Professional Documents
Culture Documents
Sandvik Instruction CH430 - (English)
Sandvik Instruction CH430 - (English)
Sandvik Instruction CH430 - (English)
490 en
SANDVIK CH430:01
This document is valid for:
SANDVIK CH430:01
© Copyright 2007 Sandvik SRP AB.
All rights reserved. No parts of this document may be reproduced or
copied in any form or by any means without written permission from
Sandvik SRP AB. All data and information in this manual may be
changed without further notice. Reservations for misprints.
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.......................................................... 6
1.1.1 Document information.............................................. 9
1.2 Operating principles of a cone crusher ............................... 10
1.2.1 Description ............................................................. 12
2. Safety precautions
2.1 Hazard information ............................................................. 16
2.1.1 Warning signs ........................................................ 16
2.1.2 Risk levels.............................................................. 16
2.1.3 Prohibition signs..................................................... 16
2.1.4 Mandatory signs..................................................... 16
2.2 Personnel............................................................................ 17
2.2.1 Personal protection ................................................ 18
2.3 General safety precautions................................................. 18
2.3.1 Machine safety guards........................................... 19
2.3.2 Electrical safety...................................................... 20
2.3.3 Welding .................................................................. 20
2.3.4 Hydraulic system.................................................... 21
2.3.5 Lifting and moving loads ........................................ 21
2.3.6 Feed and jams ....................................................... 22
2.4 Emissions ........................................................................... 22
2.4.1 Dust........................................................................ 22
2.4.2 Noise...................................................................... 23
2.4.3 Radioactivity........................................................... 23
3. Technical data
3.1 General data ....................................................................... 26
3.2 Processing data .................................................................. 26
7. Lubrication
7.1 Lubricant requirements ....................................................... 54
7.1.1 Miscibility................................................................ 54
7.1.2 Low temperatures .................................................. 54
7.1.3 High temperatures ................................................. 55
7.2 Oil for lubrication system .................................................... 55
7.3 Oil for Hydroset system ...................................................... 57
7.4 Oil for pinionshaft lubrication .............................................. 59
7.5 Grease for spider bearing lubrication.................................. 60
9. Accumulator
9.1 General ............................................................................... 86
9.2 Flow regulator ..................................................................... 87
9.3 Charging kit (option)............................................................ 87
9.3.1 Checking the gas pressure .................................... 88
9.3.2 Charging with nitrogen ........................................... 89
12. Troubleshooting
12.1 Faults and suggested corrective actions........................... 102
Appendix A: Inspection
Crusher identification
The figure below shows an example of the crusher’s identification plate. The
identification plate contains data needed when contacting Sandvik SRP AB
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 CH430-M/B/M-36/29/32/34:1
13 Eccentric throw (mm)
14 Mark number
9 10 12 13 14
11
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
SRP AB will not take responsibility for this compliance when customers
modify any configuration of the cone crusher.
1
2
1 Spider bearing 3
2 Topshell 4
3 Concave ring 5
4 Mantle
5 Eccentric assembly
6
6 Mainshaft
Setting adjustment
Due to the need to compensate for wear and the need to produce different
product sizes the crusher has a setting control system. It basically consists of
a robust hydraulic jack, named Hydroset, which supports the mainshaft and
adjusts its position. By moving the mainshaft up and down, the discharge
setting can be changed and the size of the crushed material can thereby be
changed. Read more in section 11. Setting measurement.
setting decrease = finer product setting increase = coarser product
= =
1.2.1 Description
The following figures show an overview of the cone crusher’s nomenclature
and components. Grey areas indicate cross-sections.
Cone crusher – intersected view
1
1 Spider cap 2
2 Spider bushing
3 Head nut
4 Mantle
3
5 Concave ring
4 20
6 Mainshaft with headcentre
7 Eccentric wearing plate 5
6 19
8 Bottomshell bushing
9 Eccentric 18
10 Eccentric bushing
11 Step bearing 17
12 Hydroset piston 7 16
13 Pinionshaft housing 8 15
14 Pinionshaft
15 Dust collar
16 Locating bar
17 Dust seal ring
18 Bottomshell
19 Topshell
20 Filler ring 9 14
10
13
11
12
21
21 Hole for level indicator
22 Inspection door
22
23 Feed hopper 23
24 Inspection hatch
24
25 Over-pressure blower
25
26 Over-pressure air regulator
27 Tank unit
28 Water/oil heat exchanger 26
29 Air/oil heat exchanger
30 Charging kit for accumulator
27
28
29
30
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!
Do not remove
guards
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
Sandvik SRP AB provides technical documentation appropriate to all three
work roles:
• Installation manual
• Operator’s manual and Wear parts catalog
• Maintenance manual and Spare parts catalog
Sandvik 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.
Always switch off power and lock out the equipment (secure it cannot be
switched on) before any maintenance work is started. Also ensure that it is
not possible for anyone else to switch the power on while maintenance work
is being done.
(Continued)
Risk of crushing
Never remain on the crusher while crushing. Moving parts constitute a
risk of crushing. Falling into the crusher implies danger of being
DANGER! crushed.
Risk of crushing
If the crusher is mounted on rubber dampers, there is a risk of
crushing between the oscillating parts of the crusher and the
WARNING! stationary frame.
Ejection
Never look into the crusher while crushing. Fragments and possibly
harmful substances fed to the crusher may be ejected.
WARNING!
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.
Platforms with guard rails shall be installed around the crusher’s feed
opening. Walkways, stairs and ladders must be designed in accordance with
applicable regulations. (These parts are not included in the crusher’s standard
specification).
Make sure all defective guards and dust sealing components are checked,
repaired and replaced before starting the equipment.
Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven
dead by proper testing procedures.
DANGER!
Make sure all broken or damaged electrical cables and connectors are
checked, repaired and replaced before starting the equipment.
Control cabinets must be lockable.
2.3.3 Welding
CAUTION! Welding on the crusher is only permitted when and as described in the
manual. For all other welding operations on the crusher local Sandvik
Rock Processing service personnel must be consulted.
If welding an item to the crusher, ground must be attached to the item itself.
If a crusher component is to be welded, ground should be attached as near to
the welding area as possible.
Toxic gases
Inhalation of welding fumes can be dangerous to health. Always follow
instructions provided by the welding equipment supplier.
WARNING! Some parts of the crusher are made of manganese steel. Long-term
exposure to manganese oxide can affect the nervous system.
