2 CV215-229-01 - OM - S226 051-02 en PDF

operation & maintenance manual S 226.051.
en
SANDVIK CV215-CV229
This document is valid for:
Serial no. / Machine no. Sign.
SANDVIK CV215-CV229
© 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 226.051.en

Original instructions
Issue: 20110117
Version: 02
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Phone: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
OM Sandvik CV215-CV229
1. Principles of operation
1.1 Control of crushed product sizes ........................................ 11
1.2 Rotor speed ........................................................................ 11
1.3 Bi-flow® .............................................................................. 11
1.4 Vibration protection............................................................. 12
2. Safety precautions
2.1 Hazard information ............................................................. 14
2.1.1 Warning signs ........................................................ 14
2.1.2 Risk levels.............................................................. 14
2.1.3 Prohibition signs..................................................... 15
2.1.4 Mandatory signs..................................................... 15
2.1.5 Other signs............................................................. 15
2.2 Personnel............................................................................ 15
2.2.1 Personal protection ................................................ 16
2.3 General safety precautions................................................. 17
2.3.1 Machine safety guards........................................... 17
2.3.2 Safety interlock system .......................................... 18
2.3.3 Crusher safety inspection procedure. .................... 18
2.3.4 Vibration protection ................................................ 19
2.3.5 Electrical safety...................................................... 20
2.3.6 Welding .................................................................. 20
2.3.7 Hydraulic system.................................................... 20
2.3.8 Lifting and moving loads ........................................ 21
2.3.9 Feed and jams ....................................................... 21
2.4 Emissions ........................................................................... 22
2.4.1 Dust........................................................................ 22
2.4.2 Noise...................................................................... 22
2.4.3 Radioactivity........................................................... 22
3. Component identification
3.1 Exterior of crusher .............................................................. 24
3.2 Interior of crusher................................................................ 25
3.3 Component identification reference list............................... 26
3.4 Rotor and wear parts .......................................................... 27
© 2010 Sandvik SRP AB S 226.051.en-02 3

4. Start up procedure
4.1 Before start-up .................................................................... 30
4.2 Initial start-up ...................................................................... 31
4.3 Operation ............................................................................ 34
4.4 Noise levels......................................................................... 34
4.5 Vibration.............................................................................. 34
4.6 Flow of material................................................................... 35
4.7 Dust emission ..................................................................... 35
4.8 Feed control ........................................................................ 35
4.9 Bi-Flow® control.................................................................. 36
5. Shut down procedure

5.1 Shut-down........................................................................... 40
6. Inspection and servicing

6.1 General recommendations.................................................. 42
6.2 Lubrication .......................................................................... 43
6.3 Grease requirement ............................................................ 44
6.4 Recommended greases...................................................... 46
6.5 Bearing cartridge................................................................. 46
6.6 Operating temperature........................................................ 47
6.7 Grease discharge................................................................ 47
7. Rotor servicing
7.1 Access ................................................................................ 50
7.2 Cleaning out rotor ............................................................... 50
7.3 7.3 Rotor tip assembly ....................................................... 51
7.3.1 HP & LP / EP Rotor Tip Assembly ......................... 51
7.3.2 Rotor Tip Assembly ................................................ 51
7.3.3 Rotor Tip Assembly ................................................ 52
7.3.4 Selection Of Rotor Tips .......................................... 52
7.3.5 Removal / Installation Removal.............................. 53
7.3.6 Installation .............................................................. 54
7.4 Upper and lower wear plates removal ................................ 55
7.4.1 Upper Wear Plate................................................... 56
7.4.2 Upper & Lower Wear Plate Assembly .................... 56
7.5 Distributor plate................................................................... 57
4 S 226.051.en-02 © 2010 Sandvik SRP AB

7.5.1 Premature Wear..................................................... 57

7.5.2 Selection Of Distributor Plate................................. 57
7.5.3 Distributor Plate ..................................................... 57
7.5.4 Removal................................................................. 58
7.5.5 Refitting.................................................................. 58
7.6 Feed tube........................................................................... 59
7.6.1 Uneven Wear ......................................................... 60
7.6.2 Cracking and Breakage ......................................... 60
7.6.3 Removal................................................................. 61
7.6.4 Installation.............................................................. 62
7.7 Trail plates .......................................................................... 63
7.7.1 Removal................................................................. 65
7.7.2 Installation.............................................................. 65
7.8 Rotor body .......................................................................... 66
7.8.1 HP Rotors .............................................................. 66
7.8.2 LP / EP Rotors ....................................................... 66
7.8.3 Top wear plate........................................................ 67
7.8.4 Top edge wear ....................................................... 67
7.8.5 Streaming Wear ..................................................... 68
7.8.6 Bottom edge wear.................................................. 69
7.8.7 Rotor wear protection plates – Top wear plate....... 69
7.8.8 Cavity Wear Plates ................................................ 71
8. Rotor build-up
8.1 Primary function.................................................................. 74
8.2 Secondary function ............................................................. 74
9. Rotor tuning
9.1 General information ............................................................ 76
9.1.1 Rotor ...................................................................... 76
9.1.2 Different material characteristics............................ 76
9.1.3 Tuning on site......................................................... 76
9.1.4 Primary function ..................................................... 76
9.1.5 Basic principles ...................................................... 76
9.2 Adjustment of rotor build-up................................................ 77
9.2.1 Adjustment Of Rotor Build-Up................................ 78
9.2.2 Rotor servicing ....................................................... 78
9.2.3 Rotor Rebuilding .................................................... 79

