CAUTION! The valve setting must not be altered. The valve is set at 0.7 MPa
(102 p.s.i.).

2 Temperature gauge
1
3 Pressure gauge
4 Lubrication oil pump unit
2 10
5 Pressure gauge connection 3
6 Pressure drop sensor 4 11
8 Dirt trap
6 8
9 Shut-off valve
7 16
11 Shut-off valve 17
12 Oil inlet (return from crusher)
13 Oil outlet (to crusher)
16 Oil inlet (return from heat exchanger)

8.2.8 Return oil flow switch

The return oil flow is monitored by an oil flow switch inside the return oil
chamber in the oil tank.
The return oil flow switch is connected in such a way that the crusher’s drive
motor cannot be started unless sufficient oil is pumped to the crusher and
thus back to the tank via the return oil flow switch. In addition, the
lubrication oil pump (4) cannot be started unless the return oil flow switch is
functioning properly.
The return oil flow switch is connected to a float (20) in the return oil
chamber (24) in the tank and monitors whether the float is up or down. The
return oil chamber has an adjustable lower outlet (22) and an overflow
weir (21).
CAUTION! The lower outlet has been adjusted at the factory before delivery and
must not be altered.
When a sufficient flow of oil is returning to the tank, the oil level in the
return chamber should be 5 mm (0.20") above the weir. With this oil level in
the return chamber, the float is completely immersed in oil but the oil’s
lifting force pushes the float up against its upper stop.
If the oil flow decreases, the oil level will drop in the return chamber. When
the oil level has dropped about 15 mm (0.59"), the float will be floating on
the oil about 5 mm (0.20") below the upper stop. In this position the
microswitch opens and stops the crusher’s drive motor.
Check
Check the level monitor by pushing the float down about 5 mm (0.20") from
its upper stop. The crusher’s drive motor must then stop.
20
21
20 Float 22
21 Weir
23
22 Adjustable lower outlet
23 Oil strainer
24 Return oil chamber
25 Deaeration screen
25 24

8.2.9 Oil strainer

The oil strainer (23) separates coarser contaminants from the oil and
deaerates the oil.
In the tank beneath the oil strainer there is an additional deaeration screen
(25). Its purpose is to any remove air bubbles in the oil returning to the tank
and to prevent them going back to the crusher through the pump.
Check
The oil strainer requires careful inspection, and especially during the
running-in period, it should be checked daily. An abnormal amount of metal
particles on the oil strainer can indicate trouble, and the cause should be
investigated to forestall possible damage.
20 Float 20
21 Weir
21
22 Adjustable lower outlet
23 Oil strainer
22
24 Return oil chamber 23
25 24
8.2.10 Thermostats
Two thermostats have their sensing heads in the return oil chamber (24) in
the oil tank. The thermostat for the heat exchanger (TG 2) controls the
cooling of the oil pumped to the crusher, while the protective thermostat (TG
1) shuts down the crusher’s drive motor if the oil temperature is too high.
26
26 Protective thermostat TG 1 27
27 Thermostat for heat exchanger TG 2
28 Oil heating thermostat TG 3
29 Level indicator, lubrication oil tank 28
30 Heating elements
29
30
(Continued)

CAUTION! It is important that the correct temperature settings are used. Set the
thermostats according to the tables below for different operating
conditions.
TG 1 Crusher drive motor shut-down function

Operating Normal operating Operating at elevated Operating in low
conditions conditions temperature temperatures
Ambient air tempera- Max. 32°C (90°F) Max. 40°C (104°F) Below 0°C (32°F)
ture
Oil viscosity ISO VG 150 ISO VG 220 ISO VG 100
Protective thermostat TG 1
Basic setting 60°C (140°F) 65°C (149°F) 52°C (126°F)
Closes at 60°C (140°F) 65°C (149°F) 52°C (126°F)
Opens at 63°C (145°F) 68°C (154°F) 55°C (131°F)
Differential setting 1 1 1
CAUTION! The protective thermostat (TG 1) shuts down the crusher when a
serious fault occurs in the lubrication system so that the oil
temperature rises excessively, for instance if the cooling system
doesn’t work correctly. It is therefore important that none of the
components are by-passed. Check the cause of the stoppage and
correct it before the crusher is re-started.
TG 2 Oil cooling control

Operating Normal operating Operating at elevated Operating in low
conditions conditions temperature temperatures
Ambient air tempera- Max. 32°C (90°F) Max. 40°C (104°F) Below 0°C (32°F)
ture
Thermostat for heat exchanger TG 2
Closes at 45°C (113°F) 51°C (124°F) 37°C (99°F)
Opens at 40°C (104°F) 47°C (117°F) 33°C (91°F)
Check
Check the thermostat for heat exchanger (TG 2) by holding a thermometer
near the sensing head and note the temperatures at which the cooling fan or
water pump starts and stops or at which the water valve opens and closes.
Check the protective thermostat (TG 1) by immersing the sensing head in a
slowly warmed oil bath together with a thermometer. Note the temperature at
which the contacts break and then allow the oil to cool and note the
temperature at which the contacts close.

8.2.11 Oil heating

The oil should be heated to the temperature given in the table below before
the crusher is started. This is to prevent oil overflowing the dust collar.
The standard oil tank unit is fitted with electrical immersion oil heaters (29).
The heating elements are installed in tubes so that the oil is heated indirectly.
There is a separate oil heating thermostat (TG 3) (28) which controls the
heating elements.
26
26 Protective thermostat TG 1 27
27 Thermostat for heat exchanger TG 2
28 Oil heating thermostat TG 3
29 Level indicator, lubrication oil tank 28
30 Heating elements
29
30
TG 3 Oil temperature
Operating Normal operating Operating at ele- Operating in low
conditions conditions vated temperature temperatures
Ambient air temperature Max. 32°C (90°F) Max. 40°C (104°F) Below 0°C (32°F)
Suitable temperature before 30°C (86°F) 37°C (99°F) 25°C (77°F)
crusher is started
Oil heating thermostat TG 3
Closes at 30°C (86°F) 37°C (99°F) 20°C (68°F)
Opens at 35°C (95°F) 42°C (108°F) 25°C (77°F)
NOTE! The oil heating should run for 24 hours a day. The heating elements are
automatically controlled by the oil heating thermostat.
Check
Check that the heating elements and the sensor of the oil heating thermostat
are always covered by oil during operation.
8.2.12 Level indicator

Check max. oil level
Check the level on the level indicator (29) when the oil pump is not running.
The oil should not be above the max. indicator.
Check min. oil level
Check the level on the level indicator (29) when the oil pump is running. The
oil should not be below the min. indicator.