CAUTION! Never adjust pressure relief valves beyond the recommended values.
Oil temperature
Hydraulic oil can get very hot in operation. Allow the oil to cool before
working on the hydraulic system.
WARNING!
Make sure all defective hoses, valves or fittings are checked, repaired and
replaced before starting the equipment.
Hanging load
Never work or stand underneath a crane that is lifting material. Keep a
safe distance from a hanging load.
DANGER!
Make sure that the capacity of the lifting equipment is adequate and that the
equipment itself is in good working order.
If a lifting tackle has to be made up by joining separate components, make
sure that the joints are secure and have the same lifting capacity as the rest of
the tackle.
NOTE! Always use lifting tackle certified in accordance with local conditions.
Always engage the safety clips on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and maneuver loads. Do not use hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.
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.
2.4 Emissions
2.4.1 Dust
Health hazard
Crushing and processing material will create dust. Such dust can be
more or less dangerous to the health. Use a breathing mask.
DANGER!
Sandvik SRP AB strongly recommends using additional equipment for dust
suppression. Examples are dust extraction (vacuum) and dust encapsulation
by water spray or foam. Such equipment is not included in the crusher’s
standard specification.
Sandvik 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!
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.
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 SRP AB regarding application of the crusher.
4.1 General
Each cone crusher delivered by Sandvik Rock Processing 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.
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) 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 proce-
dure.
h) Bleed the Hydroset system. See section 4.2.3 Bleeding air from the
Hydroset system.
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 8.6.5 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 8.6.5 Pressure gauge.
o) Check and record the main lubrication oil pressure, see section 8.2 Main
lubrication 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) Check the oil level in the pinionshaft housing when the crusher is
standing still. See section 7.4 Oil for pinionshaft lubrication.
s) After running-in is completed, check the tightness of all bolts and re-
tension the V-belts. See section 6.4.2 V-belt tension.
3
1 Measuring nipple
2 Air bleed hose
3 L1 push button box
1 2
a) Raise the mainshaft a few millimetres (mm) by using the L1 push button
box (3), which is located in the vicinity of the cone crusher.
b) Prepare to connect the air bleed hose (2) to the measuring nipple (1).
c) Position the free end of the air bleed hose in a suitable receptacle.
d) Screw the hose onto the measuring nipple. The non-return valve in the
measuring nipple will automatically open when the hose is screwed on.
e) When bubble-free oil comes out of the air bleed hose, raise the mainshaft
a few millimeters (mm) more.
f) Unscrew the hose from the measuring nipple. The non-return valve in
the measuring nipple will automatically close.
g) If necessary, repeat the air bleeding procedure until completely bubble-
free oil flows out.
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.
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.
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 temperature. In such a case, contact Sandvik Rock
Processing. 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 temperatures
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 element and clean the dirt
trap, return oil strainer, tank and air/oil heat exchanger.
c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system
and exchange oil in the Hydroset system. Also change the filter element
and clean the dirt trap, see section 8.6.2 Oil filter and section 8.6.3 Dirt
trap (magnetic plug).
d) Exchange the oil in the pinionshaft housing. Use the same oil as in the
main lubrication system, see section 7.4 Oil for pinionshaft lubrication.
e) If thermostats TG 1, TG 2 and TG 3 are not already set for operation at
elevated temperatures, reset them according to section
8.2.11 Thermostats and section 8.2.12 Oil heating.
The oils viscosity increases at low temperatures, 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 for freezing including e.g. insulation and extra heating. See
the Installation manual and consult Sandvik Rock Processing.
Nevertheless, in extremely low 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.
b) Exchange the main lubrication oil according to section 8.3 Exchanging
main lubrication oil. Also change the filter element and clean the dirt
trap, return oil strainer, tank and air/oil heat exchanger.
c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system
and exchange oil in the Hydroset system. Also change the filter element
and clean the dirt trap, see section 8.6.2 Oil filter and section 8.6.3 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
Rock Processing.
d) Exchange the oil in the pinionshaft housing. Use the same oil as in the
main lubrication system, see section 7.4 Oil for pinionshaft lubrication.
e) For operation under extreme ambient temperatures, consult the lubricant
supplier regarding grease for spider bearing lubrication, see section
7.5 Grease for spider bearing lubrication.
f) If thermostats TG 1, TG 2 and TG 3 are not already set for operation in
low temperatures, reset them according to section 8.2.11 Thermostats
and section 8.2.12 Oil heating.
5.5 Accumulator
Checking the gas pressure and charging is described in section 9.3 Charging
kit (option).
6.1.1 Daily
It’s in the operator’s role to be responsible 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
Check the oil level in the Hydroset tank. Before starting the crusher 8.6
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 oil returns to the tank and that the oil is After starting the lubrication 8.2
clean. pump
Check that the oil lines do not leak. After starting the pumps –
Check the CSS. Running idle 4.2.1
Check that material has not jammed in the feed hopper or Running idle –
splitter and 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 8.2.7
Check the drive motor current or power consumption. While crushing 4.2.4
Check the Hydroset pressure and that the pressure gauge While crushing 8.6
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 of the main lubrication system at nor- While crushing 8.2.5
mal operating temperature.
Check that there is no oil leakage. While crushing –
Check that no bolts have come loose. While crushing –
6.1.2 Weekly
It’s in the operator’s role to be responsible for these inspections weekly or
after every 40 hours of operation.
Action When See section
Inspect the oil filter (check if the red button on the pressure With crusher and lubrication 8.2.3, 8.3.3
drop sensor protrudes). pump stopped
Clean the dirt trap and inspect the oil tank of the main lubrica- With crusher and lubrication 8.2.1, 8.2.2,
tion system. pump stopped 8.3
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 and wear. While crushing. 8.2.4, 8.6.1
Check wear and tension of the V-belts. With crusher stopped –
Check the oil level in the pinionshaft housing. With crusher stopped 7.4
Check the cooler core of the air/oil heat exchanger (option). With crusher and lubrication 8.5
pump stopped
Clean the damping valve for the Hydroset pressure gauge. With crusher stopped 8.6.5
Check the air pressure (blower running or regulator working) of Running idle 6.7
the over-pressure dust sealing.