10. Rotor removal

10.1 Removal.............................................................................. 82
10.2 Rotor installation ................................................................. 85
11. Rotor balancing

11.1 Assembly of Rotor Balance Machines ................................ 90
11.2 Balancing procedure ........................................................... 92
11.3 Rotor balancing troubleshooting ......................................... 94
12. Maintenance
12.1 The rotor balance machine ................................................. 96
12.2 Crushing chamber build-up................................................. 96
12.3 Chamber wall (low build-up) ............................................... 97
12.4 Excessive build-up .............................................................. 97
12.5 Chamber gussets................................................................ 97
12.6 Toe-board............................................................................ 98
13. Crushing chamber

13.1 Cavity ring ......................................................................... 100
13.2 Hopper Bi-Flow®............................................................... 100
13.3 Hopper body ..................................................................... 101
13.4 Control plate...................................................................... 101
13.4.1 Removal ............................................................... 101
13.4.2 Assembly.............................................................. 101
13.5 Hydraulic rotor feed throttle gate....................................... 102
13.5.1 Normal running adjustment .................................. 102
13.5.2 Removal ............................................................... 103
13.6 Cylinder............................................................................ 104
13.6.1 Removal ............................................................... 104

14. Crusher servicing

14.1 Feed tube centralisation and height adjustment ............... 106
14.2 Wear skirt.......................................................................... 107
14.2.1 Removal............................................................... 108
14.2.2 Installation............................................................ 108
14.3 Safety interlock ................................................................. 109
14.4 Vibration switch................................................................. 109
14.5 Inspection doors and hatches........................................... 109
14.6 Crusher base and discharge chutes ................................. 110
14.7 Base liners ......................................................................... 111
14.7.1 Removal................................................................ 111
14.7.2 Assembly .............................................................. 111
14.8 Gusset wear castings ....................................................... 112
14.9 Grease discharge chute.................................................... 112
14.10Belt guards ....................................................................... 112
14.11Motors............................................................................... 112
14.12Bearing cartridge.............................................................. 113
14.13Bearing cartridge seals .................................................... 114
14.14Bearing cartridge removal from base ............................... 117
14.15Bearing cartridge refitting in base .................................... 119
14.16Drive belt tensioning......................................................... 121
14.16.1 Procedure for Adjustment and/or Removal of
wedge belts .......................................................... 121
14.16.2 Re-fitting and tensioning of wedge belts .............. 121
14.16.3 Measuring ............................................................ 122
14.16.4 Adjustment ........................................................... 123
14.16.5 Dual Drive ............................................................ 124
15. Bolt torque reference chart

15.1 Bolt Torque Settings Nm (ft lbs) ........................................ 128

This page is intentionally left blank

1. Principles of operation
OM Sandvik CV215-CV229 9
OM Sandvik CV215-CV229 1. Principles of operation
The Sandvik CV215-229 autogenous crusher uses a rock lined rotor that
accelerates a continuous rock stream into a stone lined crushing chamber.
Material fed into the top of the machine is accelerated in the crusher's rock
lined rotor, achieving exit velocities in excess of 45 meters per second.
The rotor continuously discharges material into the crushing chamber. This
process replenishes the rock lining, while at the same time maintains a
continuous chain reaction of crushing and grinding.
A second stream of material (Bi-Flow®) can be fed into the crushing
chamber in a controlled and directed flow. This Bi-Flow® can further
increase the amount of energised material within the Crushing Chamber, thus
improving the energy transfer. This, in combination with other variables of
rotor diameter, speed and crushing chamber profile, maximises power
efficiency, ensures the lowest operating cost (cost per Tonne) and provides
an efficient means of controlling the grinding and crushing action, to either
increase or decrease the production of fines.
1
1 Bi-Flow® Port
2 Bi-Flow® adjustment gates
2
3 Bi-Flow® material
4 The position of the throttle gate 4
controls the flow of material into
rotor. Excess material unable to
flow through to the rotor,
overflows through the Bi-Flow® 3
ports.
5 Material from the rotor and the
Bi-Flow® material recombine. A
constant cloud of airborne
particles move around the
crushing chamber. Particles are
retained for 5-20 seconds before
losing energy and falling from
the crushing chamber. 5
6 The rotor accelerates material
and continuously discharges it
into the crushing chamber.
Particle exit velocities in excess
of 45m/s