8.3 Exchanging main lubrication oil

NOTE! The following instructions can with advantage be followed in a sequence.
8.3.1 Cleaning the tank

Contaminants such as stone dust, water etc., which enter the lubricating oil
will, to a certain degree, sink towards the bottom of the tank. This should
therefore be cleaned out at least twice a year. This periodical cleaning
prevents sludge following the oil withdrawn from just above the tank bottom.
See section 8.3.5 Cleaning the return oil strainer and tank.
Condensation can be removed by taking out the screw in the water drain plug
(14) beneath the lubrication oil tank. This must be done regularly to avoid
too high a percentage of water in the oil.
Stop the pump when the oil level has dropped to just above the suction
inlet (tank outlet), as there will otherwise be a major risk of pump
damage. Never let the pump operate dry.
14 Water drain plug, lubrication oil tank

15 Drain plug, lubrication oil tank
15 14
8.3.2 Draining the main lubrication system

a) Disconnect the oil line from the lubrication outlet (13) on the tank.
NOTE! This must be done at the lowest point – usually at the oil tank connection.
b) Drain all oil from the crusher.

c) Raise the mainshaft by using the L1 push button box (31), which is
located in the vicinity of the cone crusher, to drain the lubricating oil
trapped in the Hydroset piston cavity.
d) Reconnect the oil line to the lubrication outlet (13).
e) Empty the oil from the heat exchanger by disconnecting the oil line at
the lowest point.
NOTE! The lowest point is usually at the oil tank connection.
f) Drain all oil from the heat exchanger.

g) Reconnect the disconnected oil line.
12 Lubrication inlet 12 31
(from crusher)
13 Lubrication outlet
(to crusher)
31 L1 push button box
13
h) Drain the lubrication oil tank by taking out the screw in the drain plug
(15) beneath the lubrication oil tank.
8.3.3 Cleaning the dirt trap

a) Close the shut-off valve ahead of the dirt trap.
b) Have a bucket ready to catch the oil which runs out.
c) Unscrew the plug (19).
d) Take out and clean the gauze element (18).
e) Install the gauze element and the plug.
f) Open the shut-off valve.
18 Gauze element
19 Plug
18
19
NOTE! During the running-in period, and when the tank has been cleaned, check the
dirt trap daily.

8.3.4 Changing filter elements

a) Close the shut-off valve (11) between the filter assembly (7) and the heat
exchanger.
b) Close the shut-off valve (9) between the tank and the dirt trap (8).
c) Change the filter elements.
d) Inspect the old filter elements to check for larger particles on the filter
material, as this indicates damaged or worn components in the
lubrication system.
e) Open the shut-off valve (9) between the tank and the dirt trap.
f) Open the shut-off valve (11) between the filter assembly and the heat
exchanger.
Checks
Check the pressure drop across the filter assembly (7) regularly so that new
filter elements can be ordered in good time before the next change.
NOTE! When the fan of the air/oil heat exchanger is running, the pressure in the oil
system generally rises. Avoid reading off the pressure at such times.
2 Temperature gauge
3 Pressure gauge 1
4 Lubrication oil pump 2 10
3
8 Dirt trap 5 9
9 Shut-off valve 6 8
10 Pressure relief valve 7 16
11 Shut-off valve
16 Oil inlet (return from heat exchanger) 17

8.3.5 Cleaning the return oil strainer and tank

a) Take off the cover over the lubrication oil tank.
b) Lift out the oil strainer (23).
c) Rinse contamination from the oil strainer with diesel oil or white spirit.
d) Blow the oil strainer clean with compressed air.
NOTE! Replace the oil strainer with a new one if it is damaged.
e) Check the bottom of the oil tank. If sediment is discovered, clean out
contamination from the bottom of the tank with diesel oil or white spirit.
f) Put the oil strainer back into place in the tank.
20
21
20 Float
21 Weir
22
22 Adjustable lower outlet 23
23 Oil strainer
24 Return oil chamber
25 24

8.3.6 Cleaning the air/oil heat exchanger (option)

When the lubrication oil is changed, flush out the air/oil heat exchanger with
diesel oil.
a) Pour diesel oil into the oil tank.
NOTE! The return oil line from the heat exchanger should be detached from the
crusher line and arranged so that the diesel oil runs back to the tank without
passing through the crusher.
b) Pump the diesel oil through the heat exchanger.
8.3.7 Refilling the main lubrication system

NOTE! Before filling the tank with new oil, flush out the tank, oil lines and heat
exchanger with clean new oil to remove any remaining diesel oil.
a) Refit the drain plug (15) beneath the lubrication oil tank.
b) Take off the cover over the lubrication oil tank.
c) Connect a hose to an oil drum.
d) Fill the tank with new oil (400 litres) through the oil strainer (23).
e) Check for possible leaks in connectors and valves.
f) Remove the hose from the lubrication tank.
g) Refit the cover over the lubrication oil tank and tighten the clamps.
14 Dehydration plug, lubrication oil tank

15 Drain plug, lubrication oil tank
16 Drain plug, Hydroset oil tank
17 Dehydration plug, Hydroset oil tank
15 14

8.4 Pinionshaft lubrication system

The pinionshaft bearings are lubricated by a separate circulatory system. A
small flow of oil is bled off from the main lubrication system and is pumped
to the oil inlet in the top of the pinionshaft housing. The volume in the
pinionshaft housing is limited by a level tube and excess oil returns to the
main lubrication tank by gravity.
1
2
3
4
5
6
1 Pressure drop lamp 7

2 Pressure gauge
3 Pinionshaft oil pump unit
6 Oil filter
7 Pinionshaft outlet (to crusher)
8.4.1 Oil filter

The type of oil filter (6) used is full-flow, which means that all oil pumped to
the pinionshaft housing is filtered. The filter element is of the throw-away
type.
The filter element must be changed when the pressure drop across the filter
exceeds 0.22 MPa (32 psi) at normal operating temperature.
There is a by-pass valve in the filter base. It opens when the pressure drop
across the filter exceeds 0.35 MPa (51 p.s.i.). When the valve is open, part of
the oil flow by-passes the filter and is thus not filtered.
Check
Check the pressure drop across the filter (6) regularly so that new filter
elements can be ordered in good time before the next change.

8.4.2 Oil pump

The pinionshaft oil pump unit (3) has a capacity of 0.7 l/min. (0.18 US gal./
min.) at normal operating temperature and pressure, when the motor is
connected to a 50 Hz supply. (If the motor is connected to a 60 Hz supply, the
flow will be 0.8 l/min. (0.21 US gal./min.)).
Exchange
Exchange the pinionshaft oil pump (3) when the flow has dropped below
0.5 l/min. (0.13 US gal./min.).
Check
Check the oil delivery by disconnecting the outlet line (7) from the
pinionshaft housing and measuring the time taken to fill a bucket with a
known volume. Carry out this check above the opening of the main
lubrication oil tank – after removing the cover – to avoid oil spillage.