Check the hose and filter of the over-pressure dust sealing With crusher stopped 6.7
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
Clean the air vent nipple on the pinionshaft housing. Operator 7.4
Check the dust seal ring for wear. Operator 6.3.1
Check the condition of the scraper which rotates above the Operator 6.3.2
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 quality of the lubrication oil. Operator 7.2
Check the function of the return oil flow switch. Operator 8.2.9
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
6.1.5 Yearly
These inspections should be carried out yearly or after every 2000 hours of
operation. The crusher must be stopped.
Action Responsible See section
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
Change oil in the pinionshaft housing. Operator 7.4
Check the function of the temperature gauge. Operator 8.2.7
Check the function of the protective thermostat TG 1 and the Operator 8.2.11
thermostat for heat exchanger TG 2
1
1 Cover / inspection hole
2 Retaining ring
3 Dust seal ring
4 Dust collar
5 Scraper
5 4 3 2
Use a feeler gauges to check the play between the dust seal ring and the
mainshaft.
Max. permissible play between dust seal ring and dust collar
mm/(inches)
1.3/(0.051)
6.3.2 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.
6.4 V-belts
Do not remove fixed guards
Never operate the cone crusher unless the fixed guards around its
moving parts are mounted.
PROHIBITION!
F
2
1 F-scale 1
6
6 14 12 10 8
W
2 D-scale
D = deflection D
5
W = belt span F
4
F = deflection load 2
3
2
D
1
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 6.7.2 Blower and section 6.7.3 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.)
6.7.2 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.
4 Blower 6
6 Filter
3 Pressure gauge
7 Air regulator
8 Filter
9 Compressed air connection
3 7 8 9
7.1.1 Miscibility
NOTE! Never mix different brands or types of lubricants, unless mixing is known to
be appropriate. A bad mixture may cause precipitation and a loss of the
lubricant’s characteristics.
Normally, old lubricants must be flushed out very carefully before replacing
with new lubricants. The lubricant manufacturer(s) can provide information
on whether mixing is appropriate.
(Continued)
Examples of lubricants
The examples listed below are lubricants which – according to the respective
manufacturer – comply with Sandvik Rock Processing’s requirements.
Local variations can occur in different countries. For safety’s sake, check
with your supplier that the selected lubricant complies with the requirements
in question.
In addition to the lubricants listed, a number of other brands and qualities
meet Sandvik Rock Processing’s requirements and are accordingly also
usable.
Mineral oils
For operation under normal conditions:
BP Energol GR-XP 150 Molub-Alloy Tribol 1100/150
ESSO Spartan EP 150 Shell Omala 150
Klüber Klüberoil GEM 1-150 Statoil LoadWay EP 150
Mobil Mobilgear 629 Texaco Meropa 150
For operation at elevated temperatures:
BP Energol GR-XP 220 Molub-Alloy Tribol 1100/220
ESSO Spartan EP 220 Shell Omala 220
Klüber Klüberoil GEM 1-220 Statoil LoadWay EP 220
Mobil Mobilgear 630 Texaco Meropa 220
For operation in low temperatures:
BP Energol GR-XP 100 Molub-Alloy Tribol 1100/100
ESSO Spartan EP 100 Shell Omala 100
Klüber Klüberoil GEM 1-100 Statoil LoadWay EP 100
Mobil Mobilgear 627 Texaco Meropa 100
Biologically degradable oil
If a biologically degradable oil is to be used, Sandvik Rock Processing
recommends that only a 100 % synthetic oil of ester type is selected. Due to
the higher viscosity index of this type of oil, an ISO VG 150 grade can
normally be used all year round.
If the ambient air temperature is over 32°C (90°F), it may still be necessary
to reset thermostats TG 1 and TG 2 for “Operation at elevated temperatures”
since TG 1 could otherwise trip because of excessively high oil temperature
and thus stop the crusher, see section 8.2.11 Thermostats.
Example: Tribol Bio Top 1418/150 (VI > 170)
(Continued)
Oil quantity
Capacity
Lubrication oil tank 150 litres / (40 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 remain 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 element tubes and their thermostat are al-
ways 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 lead
additives 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 oil
in the Hydroset piston runs out.
Oil quantity
Capacity
Hydroset oil tank 40 litres / (10.7 US gal.)
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.
Oil changes
The oil in the Hydroset system should be changed when the lubricating oil is
changed. See section 5.3 Changing oil and section 7.2 Oil for lubrication
system – Oil changes.
There is a drain plug (4) and an oil level tube (3) mounted in the bottom of
the pinionshaft housing. When oil is added, the drain plug must be in place.
Slightly more than the required quantity should be added. When the oil level
has stabilized in the pinionshaft housing, drain out the excess oil through the
level tube by taking out the drain plug.
NOTE! Top up and drain off excess oil every time the oil level is to be checked since
there is otherwise a risk that a small amount of oil in the level tube will run
out and give the impression that the oil level is high, even though it is in fact
low.
1 Filler plug
2 Oil level
1
3 Level tube 2
4 Drain plug 3
4
(Continued)
Oil changes
Check the oil level regularly and change the oil after approximately 2000
operating hours or about once a year. Drain out the oil by unscrewing the
level tube and drain plug.
The filler plug on the top of the pinionshaft housing is fitted with an air vent
nipple. This nipple should be cleaned at intervals of about two months as
there is otherwise a risk of damage to the seals and leakage could then occur.
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 under 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 Rock Processing’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 Rock Processing’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 4–6 kg / (8.8–13.2 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 can be pumped in through a pipe (1) inside one of the topshell spider
arms.
1 Grease pipe
2 Grease level
3 Observation hole
4 Spider bearing seal 1 5
5 Air vent line
2 4
3
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
1 Hydroset tank cover
2 Lubrication tank cover 2
3 Identification plate
4 Cabinet
3
8.1.2 Cabinet
The cabinet contains components of the main lubrication system and
Hydroset system.
13
14 15 16 17
Condensation can be removed by taking out the screw in the dehydration
plug (14) beneath the lubrication oil tank. This must be done regularly to
avoid too high a percentage of water in the oil.
CAUTION! 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 dam-
age. Never let the pump operate dry.
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
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 38 10.0
Min. capacity 32 8.4
Supply frequency 60 Hz Normal capacity 46 12.2
Min. capacity 32 8.4
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 20 seconds to fill a 10 litre bucket. The oil flow is thus:
(10×60)/20 = 30 l/min.