1.1 Control of crushed product sizes

The crusher offers a number of controllable options that can affect the final
product grading. Listed below are two of the main options, that in general
iterms describe the effects of those adjustments.
1.2 Rotor speed

Increasing rotor speed increases the particles kinetic energy and increases the
reduction achieved. However, rotor throughput (T.P.H.) will decrease as
rotor speed increases.
1.3 Bi-flow®
Increasing the Bi-Flow® flow up to 20% of the crushers maximum rotor
throughput, increases the crushers optimum maximum capacity and
reduction ratios. Increases of Bi-Flow® above 20% generally decreases the
reduction ratio achieved whilst increasing the capacity of the crusher.
Crushing Chamber Profile: Material size, moisture content, and feed
capacity will effect the amount and shape of retained material within the
Crushing Chamber. This can be adjusted by the removal of the bolted in
Chamber Gussets if the retained material is excessive, or by the fitting of
more (or modified shaped) gussets if the retained material is not sufficient.
Rotor Diameter: Rotor diameters are constant for each model. Changes to
the Tip Speed (M/sec.) of the rotor is achieved either by adjustment to the
drive pulleys, or by the utilisation of an electrical speed inverter (increase or
decrease speed).
(Continued)

Min. % Bi-Flow
Feed Feed
Products
High
speed
Products
Low Decreased
speed rotor speed
Max.% Bi-Flow
Sieve size Sieve size
Feed gradation Screen aperture

Changing the size distribution of the feed to When operating in closed circuit the final product
the crusher will affect size distribution size produced by the crusher is controlled by the
screen aperture
Product screen
Undersize 5mm
Feed
Product screen
Product 1 Undersize 10mm
Product 2
Feed1
Feed2
Crusher
discharge
5mm 10mm
Screen aperture
1.4 Vibration protection

Full wiring instructions are supplied with the vibration protection system.
Machines without a vibration protection system will not be covered by
warranty.

2. Safety precautions
To ensure maximum safety, always read this section carefully before doing
any work on Sandvik equipment or making any adjustments.
OM Sandvik CV215-CV229 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, risk levels are indicated with “DANGER”,
“WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels
are accompanied by a warning sign (see above).
Failure to observe information marked “DANGER!” can result in

life-threatening injuries!
DANGER!
Failure to observe information marked “WARNING!” can result in
personal injury and/or serious damage to, or destruction of,
equipment!
WARNING!
CAUTION! Failure to observe information marked “CAUTION!” can result in
damage to equipment!

2.1.3 Prohibition signs
Do not remove Do not clear crusher Do not open

guards while operating inspection door
while operating
2.1.4 Mandatory signs
Disconnect current Read the manual
2.1.5 Other signs
Point where the whole

machine can be safely lifted from.
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
(Continued)

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
• It is the responsibility of the owners to assess the required level of
education for non professional personnel, is satisfactory for the safe
operation and maintenance of the crusher.
• Risk assessments and method statements must be performed to assess
the hazards of material being crushed. Specific attention must be paid to
risk from explosion (combustible material) that may be caused by heat or
friction within the crushing chamber and or hazardous dust (silica) etc.
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 or 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 respirator

apparatus when
appropriate

2.3 General safety precautions

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 equipment, unless necessary for maintenance work.
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.
CAUTION! Clear the feed arrangement from process material before any
maintenance work is carried out inside or below the crusher, to prevent
stones from falling down.
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 must be prevented by
guards. Always attach guards after maintenance work.
WARNING!
Flying fragments
Fragments ejected upwards may fall down in the vicinity of the
equipment. Provide adequate guards and warning signs at appropriate
WARNING! places around the danger zone.
Platforms with guard rails shall be installed around the crusher’s feed
opening. Walkaways, stairs and ladders must be designed in accordance with
applicable regulations. (these parts are not included in the crusher’s standard
specification).
Make sure all defective guards and dust sealing components are checked,
repaired and replaced before starting the equipment.

2.3.2 Safety interlock system

The Safety Interlock System is designed to prevent the crushing chamber
service door from being opened while the machine is in operation, or on shut-
down, before sufficient time has elapsed to allow the rotor to stop rotating.
The interlock also prevents accidental start-up while the crusher is being
serviced, or when the door is left open. Under no circumstances should any
maintenance work or internal inspection be carried out on the crusher, until it
has been locked out using the Safety Interlock System.
NOTE! For installation and maintenance of the safety interlock system refer to the
Mechanical Safety Interlock System Manual.
2.3.3 Crusher safety inspection procedure.