The pressure gauge (2) gives the pressure measured by the pressure gauge
connection (4) between the oil pump (3) and the filter (6).
Check
Check the pressure at regular intervals and keep a record of the readings. If
the pressure ahead of the oil filter rises, this is a sign that the filter should be
changed. An abnormally low pressure can mean that the pump is worn.
8.4.4 Pressure drop indicator

The pressure drop sensor (5) monitors the pressure drop across the filter and
gives a signal when the pressure drop exceeds 0.22 MPa (32 p.s.i.). This
signal indicates that the filter element should be changed.
The signal is given both electrically – to a pressure drop lamp (1) on the
outside of the tank unit – and in the form of a red button which protrudes
(about 4 mm) from the top of the sensor.
NOTE! During a cold start, the indicator can incorrectly give a signal due to higher
oil viscosity.
The electrical signal will automatically be reset when working temperature
has been reached, but the mechanical signal (the red button) must be reset
manually. If the red button jumps out again immediately, or if the lamp does
not go out when working temperature has been reached, the filter element
must be changed.

8.5 Water/oil heat exchanger (option)

Plate-type heat exchangers normally need no maintenance. When the
lubricating oil is changed – or if the oil channels are blocked – flush out the
heat exchanger by pumping diesel oil through the oil channels.
1
2
1 Oil in
2 Water out
3 Water in
4 Oil out (to crusher)
3
4
If the water channels are blocked by dirt, flush them out by reversing the
water flow direction. If the water channels are blocked by lime, clean them
out with a deliming agent, e.g. a 15% hydrochloric acid solution which is
then neutralized with a 5% soda solution and finally flushed out with clean
water.
NOTE! Ventilate the heat exchanger when a deliming agent is used, to provide
ventilation for any gas which may be produced.
To control the temperature, the thermostat for heat exchanger TG 2 can be

used to start and stop a water pump. If instead the supply pipe is connected
via a solenoid water valve, thermostat TG 2 can be used to open and close
the valve. The amount of water required depends on the water temperature,
etc.
NOTE! If a water/oil heat exchanger is used, set the thermostats TG 1, TG 2 and
TG 3 at the values given for “normal operating conditions”, whatever the
ambient air temperature. See section 8.2.10 Thermostats and section
8.2.11 Oil heating.
Use clean fresh water. If only contaminated water is available, contact

Sandvik first!
NOTE! Drain all water out of the heat exchanger if the crusher is shut down during
the winter (below 5°C/41°F).

8.6 Air/oil heat exchanger (option)

Keep the cooling efficiency as high as possible by regularly blowing the air/
oil heat exchanger core clear with compressed air. If vibration occurs in the
fan, it should be cleaned or replaced, to avoid damage to the heat exchanger.
To provide the maximum cooling effect, the air must be sucked through the
heat exchanger core.
Air
Since there is a large oil flow through the heat exchanger, the oil inlet to the
1 radiator core can be either at the top or the bottom. It is normally
unnecessary to bleed air from the heat exchanger.
1 Air/oil heat
exchanger The fan motor is controlled by the thermostat for heat exchanger TG 2. See
section 8.2.10 Thermostats.
8.7 Hydroset system

The Hydroset system makes it possible to change the crusher’s setting. The
setting of the crusher is changed by raising (setting decrease) or lowering
(setting increase) the Hydroset piston and the mainshaft assembly (complete
with mantle) which is supported by the Hydroset piston. When the setting is
decreased, oil is pumped into the Hydroset cylinder. When the setting is
increased, oil is pumped back to the Hydroset tank. The tank has a pressure
gauge (1) which indicates the pressure in the Hydroset system.
2
3
4
5
6
1 Pressure gauge 7
2 Oil filter
3 Hydroset pump unit
4 Damping valve
5 Control valve
6 Dirt trap (magnetic plug)
7 Hydroset connection

8.7.1 Hydroset pump

The Hydroset pump (3) is a reversible gear pump.
When the pump is started, the tank must be filled with oil up to the right
level.
8.7.2 Oil filter

The type of oil filter used is full-flow, which means that the oil passing
through is filtered. The filter element is of throw away type.
Exchanging the filter element
Change the filter element each time the Hydroset oil is changed or every six
months.
8
a) Relieve the pressure in the system by lowering the mainshaft and
Hydroset piston to their bottom position. Use the L1 push button box (8)
which is usually located in the vicinity of the cone crusher.
b) Unscrew the filter bowl, take out the filter element and replace it with a
new one.
8.7.3 Dirt trap (magnetic plug)

The purpose of the magnetic plug (6) is to remove magnetic particles from
the system.
NOTE! If the crusher is fitted with an the ASRi system, the magnetic plug is replaced
with a sensor.
Cleaning
Clean the dirt trap each time the Hydroset oil is changed or every six months.
a) Relieve the pressure in the system by lowering the mainshaft and
Hydroset piston to their bottom position. Use the L1 push button box (8).
b) Have a bucket ready for escaping oil.
c) Unscrew and clean the magnetic plug.

8.7.4 Control valve

Between the crusher and the Hydroset pump is the control valve (5), which is
a flow-actuated non-return valve. A pressure limiting valve is incorporated to
protect the pump.
Emergency manual valve actuation
The control valve (5) has a manual actuation facility for emergency use if
contamination in the oil has blocked the valve so that normal motorised
setting increase is impossible.
Manual operation is carried out as follows:
a) Unscrew the cap (11).
b) Push in the pin (10). If this cannot be done by hand, place a Ø10 mm ball
or other suitable object in the cap and screw it back on so that the pin is
pushed in.
c) Start the pump for setting increase (by using the L1 push button box (8))
and lower the mainshaft to the desired position.
d) Stop the pump.
NOTE! If the valve does not operate correctly, it must be removed and cleaned. If the
valve does operate correctly, replace the cap (11).
Always keep the Hydroset system clean to reduce the risk that contamination
interferes with the valve.
9
9 Pressure limiting valve
10
10 Pin
11 Cap 11


The pressure gauge (1) displays the Hydroset pressure, measured at the
control valve (5).
A damping valve (4) between the Hydroset line and the pressure gauge
provides a smoother pressure reading when the crusher is in operation.
Cleaning
Open the damping valve (4) once each week to clean out the needle valve.
When this has been done, close the damping valve until the pointer of the
pressure gauge (1) moves smoothly during normal operation.
1 Pressure gauge
2 Oil filter 1
3 Hydroset pump
2
4 Damping valve
5 Control valve
3
6 Dirt trap (magnetic plug) 4
7 Hydroset connection 5
6
8.7.6 Level indicator