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
20 Float
21 Weir
21
22 Adjustable lower outlet 22
23 Oil strainer 23
24 Return oil chamber
24
20
20 Float
21 Weir
21
22 Adjustable lower outlet 22
23 Oil strainer 23
24 Return oil chamber
24
8.2.11 Thermostats
Two thermostats have their sensing heads in the return oil chamber (24) in
the oil tank. The thermostat for 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 Protective thermostat TG 1 26
27 Thermostat for heat exchanger TG 2
28 Oil heating thermostat TG 3
29 Level indicator, lubrication oil tank 27
30 Heating elements
28
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 condi-
tions.
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.
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.
26 Protective thermostat TG 1 26
27 Thermostat for heat exchanger TG 2
28 Oil heating thermostat TG 3
29 Level indicator, lubrication oil tank 27
30 Heating elements
28
29
30
TG 3 Oil temperature
Operating Normal operating Operating at ele- Operating at low
conditions conditions vated temperature temperatures
Ambient air temperature Max. 32°C (90°F) Max. 40°C (104°F) Below 0°C (32°F)
Oil viscosity ISO VG 150 ISO VG 220 ISO VG 100
Suitable temperature before 30°C (86°F) 37°C (99°F) 25°C (77°F)
crusher is started
Oil heating thermostat TG 3
Basic setting 30°C (86°F) 37°C (99°F) 20°C (68°F)
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)
Differential setting 3 3 3
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.
12 Lubrication inlet
(from crusher)
13 Lubrication outlet 12
(to crusher)
31 L1 push button box
31
13
(Continued)
h) Drain the lubrication oil tank by taking out the screw in the drain plug
(15) beneath the lubrication oil tank.
14 15 16 17
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.
20
20 Float
21 Weir
21
22 Adjustable lower outlet 22
23 Oil strainer 23
24 Return oil chamber
24
14 15 16 17
1 Oil in
2 Water out 1
3 Water in
2
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 8.2.11 Thermostats and section
8.2.12 Oil heating.
Use clean fresh water. If only contaminated water is available, contact
Sandvik Rock Processing first!
NOTE! Drain all water out of the heat exchanger if the crusher is shut down during
the winter (below 5°C/41°F).
7
1 Pressure gauge
2 Oil filter
3 Hydroset pump unit
4 Damping valve
5 Control valve
6 Dirt trap (magnetic plug)
7 Hydroset connection
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.).
1 Accumulator
2 Anti-extrusion valve
3 Air bleed screw
4 Flow regulator
1
2
3
4
(Continued)
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.
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
FBU-1
1
2 10 11
8 7
3 6 12
4
5
1 Protective cap 7 Screw connector
2 Protective cap 8 Bleed valve
3 Nipple 9 Spindle
4 O-ring 10 Connector
5 Adaptor 11 Charging hose
6 Hexagon screw 12 Connector
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! Recheck the charging pressure after 1, 2 and 3 weeks and thereafter at 6-
month intervals.
NOTE! Remove the feed distributor (if fitted) and clean out the feed hopper from
processing material before removing the spider cap.
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.
– 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.
– Check that the lubrication passage through the topshell is
unobstructed.
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.
A A-dimension A
B Groove
C Groove
B
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.
11.1 General
The setting adjustment system is designed to compensate for mantle and
concave 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 ring is recommended to make sure that it
has not been worn unevenly or has 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 ≤ 15 mm (0.6").
If the mainshaft is raised further it can cause damage to the spider bear-
ing in the topshell. See section 10.2 Inspection of crushing chamber.
= =
Check that lubricating oil returns to tank and that oil is clean.
Inspection checklist
10
11
12
13
14
15
16
17
18
19
SANDVIK CH430:01
This document is valid for:
SANDVIK CH430:01
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
WPC Sandvik CH430:01
General
Ordering information
When ordering parts, always state the machine type, manufacturing number,
serial number and order number according to the identification plate on the
cone crusher or tank. State quantity, article number and denomination for
each ordered part. The quantities listed in this catalog show how many pieces
of each part that are usually exchanged in a certain position.
Crusher’s identification plate
The figure below shows an example of the crusher’s identification plate. The
identification plate contains data needed when contacting Sandvik
concerning wear parts.
Please enter the serial number of the associated machine in the intended field
on the first page of this wear part catalog (the copyright page).
Identification plate:
1 Machine type
2 Part number
3 Serial number
4 Order number
1 2 3 4
Identification plate:
1 Type
2 Part number
3 Serial number
4 Order number
1 2 3 4
Think ahead!
Avoid unnecessary downtime and increased freight charges by ordering parts
well in advance.