P
Safety interlock system

The crusher must be isolated using the Safety Interlock System
(see the Safety interlock manual) before any inspection or maintenance
activity is undertaken.
PROHIBITION!
NOTE! If the operations of ancillary equipment (e.g. feeders, conveyors) present any
danger to this inspection or maintenance activity, these must also be isolated.

2.3.4 Vibration protection

A vibration protection system protects the machine from the effects of severe
vibration. With this installed, the machine will be shut down and/or an alarm
sounded if vibration becomes excessive. In normal operation, the crusher has a
slight vibration which varies from time to time, due to the wear and
replacement of material within the rotor. As material wears away it is
continually replaced. Consistent or excessive vibration should always be
investigated. A likely cause is breakage of a rotor tip or uneven build-up
within the rotor. High pitched vibration may be caused by poor rotor taper lock
seating or a bent shaft.
Recommended position for Vibration Switch
Vibration
All machines must have a vibration protection system properly fitted
and connected.
WARNING!

2.3.5 Electrical safety

CAUTION! Only electrical personnel working according to European Standard EN
50110 or similar are permitted to perform electrical operations on the
crusher.
P
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.
2.3.6 Welding
CAUTION! Only welders qualified according to European Standard EN 287 or
similar are permitted to perform welding operations on the crusher.
CAUTION! Welding on the crusher is only permitted when and as described in the
manual. For all other welding operations on the crusher local Sandvik
service personnel must be consulted.
If welding an item to the crusher, the earth must be attached to the item itself.
If a crusher component is to be welded, the earth should be attached as near
to the welding area as possible.
NO welding should be done on the rotor whilst it is in the machine.
P
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.
2.3.7 Hydraulic system

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

2.3.8 Lifting and moving loads

CAUTION! Only personnel with adequate lifting training are permitted to perform
lifting operation.
.
P
Hanging load
Never work or stand underneath a crane that is lifting material. Keep a
safe distance from a hanging load.
WARNING!
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 manoeuvre 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
2.3.9 Feed and jams

Always follow local regulations when attempting to clear a jam.
P
Risk of crushing
Never stand inside the crusher when a blockage is broken up. You
maybe pulled sharply downwards together with the material in the
PROHIBITION! crushing chamber and crushed.
Never use a bar or rod to clear blockages in the feed hopper, bar or rod
could touch spinning rotor and cause severe injury.

2.4 Emissions
2.4.1 Dust
P
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
encapsulation and dust extraction. 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
P
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
P
Health hazards
Radon is a radioactive gas that occurs naturally in bedrock. Radon may
cause lung cancer. Mineral type, ventilation and water are all factors
that influence the contents of radon gases.
DANGER!

3. Component identification
OM Sandvik CV215-CV229 3. Component identification
3.1 Exterior of crusher

This section has been included to help you identify the various components
and parts of your crusher. These terms will be used throughout the manual
and parts listings that are provided.
The letters refers to the table below for the correct terminology for that item.
Q P
C
CV228/CV229
R B
O
F1
F2
O
H D1
D2
K
T1 T2
S Q
CV218/CV217
CV215/CV216 R
P
A C
B
D2
D1
O
H

3.2 Interior of crusher

The letters refers to the table below for the correct terminology for that item.
J1
I
CV228/CV229
E1 L E2
G M
D2 D1
T1 T2
J2
CV218/CV217
CV215/CV216
L U G E2
M
D1 D2

3.3 Component identification reference list

Letter Description
A Crushing chamber
B Support frame
C Motor mount assemblies
D1 Support leg short
D2 Support leg short
E1 Hydraulic cylinder bracket
E2 Hydraulic cylinder bracket
F1 Leg gusset
F2 Leg gusset
G Crusher drive pulley
H Crusher base
I Feed kit holder assembly
J1 High profile rotor
J2 Low profile rotor
K Skid frame
L Grease chute
M Grease duct
N Feed hopper
O Guard assembly
P Hydraulic unit
Q Hydraulic cabin
R Grease keg
S Grease hand pump
T1 Support leg long
T2 Support leg long
U Bearing cartridge assembly

3.4 Rotor and wear parts

Sandvik LP / EP Rotor
2 3
4
1 Distributor plate
2 Top wear plate
3 Trail plate
4 Upper wear plate 7
5 lower wear plate
6 Rotor body 5
7 Top cavity wear
plate 9
8 10
8 Bottom cavity wear plate
9 Back-up tip
6
10 Rotor tip
11 Rotor boss
12 Taper lock
11
12