The Hydroset tank has a level indicator. The level indicator is a two piece
serial system.
Check max. oil level
a) Lower the mainshaft to the bottom by using the L1 push button box (8),
which is located in the vicinity of the cone crusher.
b) Check the level on the upper level indicator (12). The oil should not be
above the max. indicator.
Check min. oil level
Check the level on the lower level indicator (13). The oil should not be
below the min. indicator, whatever the mainshaft position.
8 L1 push button
box
12 Upper level
indicator
13 Lower level 12
indicator
8
13

9. Accumulators
This section describes the care procedures for the accumulators of the cone
crusher.
OM Sandvik CH660:02 9. Accumulators
9.1 General
Risk of explosion
A damaged accumulator entails a risk of explosion. Protect the
accumulator from mechanical or thermal damage (impact, welding,
WARNING! etc.).
The accumulator (1) is a cylindrical steel pressure vessel which contains a

rubber bladder fixed at the top of the vessel by a charging valve. The rubber
bladder is filled with Nitrogen. There are two accumulators on this crusher
type. They are mounted on the two feet opposite the pinionshaft. Each
accumulator is connected to the Hydroset cylinder cover by a hose. The
Hydroset line to the tank unit is connected to the flow regulator beneath one
of the accumulators.
1 Accumulator
2 Anti-extrusion valve
3 Air bleed screw
4 Flow regulator 1
2
3
4
Increase of setting due to overload

Oil is forced out of the Hydroset cylinder and into the accumulator, allowing
the mantle to sink far enough to let the tramp iron pass through the crushing
chamber. The gas pressure in the accumulator forces the oil back into the
Hydroset cylinder as soon as the obstruction has left the crushing chamber
Owner’s responsibility
The crusher’s owner must arrange for re-certification of the accumulator (1)
if there are grounds to suspect that the accumulator has been damaged. New
components are best obtained from Sandvik.

9.2 Flow regulator

The flow regulator (4) is a throttling check valve between the Hydroset
cylinder and the accumulator (1). It prevents the mainshaft rising too quickly
after the tramp iron has passed through the crusher. When oil flows from the
crusher to the accumulator, it passes unhindered through the flow regulator.
When the oil returns from the accumulator, it is slowed down so that the
mantle is slowly raised to its original position.
9.3 Charging kit (option)

Risk of explosion
Use only nitrogen (N2) in the accumulator. A mixture of air (oxygen)
and oil under high pressure constitutes a risk of explosion.
WARNING!
An optional charging kit (FPU-1) can be used to check the gas pressure in the
accumulator and to add nitrogen when necessary. The charging kit consists
of a connector assembly with pressure gauge and bleed valve, a hose and an
adapter for connection to the accumulator.

9.3.1 Checking the gas pressure

Fitting the charging kit
a) Unscrew the protective cap (1) and (2) from the accumulator’s charging
valve.
b) Unscrew the internal hexagon screw (6) so the cut on its side is visible
over the top of the adaptor (5).
c) Close the bleed valve (8).
d) Attach the adaptor (5) to the accumulator’s charging nipple (3). Tighten
by hand sufficiently to prevent gas leakage.
e) Attach the screw connector (7) to the adaptor (5). Tighten by hand
sufficiently to prevent gas leakage.
f) Screw down the spindle (9) so that the valve in the accumulator opens.
g) Read off the charging pressure on the pressure gauge.
Removing the charging kit
h) Unscrew the spindle (9).
i) Open the bleed valve (8).
j) Unscrew the screw connector (7) and remove the charging kit (FBU-1).
k) Unscrew the adaptor (5) and remove the adapter from the accumulator’s
charging nipple (3).
l) Check that there is no gas leakage from the valve. Use soapy water or oil
for this check.
m) Refit the protective caps on the accumulator’s charging valve.
9
FPU-1
1
2 10 11
8 7
3 6 12
4
5
1 Protective cap 7 Screw
2 Protective cap connector
3 Nipple 8 Bleed valve
4 O-ring 9 Spindle
5 Adaptor 10 Connector
6 Hexagon screw 11 Charging hose

9.3.2 Charging with nitrogen

Accumulator charging pressure Tolerance
Without ASR / With ASR Plus 4.2 MPa (610 p.s.i.) ±5 %
With ASRi 6.0 MPa (870 p.s.i.) ±5 %
a) Attach the screw connector (12) with the charging hose (11) to the
nitrogen gas bottle.
b) Unscrew the protective cap (1) and (2) from the accumulator’s charging
valve.
c) Unscrew the internal hexagon screw (6) so the cut on its side is visible
over the top of the adaptor (5).
d) Close the bleed valve (8).
e) Attach the adaptor (5) to the accumulator’s charging nipple (3). Tighten
by hand sufficiently to prevent gas leakage.
f) Attach the screw connector (7) to the adaptor (5). Tighten by hand
sufficiently to prevent gas leakage.
g) Screw down the spindle (9) so that the valve in the accumulator opens.
h) Carefully open the valve on the nitrogen gas bottle so that the bladder
expands slowly inside the accumulator and closes the oil valve. Check
that this is the case before raising the pressure to the full charging
pressure given in the table above.
NOTE! Take into account that the pressure in the accumulator will drop slightly
when the compressed gas cools down. Charge the accumulator bladder to
20 % above the desired pressure.
i) Close the valve on the nitrogen gas bottle and wait for five minutes.
Check the pressure. If the pressure is too high, release gas through the
bleed valve (8) until the correct pressure is reached.
j) Unscrew the spindle (9).
k) Open the bleed valve (8)
l) Unscrew the screw connector (7) and remove the charging kit (FBU-1).
m) Unscrew the adaptor (5) and remove the adapter from the accumulator’s
charging nipple (3).
n) Check that there is no gas leakage from the valve. Use soapy water or oil
for this check.
o) Refit the protective cap (1) and (2) on the accumulator’s charging valve.
p) Remove the charging kit from the nitrogen gas bottle.
NOTE! Check again the charging pressure after 1, 2 and 3 weeks and thereafter at 6-
month intervals.