Feedback
If you have comments on this wear parts catalog or problems connected to
the crusher’s documentation, send an e-mail to: manuals.srp@sandvik.com
Feed hopper
3
5
1
4
6
8
7
Over-pressure system
9
10
12
1 Feed hopper
2 Spider cap
3 Head nut and Main shaft sleeve Tank unit
4 Liners
5 Air filter
6 Support ring
7 Dust sealing
8 Bottomshell wearing
9 Step bearing set
10 Chevron packing
11 Hydroset
12 Over-pressure system
13 Tool list
11
1. Feed hopper
6 8 1 1
9, 10, 11
17,19
7
16, 18
2. Spider cap
5650-0
5685-0,-2
5675-0 5655-0,-2
5150-0
5705-0
5651-0
4205-0
4025-0 4205-2
4205-1
4. Liners
6007-2
6007-0
6007-1
6006-0
6005-0
4175-0
CH430-M/B/M-36/29/32/34:1
5. Air filter
5650-1
6. Fasteners
6020-1
6020-2
6020-8
6020-4
6020-0
7. Dust sealing
4305-0
4350-0
4355-1
4365-1 4365-0,-2
4355-0
Cat. no. Qty. Part number Alternative Description Remarks
4305-0 1 442.8017-01 Dust seal ring
4350-0 1 442.8020-01 Retaining ring
4355-0 1 442.8021-01 Retainer
4355-1 1 442.8022-01 Scraper
4365-0 11 840.0068-00 Screw M6S 16x50 8.8 ISO 4017 Fasteners for dust sealing and scraper
4365-2 12 847.0016-00 Washer BRB 17x30 HB200 ISO 7089
4365-1 1 840.0070-00 Screw M6S 16x60 8.8 FZB ISO 4017
1320-1 1320-2
1320-5
1320-4
1320-6
1320-5
1320-2 1320-3 1010-1
Cat. no. Qty. Part number Alternative Description Remarks
1010-1 1 442.7915-01 Liner-Pin shaft arm Arm liners
1010-2 2 442.7914-01 Liner-Narrow arm
1320-1 2 442.8864-01 Wearing plates
1320-2 2 442.8865-01 Wearing plates
1320-3 1 442.8866-01 Wearing plates
1320-4 2 442.8867-01 Wearing plates
1320-5 2 442.8868-01 Wearing plates
1320-6 2 442.8869-01 Wearing plates
9 442.8799-06 Bar 1312-00 4-kt 12x60
6 847.0059-00 Washer TBRSB 13,5x36 1370
2 840.0048-00 Screw M6S 12x45 8.8 ISO 4017
4075-0
2280-0
2260-0
2401-1 2305-0
11. Hydroset
1
4
2
13 Tool list
Cat. no. Qty. Part number Alternative Description Remarks
1 442.8045-00 Tool box complete
1 442.8042-00 Lifting tool Eccentric bushing
1 442.8043-00 Lifting tool Bottom shell bushing
3 843.1330-00 Lowering rod with nut M24x500 Removal of piston
3 845.0012-00 Nut M6M M24 8 Lowering rod M24x500
1 442.9994-00 Piston stop plate Holding piston
1 442.8044-00 Eye bolt Lift, main shaft step
1 899.0299-00 Eye bolt SS 1899-M42 Mainshaft
3 899.0160-00 Eye bolt SS 1899-M20 Spider bushing
4 899.0147-00 Eye bolt SS 1899-M16 Dust collar
4 899.0155-00 Eye bolt SS 1899-M12 Eccentric unit, piston
2 899.0099-00 Eye bolt SS 1899-M10 Bottom shell bush, ecc. bushing
2 899.0244-00 Eye bolt SS 1899-M8 Mainshaft sleeve
1 920.0109-00 Ring spanner striking NV 55 mm Screw & nut M36
1 920.0151-00 Ring spanner striking NV 36mm Screw M24
1 920.0135-00 Ring spanner striking NV 36 mm Screw & nut M24
1 920.0105-00 U-ring spanner NV 36 mm
1 920.0134-00 U-ring spanner NV 30 mm Screw
1 920.0022-00 U-ring spanner NV 24 mm Screw & nut M16
1 920.0244-00 U-ring spanner NV 18 mm Screw & nut M12
1 920.0186-00 U-ring spanner NV 13 mm Screw & nut M8
1 920.0040-00 Socket screw key NV 14 Screw 16
1 920.0038-00 Socket screw key NV 10 Screw 12
1 920.0037-00 Socket screw key NV 8 Screw 10
1 920.0036-00 Socket screw key NV 6 Screw 8
1 920.0035-00 Socket screw key NV 5 Air bleeder valve
1 920.0032-00 Socket screw key 5/8” Plug Spider Cap
5 442.0800-90 Chunk of lead Check of close side setting
1 923.0422-00 Feeler gauge 0,05-1 mm L=300
1 904.0585-00 Air bleeder hose
SANDVIK CH430:01
This document is valid for:
SANDVIK CH430:01
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
SPC Sandvik CH430:01 Table of contents
Contents Page
2. Cone crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8. Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9. Check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2. Cone crusher
1010-2
1320-4 1320-6
1320-1 1320-2
1320-5
1320-4
1320-6
1320-5
1320-2 1320-3 1010-1
2, 3, 4, 5
7, 9
6, 8
2, 3, 4, 5
1, 2
3
4
5, 6
6, 7
6, 8, 9
4
5, 6
7
8. Accumulator
9. Check valve
8
7
4
5
3
6
30 31 32 33 34 36 35 13
37
39
7
35
442.8642-90
442.8642-00 15
14
20 21 22 23 24 13 2
3
4 3 2
4
3
14
2
13 6 2 3
442.8642-00
12
TANK
01 1 879.0437-00 V-belt Pulley 375 MGT 100 6xSPC For part no 442.9938-00 following
includes
02 1 869.0189-00 Bushing for grooved pulleys MGT no.
100 Di=80
04 1 857.0346-00 Key R 22x14x80 SMS 2306
05 1 442.9940-00 Spacer D95/80x24
06 1 442.7955-01 Washer 2142-50 D95/17x10
07 1 847.0016-00 Washer BRB 17x30 HB200 ISO 7089
08 1 840.0066-00 Screw M6S M16x40 8.8 fzb ISO 4017
Installation
&
Operating Instructions
1.0 INTRODUCTION
2.0 INSTALLATION
2.1 Control Unit Mounting
2.2 Sensor coil Mounting
2.2.1 Flat Pack Coil - Idler Conveyors
2.2.2 Trough Coil - Vibrator or Belt Conveyors
2.2.3 Plate Coil
2
METALARM 3000
1.0 INTRODUCTION
The Metalarm Metal Detector consists of a control unit, one or more sensor coils dependent upon the
application, a sensor coil for clip detection and optional accessories such as the sack dropper.
These instructions are concerned with the installation and operation of the control unit, sensor coils and
accessories.
380.00
350.00 150.00
350.00
400.00
DETECT POWER
MET ALARM
3000 CE
PULSE RESET ON
TECHNOLOGY
160.00
300.00
12.00
Figure 1
3
2.0 INSTALLATION
The Metalarm 3000 control unit is supplied with mounting brackets for wall mounting. Dimensions are shown
in the dimension diagram above.
Ideally the control unit should be mounted within 3-5 metres of the sensor coil unit and no more than 20
metres.
The Metalarm 3000 control unit will normally be mounted by means of four M8 or 5/16 inch bolts utilizing the
four mounting holes.
Adequate clearance must be allowed below the control unit enclosure to allow for cable entry and exit.
On no account must the HDPE mounting bars be replaced, as these are provided, to electrically isolate the
control unit from the metal conveyor framework. Similarly no metal work should be in contact with the metal
control unit case after mounting on the conveyor.
Failure to comply with the above mounting procedures will invalidate the 'CE' certificate covering the EMC
regulations.
The sensor coil should be mounted near the feed point in the desired conveyor. Remove as much excess
metal in the sense area as possible. Remove any metal base plates protecting the underneath of the conveyor
and replace with non metallic materials.
Mount the sensor coil midway between two idlers, but do not mount the sensor coil over the top of a return
idler. Move the return idler or select a different sensor coil mounting location.