Sandvik HP Rotor
2
4
1 Distributor plate
2 Top wear plate
3
3 Trail plate
4 Upper wear plate
5 Lower wear plate
5
6 Top cavity wear plate
7 Middle cavity wear plate
8 Bottom cavity wear Plate 6
9 Rotor Body 10
10 Back Up Tip 7 9
11 R o t o r Tip 11
8

4. Start up procedure
OM Sandvik CV215-CV229 4. Start up procedure
This section describes the full start-up procedure, including the initial
commissioning start-up. The start-up procedure should be used after a major
repair such as bearing cartridge replacement or crushing chamber
refurbishment has taken place.
4.1 Before start-up

a) Be completely familiar with the crusher, take the time to read this
manual.
b) Have all electrical connections checked, including the operation of the
vibration switch. (See the Vibration switch manual).
c) Check pulley alignment and drive belt tensions.
See section 14.16 Drive belt tensioning.
d) Check rotor rotation - it must be counter-clockwise when viewed from
above.
Damage
Severe damage to the rotor will result if the rotation is incorrect.
DANGER!
e) On dual motor drive machines it is essential that the direction of both
motors is correct and the same. If no electronic test equipment is
available to prove this, the wedge belts must be removed and the motors
started in the normal way, the direction of each motor can then be
checked. When all connections are complete ensure all pvc shrouds are
refitted and any unused holes are blanked off to maintain the IP rating of
the enclosure.
f) Check that the safety interlock device is connected and functioning.
g) Make sure all bolts are tightened to the correct torque.
See section 15.1 Bolt Torque Settings Nm (ft lbs) for correct torque
details.
h) Loosen the transport bolts located through the rubber anti-vibration
mounts by two full turns.
i) Ensure that the feed tube / Feed Kit Holder assembly is centralized.
See section 14.1 Feed tube centralisation and height adjustment.
j) Check that all wear parts are correctly fitted in the rotor.
See ssection 3.4 Rotor and wear parts.
k) Remove all tools from on or within the crusher.
l) Ensure that all guards, doors, hatches and safety pins are in place.
m) Ensure grease hoses are full of grease before connection to the bearing
cartridge.

4.2 Initial start-up

a) Confirm ammeter is operating accurately. (Use clip-on ammeter to check
accuracy).
b) Run the crusher with rotor fitted without load for 30 minutes.
Apply a single application of grease to each of the three grease points.
See greasing procedure in section 6.3 Grease requirement
Initial Feeding Of Crusher
a) The machine can now be run with a load. Feed material should be no
larger than the maximum allowable feed size for the crusher model being
commissioned.
b) Feed a small sized chip or all-in product, preferably 5mm [¼ in.] for the
first half minute or so. A few cubic meters/yards of material is enough.
This allows an even build-up of stone in the rotor and promotes good
balance.
c) If coarse feed must be used at the start, some vibration can be expected
for several hours until fines are able to work their way through the voids
in the initial rotor build-up and bring the density of each rotor build-up
into equilibrium.
d) When first feeding the rotor there will usually be an 'out of balance' stage
for about 30-60 seconds. Do not stop the feed to the rotor at this point but
feed it as much as possible until the vibration settles down. In normal
operation there is intermittent detectable vibration about 30% of the time.
This can be felt when standing on the machine and is most noticeable
with largest feed sizes. This is due to stone lodging by one rotor tip,
causing a build-up and then being worn away. The condition is normal
and no cause for concern provided the machine returns to normal running
after a few seconds.

After 10 Minutes
a) Ensure that the feed falls centrally within the Feed Hopper. The feed
should fall squarely into the hopper and the Hydraulic Rotor Feed
Throttle should be adjusted to obtain the required motor amps draw /
throughput. Whether using rotor only or rotor and Bi-Flow®, the Feed
Hopper should be choke fed at all times.
b) Check motor power draw. If motor(s) are overloaded, reduce feed
volume or adjust the Hydraulic Rotor Feed Throttle Control, until load is
corrected. See section 13.5 Hydraulic rotor feed throttle gate.
If dual drive motors are running at different amps check belt tensioning.
See section 14.16 Drive belt tensioning.
c) After 30 minutes running, stop the machine, remove belt guards and
check bearing cartridge temperature (Use a digital thermometer).
The temperature should not exceed 70 °C [160 °F].
If temperature exceeds this, continue to run machine with no load for a
further 30 minutes and check again. If high temperatures continue
contact your service centre for advice. If temperature is within normal
range (see section 6.5 Bearing cartridge), replace guards.
d) Inspect rotor and Bi-Flow® assembly. Ensure that all rotor parts are in
place. Ensure that the feed tube is still centralized in the rotor.
See section 14.1 Feed tube centralisation and height adjustment.
e) Test vibration switch. See Vibration Control System instruction manual.