10. Topshell assembly
This section describes the care procedures for the topshell assembly of the
cone crusher.

OM Sandvik CH660:02 10. Topshell assembly
10.1 Exchanging the spider cap

Replaceable parts:
Description Cat. no. Qty. Remarks
Spider cap 5650-0 1 weight 340 kg
O-ring 5651-0 1
Screw M6S 20×65 5655-0 4
Washer TBRB 21x36 5655-2 4
NOTE! Remove the feed distributor (if fitted) and clean out the feed hopper from
processing material before removing the spider cap.
10.1.1 Removing the spider cap

Recommended tools
Lifting tackle and chain
a) Clean off processing material from the spider cap (5650-0).
Lifting sling b) Remove the four screws (5655-0) and washers (5655-2) that hold the
Mobile crane spider cap to the topshell (5005-0).
Feeler gauge
Rags
c) Position the hook of a crane vertically above the spider cap (5650-0).
30 mm Open end wrench d) Attach the lifting hook to the lifting eye (3) on the spider cap (5650-0).
e) Take up the slack in the lifting tackle.
Hanging load
Be aware of the weight of the spider cap, see table above. Handle the
spider cap with care. The tackle should now be tight but not lifting the
DANGER! spider cap. Keep clear of hanging loads, see section 2. Safety
precautions.
f) Carefully lift the spider cap from the topshell.

g) Remove the O-ring (5651-0) from the spider cap (5650-0).
h) Place the spider cap (5650-0) on the ground.
i) Clean out all grease from the spider bearing.
3 Lifting eye
5651-0 O-ring
3
5655-0 Screw 5655-0,-2
5655-2 Washer
5650-0 Spider cap
5650-0
5651-0

10.1.2 Spider cap removal checks

– Measure the play at the pivot point. See section 10.3 Spider bearing
for further information. Record the play and compare with earlier
measurements.
S
– Clean and check the O-ring (5651-0) and the rim of the spider cap
(5650-0) and topshell where the O-ring fits. If the O-ring is damaged
it must be replaced.
– Check for wear on the spider cap (5650-0). If worn, weld on wear
protection or exchange the spider cap.
– Clean and check the air vent passages in the spider cap and topshell
with compressed air.
– Check that the lubrication passage through the topshell is
unobstructed.
10.1.3 Installing the spider cap

a) Fill the spider bearing with grease before the spider cap is fitted, in
accordance with section 7.5 Grease for spider bearing lubrication.
b) Check that the grease supply line is open by pumping in a little grease.
c) Position the hook of a crane vertically above the spider cap (5650-0).
d) Attach the lifting hook to the lifting eye (3) on the spider cap (5650-0).
e) Take up the slack in the lifting tackle.
Hanging load
Be aware of the weight of the spider cap, see table above. Handle the
spider cap with care. The tackle should now be tight but not lifting the
DANGER! spider cap. Keep clear of hanging loads, see section 2. Safety
precautions.
f) Carefully lift the spider cap from the ground.

g) Grease the O-ring (5651-0) and position it on the topshell.
h) Place the spider cap on the topshell. Install the four screws (5655-0) and
washers (5655-2).

10.2 Inspection of crushing chamber

• Inspect the liners at the correct intervals. See section 6.1 Routine
inspection and care. A new machine must be inspected frequently. After
two liner changes, the intervals between inspections can be successively
increased.
• These routine inspections will give an indication of when the liners must
be changed. It is difficult to give an exact limit at which the liners are
worn out. They are probably worn out when capacity drops off or when
the thickness has been reduced so much that indentations or cracks have
occurred.
Extreme operating conditions can require liner replacement before the liners
are “worn out”. One reason can be incorrect feeding so that increased wear
occurs over a certain section of the concave ring. This also means that the
setting varies according to where measurement is carried out around the
crushing chamber. Examples of different feed arrangements are given in the
Installation manual.
A A-dimension A
B Groove
C Groove
B
C

Inspect the liners to avoid:

a) Expensive damage to the contact surfaces of the topshell and the
headcentre.
b) Loss of production due to reduced capacity, an incorrect final product or
an unscheduled shut-down.
Problems similar to those caused by an incorrect feeding arrangement can
also be experienced if the feed material is not an evenly graded mixture. If a
large proportion of the feed is close to the maximum size, crushing will be
concentrated to the upper portion of the chamber. This can give rise to an
annular groove around the entire crushing chamber (B groove). A large
proportion of fine material in the feed concentrates crushing to the lower part
of the chamber (C groove).
The benefits gained by continuing to crush with worn liners are small in
comparison with the disadvantages described above. Planned liner
replacement at the right time always gives optimum operating economics.
In addition, the liners must be replaced if the maintenance of the desired
setting entails raising the mainshaft so high that the distance between the
head nut and the underside of the spider (A-dimension) is less than 20 mm
(0.78").
Liner wear is compensated for by hydraulically raising the mainshaft so that
the desired setting can be maintained.
The A-dimension is an indication of the position of the mainshaft inside the
crusher.
CAUTION! Never raise the mainshaft so far that the A-dimension is ≤ 20 mm (0.78").
If the mainshaft is raised further it can cause damage to the spider
bearing in the topshell.
NOTE! The liners are normally worn out before this limit is reached.
Each crushing chamber is designed for a specific setting interval.

Example:
EC (extra coarse) chamber
The crushing chamber’s theoretical setting interval is 16–51 mm (0.63–2.0").
If the crusher runs with 16 mm (0.63") setting, the smallest A-dimension
20 mm (0.78") will be reached faster than if the crusher runs with 51 mm
(2.0") setting. With larger settings the liners are worn out long before the
smallest A-dimension is reached.
It is difficult to estimate the A-dimension at which the liners are worn out,
since this depends on the wear profile of the crushing chamber (see above).
Experience with the crusher and visual inspections are necessary to
determine when the liners should be changed.

10.3 Spider bearing

The spider bearing is level with the pivot point (a dot in the figure) for the
gyratory movement of the mainshaft. The spider bushing is hourglass-shaped
with a tapered outer surface.
10.3.1 Inspecting the spider bearing

Max. permissible play and position of pivot point
S mm/(inches) L mm/(inches)
2.4/(0.094) 165/(6.5)
Check the play in the spider bearing (S) each time the liners are changed or at
least twice per year (1000 h). Check the play more frequently if the material
being crushed is abrasive.
If the play (S) is close to the maximum permissible, and it is decided to keep
running with the old bushing, the lubricant must be checked and topped up
more frequently than normal. See also section 7.5 Grease for spider bearing
lubrication.
(Continued)

When the play (S) is being measured, the mainshaft must be pushed in the
direction in which it is inclined and the measurement should then be made on
the opposite side with a feeler gauge. Measure on a level with the pivot point
(L). Feeler gauges are included in the tool kit supplied with the crusher.
NOTE! Avoid damaging the spider bearing seal and the scraper with the feeler
gauge.
If the play exceeds the maximum permissible value, the spider bushing and/
or the mainshaft sleeve must be replaced. When the bearing is dismantled,
the old components can be measured and compared with the measurements
obtained from new components to determine which item is most worn and
whether acceptable play can be obtained if just one item is replaced.
If the play considerably exceeds the maximum permissible value, the
mainshaft has been given an abnormal inclination during crushing and has
thus worn the eccentric bushing at an incorrect angle. In such a case, the
eccentric bushing must also be changed.