Remove any over-the-belt metallic covers and replace the covers with covers utilising non metallic materials.
4
Install the sensor coil across the conveyor stringers and fasten utilising four small angle brackets and four
small bolts.
Allow for 25mm (1 inch) clearance between the sensor coil face and the conveyor belt under loaded
conditions. Shim if necessary, or cut notches in the sensor coil side support plates. Weld or bolt the angle
brackets to the conveyor stringers in the proper location. Drill small holes through the angle-brackets and the
sensor coil side support plates. Install four small bolts and tighten securely.
Idler assemblies on both sides of the sensor coil should be inspected for any loose nuts, or bolts and joints
and if loose, tighten securely.
To install a trough coil, it is necessary to cut out a length of the base and part of the side walls of the conveyor.
See below:-
Figure 3
The exact dimensions of the required cut out will be shown on a drawing included at the rear of these
installation notes.
The search coil is held in position by M8 counter-sunk bolts at 100mm spacing, or at least a sufficient number
to hold the search coil firmly in position. See Figure 4 on the following page.
5
Figure 4
The search coil can then be mounted temporarily in position and the holes used to mark the position of the
holes to be drilled on the conveyor section.
The holes, using a 8.5mm diameter drill, should then be drilled and the coil bolted in position.
To install a plate coil, it is necessary to remove a length of the base of the conveyor 3mm larger than the
length of the coil itself.
The search coil can then be mounted in position by support brackets, making sure that they are well away
from the coil windings to prevent damage to the coil windings. See below:-
Figure 5
6
30 ELECTRICAL CONNECTIONS - (See Figure 6.)
The standard electrical connections are for power supply connections and for sensor coil connections. Other
cables may be added as necessary for control and monitoring functions.
Please note where armoured cables are being used, the armouring must be cut back at the gland plate of the
control unit such that it does not touch the Metal Detector Control Unit, as this will compromise the electrical
isolation of the Control Unit.
Figure 6
3.1 Power Supply
The mains connection is made via the green terminal block (TB1) using 'E' for earth/ground connection, either
of the 'L' terminals for live 1/positive connection and either of the 'N' terminals for live 2/negative connection.
The spare 'L', 'N' and 'E' terminals can be used for driving external controls or the bag dropper accessory.
The Voltage Selector Switch should be set to 230V ac or 115V ac as required. This is located just above the
green connector (TB1).
On installation where a mains supply is not available then the MA3000 may be operated from a DC battery
supply.
For efficient operation of the Metal Detector the voltage of the supply should be from 15 to 25V. The capacity
of the battery will depend on length of operational time required. Contact the factory for advice.
The positive lead of the battery is connected to terminal 2 of the green connector (TB3) and the negative lead
is connected to terminal 1 of (TB3).
Note: That a 1 A A/S fuse should be connected in line with the positive lead from the battery.
7
3.3 Sensor Coil Connections
The sensor coil(s) connection is made via the green right hand 4 way terminal block (TB4). When only one
coil is used connect to terminals 3 & 4.
The inner conductor is connected to terminal 'C' and the outer braiding to terminal .
For applications where two coil windings are being used and there are two coil cables, e.g. separate
transmitter and receiver coils, one cable (receiver) lower coil being connected to TB4 1 and 2 and the other
(transmitter) TB4 3 and 4.
Connection to the output contacts of the control relay are made to terminal block (TB2) as indicated in Figure
6. Four sets of DPDT relay contacts are provided.
The contacts are rated for 5 amps resistive, for either low voltage DC application or for a maximum of 250V ac
application.
3.5 Fuse
Please note there is only one fuse on this Control Unit, located on the front panel and rated at 0.5A A/S.
METAL ARM
MA3000 CE
Figure 7
4.0 OPERATING INSTRUCTIONS - (See Figure 7)
Switch on the line power and the 'ON' lamp on the case door illuminates.
The red 'FAULT' light will be on if the sensor coil is not connected. When the sensor is properly connected the
light will extinguish.
Note: The illuminated fault light will also cause the 'Detect' lamp to be on.
8
Rotate the SET ZERO control fully clockwise. If the right hand light illuminates, rotate the Set Zero control
anti-clockwise until this light extinguishes and the green light illuminates.
This adjustment compensates or zeros out any near by metal in the sensor coil detect area. If this light cannot
be illuminated there may be too much metal near the sensor coil. This can be confirmed by positioning the
sensor coil away from all surrounding metal and repeating the test.
After these adjustments, the detector may have operated illuminating the 'Detect' light and the 'Reset' lamp on
the detector door. Pressing the 'Reset' lamp button will extinguish both lights.
The relay function is controlled by the 'Relay' switch. In the OFF position only the 'Detect light and door 'Reset'
lamp operate when metal is present in the sensing area.
In the ON position, the 4 pole DPDT relay, the 'Detect' light and the door 'Reset' lamp operate when metal is
present in the sensing area.
In the LATCH position, the relay and above indicators operate but after the metal is removed, the relay and
the indicators remain on until either the door 'Reset' button is pressed or the 'Relay' switch is turned to the ON
or OFF position.
The 'Sensitivity' control is a gain adjustment control to adjust for the detection of the desired size of material or
to allow for smaller pieces of material to be ignored.
SET ZERO
When the Metalarm is operating and correctly set, the green light of these three lights is the only one
illuminated.
If a piece of metal passing across the Sense coil is large enough it will cause the green light to go out and the
right hand red light to come on while the metal is within the detect range of the Sense coil.
DETECT
This red light illuminates whenever metal is within the detect range of the Metalarm.
COIL FAULT
This red light illuminates if the sensor is either open circuit, not connected or short circuited.
This light also causes the Detect light to illuminate to prevent operation of the Metalarm until the coil fault is
rectified.
Normally, the Metalarm control unit should not require any major re-adjustments after performing the
adjustments during installation. After switching the control unit on, the green 'Set Zero' light should illuminate
immediately without the need to turn the 'Set Zero' control. Proper operation may be verified by depressing the
'Test' button, which is mounted on the electronic circuit board beneath the front panel.
Certain extremely large objects may produce an overload signal causing the unit to indicate continuously even
after the object has passed clear of the sensor coil. Depress the 'Reset' button to cancel the indication.