After 30 Minutes
a) Stop machine and check build-up in rotor. For ideal build-up,

see rotor tuning section 9.2 Adjustment of rotor build-up.
b) Check crushing chamber build-up.
See section 12.2 Crushing chamber build-up for ideal build-up
c) Make sure feed tube is in correct position in rotor, i.e. central in
rotor feed hole and extending into rotor.
See section 14.1 Feed tube centralisation and height adjustment
d) Check that rotor tip assemblies are intact and tight.
e) Check belt tensions. See section 14.16 Drive belt tensioning.
After 4 Hours
a) Check build-up in rotor, crushing chamber and base.

b) Check bearing temperatures. (See below).
c) Check belt tensions.
d) Grease at the end of the shift, and perform daily inspections as listed.
e) Once the machine has settled down to normal running, further
adjustment of the Bi-Flow® can be under-taken.
See section 13.5 Hydraulic rotor feed throttle gate
Bearing Operating Temperature
Normal bearing temperature is 30 ° to 40 °C [54 ° to 72 °F] above feed

material or ambient temperature. A short duration temperature rise of
approximately 10 °C [18 °F] can be experienced when bearings are
lubricated.
The maximum permissible bearing temperature for continuous running is:
70 ° C (160 ° F) Normal temperature service
150 ° C (300 ° F) High temperature service

4.3 Operation
During operation it is important that the operator pays attention to the
following:
Ammeter Reading - watch for major fluctuations
High amps could indicate high feed rates, extreme build-up in the chamber or
the base, blocked discharge chutes, incorrect Hydraulic Rotor Feed Throttle
adjustment, mechanical or electrical problems.
Low amps could indicate low feed rates, incorrect Hydraulic Rotor Feed
Throttle adjustment, drive belt slippage, or electrical problems. Unbalanced
amps in a dual drive unit could indicate incorrectly tensioned drive belts,
electrical or mechanical problems.
4.4 Noise levels

An increase in noise level could indicate bearing failure, drive belt slippage,
scouring of build-up in crushing chamber, feed tube rubbing on rotor.
4.5 Vibration
An increase in vibration could indicate:
a) Uneven wear on wear parts
b) Unbalanced rotor due to uneven build-up in rotor
c) Failure of anti-vibration pads.
d) Loose rotor.
e) Loose pulley taper lock.
NOTE! The Vibration switch fitted to the crusher will, if correctly adjusted, sense
out-of-balance vibration and shut down the crusher before any damage or
danger to personnel occurs.

4.6 Flow of material

Changes in feed conditions could require adjustment of the Bi-Flow®
Adjustment Gates and or the Hydraulic Rotor Feed Throttle. Increases in
moisture content may increase build-up in the rotor, hopper, crushing
chamber and base. Observing the discharge of the crusher will often warn an
operator of build-up problems.
4.7 Dust emission

The crusher should not emit dust while being fed material. If the crusher is
emitting dust the following should be checked:
Feed rate - Very low feed rates may cause the crusher to discharge dust from
the discharge chutes.
Settings of the Bi-Flow® Adjustment Gates and Hydraulic Rotor Feed
Throttle. These should ideally be set to achieve choke feeding of the Feed
Hopper.
4.8 Feed control

The aim of Hydraulic Rotor Feed Throttle, is to govern the ratio of feed to
the rotor and Bi-Flow®. The reason for controlling this feed distribution is
very dependent on the product requirement of the operator.
The following describes the different uses of the control:
a) To protect the motor(s) from overload.
b) To achieve the absolute highest efficiency of crushing (reduction) by
using the optimum Bi-Flow® ratio and the consistent running of the
motors at full capacity.
c) To maximise the production of a particular size fraction by control of the
product gradation produced. Variation of the Bi-Flow® ratio will allow
complete control of the gradation curve. The rotor feed volume is varied
by adjustment of the Hydraulic Rotor Feed Throttle. Coarse adjustment
is made by selection of the correct sized Feed Control Plate. Fine
adjustment is made by movement of the Hydraulic Rotor Feed Throttle.
The feed opening should not be reduced to a point where bridging of the feed
opening may occur.
(Continued)