11. Setting measurement
This chapter describes the measurement of the CSS, the discharge setting.

OM Sandvik CH660:02 11. Setting measurement
11.1 General
The setting adjustment system is designed to compensate for mantle and
concave ring wear and to change the CSS (close side setting) of the cone
crusher.
The frequency with which the CSS must be checked normally depends on
the rate at which the crushing liners wear. A more abrasive stone will require
frequent checks, whereas a non-abrasive material will require only
occasional checks.
Regular inspection of the concave rings is recommended for good total
economy and to make sure that it has not been worn unevenly or they have
become oval. Also look for any localized wear or other damage in the
crushing chamber. If the crushing liners are worn, the mantle (on the
mainshaft) cannot be raised so high that it comes into contact with the
concave ring without a risk of the mainshaft’s head nut contacting the
underside of the crusher’s spider hub. This occurs relatively early in the case
of a coarse crusher which operates with a large CSS.
CAUTION! Never raise the mainshaft so far that the A-dimension is ≤ 20 mm (0.78").
If the mainshaft is raised further it can cause damage to the spider
bearing in the topshell. See section 10.2 Inspection of crushing
chamber.
setting decrease = finer product setting increase = coarser product
= =
11.1.1 Checking the setting with lead

See section 4.2.1 Checking the setting with lead.

12. Troubleshooting
This chapter comprises a guide for correcting various problems that can
appear during operation.
It is not intended that personnel in the Operator’s work role should carry out
corrective actions. The Operator’s work role is to identify the fault or error
and report to a supervisor. The supervisor decides on the appropriate action.

OM Sandvik CH660:02 12. Troubleshooting
12.1 Faults and suggested corrective actions

The following table shows possible causes and suggested corrective actions
for a number of different fault conditions.
No. Fault Check Corrective action
1 Cone crusher No “Ready for start” signal and oil Check electrical circuits and starter of pump motor.
will not start pump not running Start the pump.
No “Ready for start” signal and If the return oil flow is low, wait a few minutes to see
lubrication oil flow low if it stabilizes.
Check that oil does not overflow over dust collar.
Check oil lines and remove obstacles if return line is
blocked.
Clean dirt trap, see 8.3.3. If necessary, change filter
elements, see 8.3.4.
Check pump capacity. See No. 13. Low or no oil
capacity.
Normal lubrication oil flow, but no Check operation of return oil flow switch, see 8.2.8.
“Ready for start” signal. If protective thermostat TG 1 shuts down crusher,
check operation of thermostat, see 8.2.10.
If pinionshaft oil pump is not running, check electrical
circuits and starter of pump motor. Start pinionshaft
oil pump.
Oil pump running and “Ready for Check starter of crusher’s drive motor and other
start” signal obtained electrical circuits. See Installation manual.
Oil does not return to tank (in low Start oil pump. Let it run approx. 30 s. Bridge over
temperature) return oil flow switch so that “Ready for start” signal
is obtained. Start crusher. Let it run approx. 20 s.
Remove bridge over return oil flow switch after
approx. 40 s. If crusher still will not start, repeat
sequence again after a couple of minutes. See also
and Installation manual.
2 Crusher stops Oil pump not running Check electrical circuits and starter of pump motor.
when idling or Start pump.
with material Low lubrication oil flow Check that oil does not overflow over dust collar.
in the cham- Check oil lines and remove obstacles if return line is
ber blocked.
element, see 8.3.4.
Check pump capacity. See No. 13. Low or no oil
capacity.
Normal lubrication oil flow Check operation of return oil flow switch, see 8.2.8.


2 Crusher stops Oil too hot See No. 3. Lubrication oil temperature too high.
when idling or Pinionshaft oil pump not running Check electrical circuits and starter of pump motor.
with material Start pinionshaft oil pump.
in crushing
chamber V-belts slipping Adjust V-belt tension. Change V-belts if necessary.
Reduce load on crusher. See “Crusher’s drive motor
overloaded” below.
Crusher’s drive motor overloaded Check that eccentric throw and crushing chamber
are correct for chosen CSS and material being
crushed. Increase setting if too small.
Check for bearing failure or seizure in the crusher,
see No. 9. Bearing failure inside crusher.
Packing in crushing chamber Is material wet? Is fine content high. Increase CSS.
See 5.6.
Tramp iron or blockage in crush- Lower the mainshaft to remove the obstruction.
ing chamber. Check the liners for damage or looseness. Reset
drive motor and overload protection. Check V-belt
tension and adjust if necessary.
If lowering mainshaft doesn’t help, it might be neces-
sary to loosen topshell bolts. See Maintenance man-
ual.
3 Lubrication oil Protective thermostat TG 1 shuts Check operation of oil cooling system and thermostat
temperature down crusher for heat exchanger TG 2, see 8.2.10.
too high For a water/oil heat exchanger, check that water
channels are not blocked, see 8.5.
For an air/oil heat exchanger, check fan motor and
starter. Clean radiator core. Check that there is suffi-
cient cooling air. See 8.6.
Protect heat exchanger and tank unit from direct
sunlight.
Check that pressure relief valve does not leak so that
heat exchanger will be by-passed, see 8.2.7.
If there is a contamination increase in return oil
strainer, investigate possible incipient bearing failure.
See 8.2.9 and No. 8. Increasing bearing component
wear.
Heat exchanger cooling continu- See No 3. “Protective thermostat TG 1 shuts down
ously. the crusher” above.
If lubrication oil viscosity is incorrect, change oil. See
7.2 and 8.3.
Low lubrication oil flow Check oil lines and remove obstacles.
elements, see 8.3.4.
Check pump capacity. See No.13. Low or no oil
capacity.
Doc. no. S 223.626en Ver. 02 © 2010 Sandvik SRP AB 115