9
NOTE:
Although the control unit will adequately zero out stationary masses of background metal, it will respond to
moving metal near the sensor coil. When mounting the sensor coil, consideration should not be limited to
only large objects such as fork lift trucks, but should be extended to smaller objects such as maintenance
workers carrying metal tools and equipment in the vicinity.
Although the metal detector system is suppressed against both airborne and power supply interference, some
false alarms may nevertheless occur occasionally. Such triggering is usually due to transient effects which
are both infrequent and unpredictable.
Metallic framework encircling the search coil can act as a "shorted turn". It may be necessary to insert
insulating sections to prevent comparatively small masses of metal generating inordinately large background
signals.
The 'Sensitivity' controls permits gain adjustments for detecting or rejecting the desired size of objects. Rotate
the 'Sensitivity’ control clockwise to increase the Metalarm sensitivity or counter-clockwise to decrease the
sensitivity.
A coarse sensitivity adjustment (VR1) may be performed by means of the sensitivity adjustment control on the
control unit printed circuit board. (See Figure 8.) Extreme care must be used in performing the coarse
sensitivity adjustment. Consult the factory prior to making any coarse sensitivity adjustments.
NOTE:
Take particular care as with the mains supply connected parts of the printed circuit board will be carrying high
voltages. Therefore DO NOT touch anything other than the coarse sensitivity control you are adjusting.
The sensitivity of the control unit may be reduced by rotating the coarse sensitivity adjustment control in the
clockwise direction. Rotate this control one turn at a time, checking each time to determine whether the gain
has been reduced sufficiently.
After each coarse sensitivity adjustment, it may be necessary to rezero the internal lights using the 'Set Zero'
control and depress the reset button on the enclosure door.
This consists of a row of ten lamps which light in sequence from left to right, as the detected signal level
increases when metal approaches the sensor. The Metalarm will produce an alarm when the signal level
reaches the right hand lamp which is permanently illuminated. Normally none or perhaps the first 1 or 2 lamps
may be flickering ON and OFF.
However, if the Metalarm is suffering from 'false alarms' which are of a fairly regular nature, then this indicator
should be examined, since it may show more than the first one or two indicators flickering ON and OFF
indicating the presence of some interference which is either mains or air-borne.
The effects of this may be reduced by rotating VR10 clockwise. The signal level should now move to the left
until only 1 or 2 indicators are on. Care should be taken to not rotate this control further than necessary, since
it does reduce the sensitivity of the unit.
10
4.4 Electronic Board - Mounted switches - (See Figure 8)
For the position of the switches, which control additional optional features, refer to figure:-
Figure 8
SW2 (1) Brown - This prevents the metal detector being reset when metal is still in
the field of the search coil - Can only be used when the conveyor
belt stops immediately after metal is detected - to ensure all metal
has been removed before the conveyor belt can be restarted.
All controls on SW2 are off in the 'up' position and 'on' when in the down position.
SW4 This separates the TX and RX coil connections when switched 'on'
and is used when separate search coils are used for transmitting
and receiving, such as to create an even search field or where
magnetic o/cs are being processed.
SW6 This, when switched 'on', reduces the integrator speed. This facility
is used where belt speeds are slow, such as in the Wood Industry
and where noise levels are high.
11
5.0 ELECTRONIC CIRCUIT BOARD REPLACEMENT
Normally, access to the electronics is not required but if the circuit board requires replacement, the following
procedures must be used.
Turn off the mains supply to the control unit and disconnect all terminal blocks connected to the base of circuit
board by pulling downwards.
Undo the three panel fixing clips by turning a 1/4 turn anti-clockwise.
Undo the five screws holding the two mounting brackets and remove.
Undo the six pillars and two mounting screws. Remove the circuit board and inspect the enclosure. Remove
any foreign material such as loose pieces of metal filings or wire cutting etc.
Install the new circuit board in the reverse procedure of above. Refer to section 4 for testing and operation.
To stop the conveyor drive motor when metal is detected, connect the Metalarm normally-closed relay
contacts (terminals C and N/C on (TB2)) in series with the conveyor motor switch as in Figure 9.
When the Metalarm is wired as shown in Fig 9. the conveyor will not restart until after the metal is cleared, the
Metalarm control unit is reset AND the conveyor motor start which is depressed.
If the conveyor is required to restart automatically when the metal is cleared and the Metalarm is reset, it will
be necessary to use a second motor starter.
Figure 9.
An auxiliary relay is necessary between the Metalarm Control Unit and the motor starter when the motor wiring
system is a fully three-phase delta with no star-point and uses a motor starter with a 415V coil.
The 415 volt motor starter coil exceeds the maximum voltage rating of the Metalarm output contacts, which
are rated at 250V ac maximum. An auxiliary relay or small contactor is required for the 415V ac contacts.
12
An auxiliary relay is necessary when the plant switchgear is generating electrical interference or brushes are
arcing, or when other electrical noise is being created.
This interference will propagate through the air and may also travel along the conductors in close proximity to
the noise sources. When this occurs, interference will be fed into the Metalarm Control Unit along the
interconnecting wires, and will cause false triggering.
An auxiliary relay in a separate enclosure, external to the Metalarm and separate from the main switchgear
cabinet, will normally isolate the offending interference.
Diagram I shows an auxiliary 230V ac relay connected to C of (TB1) and drawing its power from the same
power supply as the Metalarm's power supply.
Diagram II is variant of diagram I such that the conveyor cannot operate when the power supply to the
Metalarm is interrupted.
13
8.0 EARTHING OF ASSOCIATED PLANT WHEN FREQUENCY INVERTER SPEED
CONTROLS ARE BEING USED.
Please note that when frequency inverter speed controls are being used in the vicinity of the metal detector all
earth connections must be run independently back to a single star point as shown below:-
In addition, if filters are being used they should be mounted and connected as shown below:-
Because of the complex circuit design used in these filters an Earth Leakage Current of 8 to 80mA may be
observed. It is possible that nuisance tripping of extremely sensitive type of ELCBs may occur so this figure
should be considered when choosing such a device.
It is important to provide well defined paths for the high frequency currents involved so, by far the best results
are achieved when both filter and inverter are mounted securely on the same conducting, earthed backplate
and not on rails etc.
Supply Cable
The supply cable should be a stranded conductor and not a solid conductor type to achieve proper connection
inside the terminal block, also cable lengths inside the wiring cabinet should be kept to a minimum i.e. cable
entry to filter and filter to inverter. This will reduce the effect of radiated emissions back into the input cables.