Adjust the Bi-Flow® Adjuster Gates, so that material Bi-Flows evenly

through 360°. See section 4.9 Bi-Flow® control.
1 Bi-Flow® Rotor Throttle

2 Bi-Flow® Control Plate
3 Bi-Flow® Adjuster Gate
4 Bi-Flow® Port
4
2 3
1
4.9 Bi-Flow® control

When using the Bi-Flow® mechanism, it is advisable to adjust the Bi-Flow®
Adjuster Gates, to ensure that the flow of material is equal through all six
Gates. This may necessitate positioning some Bi-Flow® Adjuster Gates
higher or lower than others, depending upon the direction of the flow of
material into the Feed Hopper.
In the case of reduced tonnage throughput and / or reduced levels of Bi-
Flow®, it is possible to operate the Hopper utilising two or three Bi-Flow®
ports only. It is essential however that two or three port operation of the Bi-
Flow® system, is set up so that the Bi-Flow® gates in operation are equally
spaced, i.e. 180º for two port or 120º for three port.
This will ensure the optimum positioning of Bi-Flow® material in the
crushing chamber and result in optimum crushing performance when feeding
reduced Bi-Flow® tonnages. As mentioned previously, choke feeding of the
Feed Hopper is the preferred mode of operation.

Dust Control
If excessive dust is emitted from the bottom of the machine, this may indicate
that the unit is being under-fed. If the feed rate cannot be increased, close off
the feed opening by adjusting the feed control plate and Hydraulic Rotor Feed
Throttle to minimize the intake of air. As mentioned previously choke feeding
of the hopper is the preferred method of operation, which will also
significantly reduce dust being vented to atmosphere. Any Bi-Flow®
adjustment gates not in use should be completely closed and those in use
opened only to the minimum open setting required.
While it is not generally necessary to suppress dust within the crusher (either
by dry dust collection or mist spray suppression), the turbulent activity within
the crushing chamber makes it an ideal environment for the addition of small
quantities of water by means of mist sprays to effectively control dust in other
parts of the process plant downstream of the crusher. However, on start-up or
shut-down with no material flowing into the crusher (completing start-up of
plant prior to crusher) there will be a discharge of dust caused by the crusher
pumping large volumes of air.
We recommend the following:
• Minimising the time that the crusher is running without material being
fed.
• Fitting of mist sprays close to the discharge that is activated
automatically from motor power on/off control so as to control the dust
emission on start-up and shut-down.


5. Shut down procedure
OM Sandvik CV215-CV229 5. Shut down procedure
Extended periods of running out the circuit with low feed rates to the crusher
can result in undue wear to the crushing chamber and rotor body. If possible
stop the main feed conveyor to the crusher without running the system circuit
clear. At the very least be aware of the excessive wear that takes place and
minimise the run-out time.
5.1 Shut-down
a) Shut down feed device (conveyor or feeder) before the crusher.
b) Observe ammeter unload prior to disconnecting power from the crusher.
c) Time run-down time of rotor and record in the Sandvik VSI Daily Log
Book. Measuring the run-down time of the rotor will provide a good
guide to the condition of the bearing cartridge. The commissioning
records for your unit will have the rotor run-down time recorded. This
will be located in the owners manual. If you cannot locate this contact
your Sandvik Service Engineer.
d) Prior to any servicing or maintenance ensure that the Safety Interlock
System is activated. See section 2.3.2 Safety interlock system

6. Inspection and servicing
OM Sandvik CV215-CV229 6. Inspection and servicing
6.1 General recommendations

Sandvik CV215-229 is a rugged machine which is mechanically simple and
extremely easy to maintain. The machine does however require ROUTINE
and REGULAR inspections and attention. The machine should not be
ignored for lengthy periods, during which potentially serious damage to wear
parts may remain undetected.
Long service and consistent trouble-free operation are the rewards of regular
inspection.
NOTE! Rotor wear parts are designed to protect the rotor body from wear. They are
not involved in the crushing action of the machine. Consequently it is not
possible to determine the state of wear of these parts from the product
discharging from the crusher.
To ensure trouble-free operation of the crusher it is necessary to inspect the
condition of the rotor wear parts and the rock build-up within the machine on a
regular basis. Any wear parts that are unable to complete another shift should
be replaced.
Sandvik recommends that you should carry out the following every 8 to 10
hours of operation:
a) Grease Bearing Cartridge.
b) Inspect Exterior Of Crusher.
c) Inspect Interior Of Crusher.
d) Inspect Rotor
Sandvik recommends the use of a Sandvik VSI Daily Log Book to record
inspection and replacement of parts. Service personnel will find the log book
extremely helpful in assisting you to maximize the life of the wear
components in your crusher.