4 Crusher will Low Hydroset pressure Check capacity of Hydroset pump. If necessary,
not hold a change pump.
constant Leakage in Hydroset system Check Hydroset oil lines. If possible – without going
CSS, or prod- below the smallest A-dimension (see 10.2) – raise
uct is over- mainshaft until liners have metal-to-metal contact.
sized Don’t exceed maximum Hydroset pressure (see
4.2.4). Check Hydroset pressure gauge to see if
pressure is falling. Seal or replace relevant compo-
nents.
Pressure relief valve leaking. Set- If there are overload pressure peaks, change feed
ting increase has caused oil level arrangement. Crusher should be choke fed without
to rise in Hydroset tank. segregation. See Installation manual.
If there are no overload pressure peaks, change
pressure relief valve.
Hydroset control valve leaking, Clean or replace Hydroset control valve.
see 8.7.4. Setting increase has
caused oil level to rise in Hydro-
set tank.
Hydroset packing leaking Check if oil level has risen in lubrication oil tank.
Replace Hydroset packing. Check Hydroset cylinder
bushing, replace if necessary.
Air in Hydroset system or accu- Bleed air from Hydroset system, see 4.2.3.
mulator gas pressure too low. Charge accumulator to correct pressure, see 9.3.
CSS increases during crushing Replace accumulator bladder or complete accumula-
but returns to pre-set value dur- tor if necessary.
ing idling.
Accumulator bladder damaged. Replace accumulator bladder or complete accumula-
Mainshaft “climbs” to metal-to- tor. Bleed air from Hydroset system, see 4.2.3.
metal position when crusher is
idling, or nitrogen leaking from
accumulator bladder, giving milky
white colour in Hydroset oil.
Crusher’s feed not evenly distrib- Change feed arrangement. Crusher should be choke
uted. Hydroset pump cannot fed without segregation. See Installation manual.
reduce CSS because of pressure
peaks.
Liners worn Check liners for wear or looseness.
Liner ovality Check setting at 4 points evenly spaced around the
crushing chamber, as described in 4.2.1. The differ-
ence between the largest and smallest reading is an
indication of the ovality.
Headcentre loose Check if there is play between headcentre and main-
shaft. See Maintenance manual.


5 Points to High temperature inside and out- Check that level tube and drain plug do not leak, see
watch regard- side pinionshaft housing. 7.4. Check that there are no other leaks.
ing pinion- Oil leakage through outer bearing Check that pinionshaft lubrication pump is running
shaft cover. and that oil reaches pinionshaft housing.
assembly
Remove pinionshaft assembly for inspection. If nec-
essary, replace worn bearings and seals. See Main-
tenance manual.
Check if outer seal ring, spacer ring or O-ring is worn
or damaged. Remove pinionshaft assembly for
inspection. If necessary, replace worn components.
See Maintenance manual.
Abnormal noise in pinionshaft Remove pinionshaft assembly for inspection. If nec-
assembly. Incipient bearing fail- essary, replace worn components. See Maintenance
ure. manual.
Vibration in crusher or pinionshaft Check V-belt pulleys. Clean off any collected dust.
housing. Check V-belt tension. Check if they are flapping.
Remove pinionshaft assembly for inspection. If nec-
essary, replace worn components. See Maintenance
manual.
Excessive axial play in bearings Check frequently for increasing noise or rising tem-
because of heavy wear on rollers perature in pinionshaft assembly. Schedule removal
and races and bearing replacement for a convenient time.
6 Abnormal Incorrectly fitted bevel gears or Remove pinionshaft assembly. Measure correct gas-
noise in incorrect gear meshing causing ket thickness. Adjust backlash. See Maintenance
crusher noise from gears. Insufficient manual.
backlash emitting a high-fre-
quency rattle.
Heavy wear on eccentric wearing Strip down crusher and replace eccentric wearing
plate leading to reduced back- plate. Readjust backlash. See Maintenance manual.
lash. Insufficient backlash emit- If eccentric wearing plate wear accelerates, see No.
ting a high-frequency rattle. 8. Increasing bearing component wear.
Crushing liner loose Check and tighten concave ring bolts. Check if there
is play between headcentre and mantle. See Installa-
tion manual.


6 Abnormal Unusual noise from spider bear- Check grease level and add more frequently if nec-
noise in ing when material is fed essary, see 7.5 and 10.3.
crusher Measure play at pivot point. If more than permissible,
replace spider bushing and/or mainshaft sleeve. If
permissible play is considerably exceeded, it might
also be necessary to replace eccentric bushing. See
10.1, 10.3 and Maintenance manual.
“Grating” step bearing compo- Reduce crusher’s operating load. Extend running-in
nents period, see 4.2.
If there is a contamination increase on return oil
strainer, investigate possible incipient bearing failure.
See 8.2.9 and No. 8. Increasing bearing component
wear.
Check for liner ovality.
Packing in crushing chamber or Check operating conditions and CSS. Increase set-
liners “metal to metal” ting.
Check for liner ovality.
Movement between flanges of Check with a feeler gauge if there is play between
topshell and bottomshell flanges. Tighten bolts. If there is still movement
between topshell and bottomshell flanges, tapered
joint needs machining. Contact Sandvik. See Mainte-
nance manual.
Excessive Hydroset action Check lower section of crushing chamber for “ski-
slopes” on the mantle and concave ring. Change lin-
ers.
7 Crusher’s “Ski-slope” formed on liners. Check feed arrangement. Make sure crusher is
capacity choke fed. Check top size and bottom size of
drops crusher’s feed. There must not be a large proportion
of material smaller than CSS. See 10.2 and Installa-
tion manual.
Extremely large play in spider Check spider bearing play, see 10.1 and 10.3. If
bearing. there is exceptionally large play in spider bearing,
check condition of eccentric bushing.
V-belts slipping Adjust V-belt tension. Change V-belts if necessary.
Inspect grooves in V-belt pulleys. See Maintenance
manual.
Feed material or composition has Altered fraction length and material hardness can
been changed. lead to changes in capacity. See Installation manual.
Bridging or blocking in crushing Check material level in feed hopper. If possible, limit
chamber. top size of feed. See Installation manual.


8 Increasing Contaminated oil leading to Check oil condition regularly. Clean tank. Change oil
bearing com- increased wear on eccentric at regular intervals. See 8.3.
ponent wear wearing plate
Oil filter blocked Change filter elements, see 8.3.4.
Dust seal ring worn or damaged If play between dust collar and dust seal ring
exceeds value given in 6.2.1, replace dust seal ring.
Over-pressure dust sealing sys- Inspect entire over-pressure system and check oper-
tem not working ation. See Maintenance manual.
9 Bearing fail- Mainshaft assembly rotates very Strip down crusher to inspect bearing components.
ure inside fast or at same speed as eccen- See Maintenance manual.
crusher tric. Seizure or incipient seizure
between mainshaft and eccentric
bushing.
Pinionshaft cannot be turned. If possible, take out bolts holding dust collar.
Seizure between eccentric and Remove mainshaft assembly and complete eccentric
bottomshell bushing. assembly. See Maintenance manual.
Pinionshaft cannot be turned. See Maintenance manual.
Bearing failure in pinionshaft
assembly.
Increased amount of swarf on Remove step bearing components. De-burr edges of
return oil strainer. Seizure in step oil grooves. Polish bearing surfaces of bushings and
bearing or bronze bushings. step bearing components. If necessary, replace step
bearing components. Inspect bearing surfaces of
bushings. See Maintenance manual.
Needle-like particles on the See Maintenance manual.
return oil strainer. Seizure or
wear in bevel gears.
Tin or lead flakes on return oil See No. 3. Lubrication oil temperature too high.
strainer. High temperature or
localized overheating and partial
seizure in bushings or step bear-
ing components.
10 Oil contami- Bronze particles on return oil Investigate possible incipient bearing failure. See
nated strainer 8.2.9 and No. 8. Increasing bearing component
wear.
High return oil temperature See No. 3. Too high lubrication oil temperature.
Excessive Hydroset pressures See No. 4. Crusher will not hold a constant CSS, or
product is oversized.
Dirt Check dust seal. A worn dust seal will allow dust into
the system.