Motor Cable
14
Since the cable between the inverter and motor is a major source of radiated and conducted interference, it
should be a screened type and as short as possible with the screen and safety earth core connected directly
to the bonded earth post at one end and to the motor earth at the other. Never connect only one end of the
screen to earth as this can be detrimental. (Pig tail effect). It is strongly recommended that the conducting
cores (not the earth or screen) are threaded through, or, if possible, wound around an output cable filter choke
as shown.
Earthing
The point here is to clearly define the paths through which high frequency earth currents flow, and thereby
minimise their harmful effect on other nearby, sensitive devices. All earthing leads, including filter earth,
inverter earth and screened cable earths, should be as short as possible and securely fastened to the bonded
backboard earth post - poor connections and loops of cable will act as aerials and pick up stray radiated
emissions.
Separation
Keep the separation of the input and output cables as great as possible to prevent feedback. Input and motor
output cables should never be run together in the same trunking or conduit.
Control Cables
The control cables to the inverter or any other equipment in the vicinity are obviously highly susceptible to
radiated emissions in the same way and should also never be run along side motor output cables.
Multiple Inverters
Where more than one inverter is used, for effective suppression, it is preferable that a separate filter should be
used for each inverter.
15
The Metalarm Control Unit generates a high frequency alternating field within and near the sensor coil. While
the field is strongest on the sensor coil face or in the throat of the sensor coil, it is inherent in the sensor coil
design that a certain amount of the field exists outside of the sensor coil. Certain environmental conditions
may sometimes effect this alternating field causing false and erratic signals.
If after installation the unit does not work properly, check for compliance with the following hook-up and
installation details before proceeding to the specific causes of interference.
All cable connections should be tight on the terminal blocks in the control unit. Any sensor coil lead splice
should be soldered and taped.
The power source cables should be isolated from varying inductive loads and should be run in a separate
conduit.
In certain locations more than one problem may exist and the problems may be interrelated.
Observing the installation site and the operation of the metal detector for repeating symptoms is very helpful in
isolating the causes of the problems.
Correlating malfunctioning occurrences is invaluable for environmental interference trouble shooting. Observe
whether interference occurs at certain specific times and in conjunction with specific activity.
Observe whether interference occurs when operated by certain personnel or only after physical change of the
environment.
Use the following to help diagnose problems and problem sources and to implement corrective measures.
Basically environmental interference may be of four types:
Movement of Metal:
Metal objects moving into or out of the electromagnetic field of the sensor coil.
Built in structural metal loops that reflect the electromagnetic field of the sensor coil may be present in the
search area.
Other smaller masses of moving metal when sufficiently close to the search unit may also cause false trips.
Interference may exist outside of the room or building and be hidden from operators view, such as vehicular
traffic in an alley next to the building wall or a chain conveyor below or above the floor, or moving metal
objects in an adjacent room.
Corrective Measures
• Secure moving metal objects or remove them altogether if possible, or replace with a non metallic
material. Re-route vehicular traffic.
• Place a metal shield securely fastened and stationary between the sensor and the source of
interference. Place a shield as close to moving object as possible. The size of the shield will depend
on the size of the moving object.
• Install the metal detector in another location free from interference sources.
A source of interference which is difficult to recognise is that of the shorted turn. A shorted turn is formed by
metal pieces forming a complete path in some plane around or near the sensor.
If this is intermittent, as in the case of two pieces of conduit occasionally touching together, the detector will
trip each time the conduits make or break connections. The intermittence may be caused by physical
deflection or vibration of equipment, and by expansion or contraction of metal due to temperature changes.
The affect of the 'shorted turn' is that of a secondary 'coil' or 'turn' coupled to the metal detector sensor coil.
The varying load of this secondary 'coil' when it makes or breaks is reflected to the sensor coil tripping the
control unit.
The following metal objects may be part of or form a 'shorted turn' by themselves: metal framework, pipes,
conduit, flexible conduit, guard railing, metal catwalks, conveyor rolls, etc.
To determine the existence of a 'shorted turn' : switch the metal detector off and disconnect the sensor lead at
the terminal block. This will disconnect the sensor from the control instrument and there will be no metal
detection.
Now, turn the control instrument on again and set gain control to maximum. Run operation under normal
conditions and observe the signal level indicator. If the indicator is stable at this time, it is most likely that a
'shorted turn' is being picked up by the sensor. However, the problem may also be a break on the sensor
cable.
Check for breaks at this time and replace the cable if necessary.
If the cable is in good condition search for a 'shorted turn' as described in the following paragraph. If the level
indicator is not stable at this time, the problem is likely to be due to excessive line voltage fluctuation.
To isolate and correct the 'shorted turn' problem, reconnect the sensor coil and turn off all surrounding
equipment in order to eliminate any vibration.
The level indicator should settle down at this time or at least reduce the number of false trips.
17
Proceed by tapping on all metal objects, starting near the sensor coil and working out from there, in order to
find where the break point is located. It is suggested that one person watch the level indicator on the control
unit in order to observe any movement while another person is tapping on metal objects around and near the
sensor coil.
In some cases, this may be several feet from the sensor coil. Sudden level indication movement when a metal
object is tapped will indicated the intermittent connection. It may be possible to fix the problem by insulating or
permanently securing this metal to metal connection. For example, in the case of broken weld, re-weld or in
the case of a loose pipe or conduit, re-secure the holders.
4Electrical interference may be in the form of line voltage 'spikes' caused on-off va10rying inductive loads of
electrical equipment on the same power line as the metal detector, or other power lines in close proximity to
the supply line for the metal detector.
Corrective Measures
• Use another power line, (without the varying inductive loads) for the metal detector.
• Disconnect electrical equipment causing the large inductive loads.
• Connect interfering electrical equipment to another power source.
• Re-route the power line to the metal detector.
• Install a constant voltage transformer (120 va. minimum) between metal detector and power source.
Electrical or electronic interference can be radiated into the sensor coil or introduced into the metal detector
from other energy emitting devices such as arcing motors, arc welders, and arcing relay points.
Corrective Measures
18
MA3000 CE
Case Assembly - Parts List
1 or 2
10
4 8
DETECT POWER
5
MET ALARM
3000 CE
3 8
PULSE RESET ON
TECHNOLOGY
MA3000 CE
19
Electronic Assembly - Parts List
METAL ARM
MA3000 CE
20