11 Broken Incorrect torque Replace all bolts if any is defect. Use only bolts
Hydroset intended as Hydroset bolts. Tighten to recommended
bolts torque.
High Hydroset pressure Operating crusher with excessive tramp metal in the
circuit can cause Hydroset bolts to fail. Remove
tramp metal ahead of crusher.
12 Broken con- Worn topshell Inspect seating area for concave ring during a liner
cave bolts change. Remove any upset metal that may stop the
concave ring from seating correctly in topshell.
Incorrectly tightened bolts Tighten bolts correctly. See Maintenance manual.
13 Low or no oil Pump sucks air through a leak Replace suction lines, if leaking.
capacity Replace shaft seal, if leaking.
Pump rotates in wrong direction Change direction of rotation. See Maintenance man-
ual.
High pressure but still low capac- Exchange oil, see 8.3.
ity because of wrong type of oil
Pump is dry Fill with oil.
Suction line blocked Remove obstruction.
Broken pump, e.g. cavitation in Replace pump.
pump or broken gear teeth.

Appendix A: Inspection
Make a copy of the inspection checklist and inspection notes in this appendix
and use them together with section 6.1 Routine inspection and care.
OM Sandvik CH660:02 A-1

OM Sandvik CH660:02
A-2 © 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02

Symbols to be marked in the squares: Week no: Week no: Week no: Week no:
X = No remarks
No. = See corresponding number in “Inspection notes” Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa Su Mo Tu We Th Fr Sa
DAILY:
Check oil level in lubrication tank.
Check oil level in Hydroset tank.
Check that shut-off valves between tanks and pumps are fully open.
Check that no material has built up on bottomshell arms.
Check that lubricating oil returns to tank and that oil is clean.
Check that oil lines do not leak.
Check that pinionshaft lubrication circuit is operating correctly.
Check CSS.
Check that material has not jammed in feed hopper or distributor and blocked feed opening.
Listen for abnormal noises in crusher.
Listen for abnormal noises in lubrication pump.
Check return oil temperature.
Check drive motor current or power consumption.
Check Hydroset pressure and that pressure gauge damping is correct.
Check temperature of pinionshaft housing.
Check oil pressure of main lubrication system and pinionshaft lubrication system at normal operating
temperature.
Check that there is no oil leakage.
Check that no bolts have come loose.
Check that oil heaters are working.
Check distance between head nut and underside of spider (i.e. A-dimension).
Check that there is no contamination increase or change on return oil strainer, e.g. an abnormal amount of
metal particles.
WEEKLY:
Inspect oil filters (check if red button on pressure drop sensor protrudes) of main and pinionshaft lubrica-
tion systems.
Clean dirt trap and inspect oil tank of main lubrication system.
Inspect crushing liners for wear and damage.
Measure setting at four points around crushing chamber to check for uneven wear.
Check pumps for abnormal noise and wear.
Check wear and tension of V-belts.
Inspect core of air/oil heat exchanger (option).
Clean damping valve for Hydroset pressure gauge.
Check air pressure (blower running or regulator working) of over-pressure dust sealing system.
Check hose and filter of over-pressure dust sealing system and that covers on tank unit are air tight.
MONTHLY:
Clean drain plug on pinionshaft housing.
Check dust seal ring for wear.
Check condition of scraper which rotates above dust collar.
Check tightness of all bolts.
Check play between mainshaft sleeve and spider bushing.
Check grease level in spider bearing.
Clean air vent passages in spider cap and topshell.
Check quality of lubrication oil.
Check function of return oil flow switch.
Check backlash in pinion and eccentric gear.
Check – using feeler gauges – between headcentre and mantle and between topshell and concave ring.
Check spider bearing grease seal for wear.
No. Remarks Sign.
1
10
11
12
13
14
15
16
17
18
19

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operator’s manual Doc. no. S 223.

Serial no. / Machine no. Sign.

Document number: S 223.626 en

CH660:02 © 2010 Sandvik SRP AB – Doc. no. S 223.626 en Ver. 02 1

3.6 Oil cooling systems ............................................................. 36

4. Starting up the cone crusher

5. Using the cone crusher

2 © 2010 Sandvik SRP AB – Doc. no. S 223.626 en Ver. 02 CH660:02

6. Inspection and care

8. Hydroset and lubrication systems

CH660:02 © 2010 Sandvik SRP AB – Doc. no. S 223.626 en Ver. 02 3

8.2 Main lubrication system ...................................................... 76

4 © 2010 Sandvik SRP AB – Doc. no. S 223.626 en Ver. 02 CH660:02

10. Topshell assembly

11. Setting measurement

CH660:02 © 2010 Sandvik SRP AB – Doc. no. S 223.626 en Ver. 02 5

6 © 2010 Sandvik SRP AB – Doc. no. S 223.626 en Ver. 02 CH660:02

1.1 Equipment information

8 © 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02

Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB 9

Tank unit identification

10 © 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02

1.1.1 Document information

Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB 11

1.2 Operating principles of a cone crusher

12 © 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02

Auxiliary lubrication systems

Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB 13

14 © 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02

Cone crusher – external view

Tank unit and auxiliary equipment

Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB 15

16 © 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02

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-

18 Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB

2.1.3 Prohibition signs

2.1.4 Mandatory signs

Disconnect current Read the manual

© 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02 19

Sandvik SRP AB provides technical documentation appropriate to all three

2.2.1 Personal protection

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or breathing

20 Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB

2.3 General safety precautions

© 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02 21

2.3.1 Machine safety guards

2.3.2 Machine access

2.3.3 Electrical safety

22 Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB

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

2.3.5 Hydraulic system

2.3.6 Lubrication system

© 2010 Sandvik SRP AB Doc. no. S 223.626 en Ver. 02 23

2.3.7 Lifting and moving loads

24 Doc. no. S 223.626 en Ver. 02 © 2010 Sandvik SRP AB

2.3.8 Feed and jams

CAUTION! Never feed combustible process material into the crusher.

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