6.2 Lubrication
Bearing Cartridge.
NOTE! The Bearing cartridge must be greased every 8 to 10 hours of operation.
The best practice is to grease the bearings when the bearing cartridge is at
operating temperature while the machine is running near the end of each
production shift.
Grease hose and grease discharge for CV228/CV229
1 Grease Hose
2 Grease Discharge
1 2
Grease hose and grease discharge for CV218/CV217/CV216/
CV215
1 Grease Hose
2 Grease Discharge
1 2

Grease unit
1 Grease Hand Pump
2 Lever for Bi-Flow throttle
3 Lever for motor 1
4 Distribution block with tell-tale
5 Lever for motor 2 (Dual Drive
Crushers only)
6 Hydraulic Hand Pump
7 Tool box
1 2 3 4 5 6 7
6.3 Grease requirement

The following amounts are recommended for every 8-10 hours of operation.
Quantities stated below are total (divide by 3 for each grease point).
Model
CV215 30g [1.06 oz] - 30cc - 15 full pumps of Sandvik VSI Grease Pump
CV218 &CV228 45g [1.59 oz] - 45cc - 22 full pumps of Sandvik VSI Grease Pump
The Sandvik VSI Grease Lubrication system fitted to the crusher is a

manually operated, keg mounted pump. It delivers metered quantities of
grease to all three greasing points of the Bearing Cartridge Assembly.
This system negates the need for use of grease guns via grease nipples, which
can cause contamination problems and or the wrong type of grease being
used.
The 15 kg keg of grease fitted to the crusher when new, is sufficient for
approx. one full years operation of the crusher (assuming 8-10 hours per day
running)
(Continued)

The grease pump feeds grease into a three outlet progressive distributor that
sub-divides the grease and feeds via high pressure hoses to the bearings.
The progressive distributor is fitted with a "tell-tale" visual indicator, to give
the operator a visual indication that the system is functioning correctly as the
pump is operated. Replacement kegs of grease can be purchased from your
local Sandvik agent.
If the visual "tell-tale" stops working during operation it should be
investigated immediately. Reasons for non operation indicate either that the
grease keg is empty and requires replacement or that air has become trapped
in the system.
If there is evidence of air becoming trapped within the distributor block or
high pressure hoses, it will be necessary to "bleed" the system. This can be
done by:
a) Ensure that the Follower Plate inside the grease keg, is sat flat on top of
the grease within the keg and is not restricted by the pump cylinder.
b) Remove the high pressure hoses from the bottom of the Bearing Cartridge
Assembly and operate the grease pump to ensure that consistent clean
grease is discharged from the ends of all three high pressure hoses.
c) Re-connect the high pressure hoses to the base of the Bearing Cartridge
Assembly.
NOTE! There is no set sequence that the hoses have to be connected, any hose can be
fitted to any connection point on the Bearing Cartridge Assembly.
However be sure that the high pressure hoses are connected so as to ensure that
they are well clear of the main drive wedge belts.

6.4 Recommended greases

Bearing cartridges are pre-lubricated with two types of grease upon
assembly, depending upon whether the crusher is to be operated at Normal
(LT) or High Temperature (HT). Please see the table below for the operating
parameters of the two main grease types.
6.5 Bearing cartridge

CV215 1300 to 2200
-20 to 65
-4 to 149) CV216 1300 to 2200 Sandvik VSI
Normal service CV217 1300 to 2200 Semi-Synthetic LT
Bearing cartridge
All speeds CV218/228 1100 to 1800
CV229 1100 to 1800
CV215 1300 to 2200

60 to 100
(140 to 212) CV216 1300 to 2200 Sandvik VSI
High temperature CV217 1300 to 2200 Semi-Synthetic HT
Bearing cartridge
All speeds CV218/228 1100 to 1800
CV229 1100 to 1800
All new Bearing Cartridge Assemblies are pre-lubricated with the grease
type listed above, for the varying applications.
Please note that the Bearing Cartridge Assembly in the crusher presents a
very unique set of operating conditions for the bearings and for this reason,
selection of alternative grease types is not a straight forward task.
Consideration must also be given to mix ability of any new grease with the
grease already in the bearing cartridge.
Mixing (especially of different thickener types) causes unpredictable
lubrication conditions and possibly premature failure of the bearing
cartridge.
If you wish to use a grease that is not on the list, please consult your Sandvik
representative to confirm its suitability for the specific application in
question.
This will be determined based on your particular application It is not
recommended that you use an equivalent grease as promoted by various oil
companies and organisations without first consulting Sandvik.

6.6 Operating temperature

Normal bearing temperature is 30 ° to 40 °C [54 ° to 72 °F] above feed
material or ambient temperature. A short duration temperature rise of
approximately 10 °C [18 °F] may be experienced when bearings are
lubricated.
The temperature on the outside of the bearing cartridge during continuous
running should not exceed:
70 ° C (160 ° F)a Normal temperature service
150 ° C (300 ° F) High temperature service
a. Actual bearing temperatures may be as high as150ºC [300ºF] for normal running.
6.7 Grease discharge

Ensure that the grease discharge is away from the drive belts and grease
hoses are undamaged.
It is also a good practice to perform a weekly inspection of the grease
discharge to ensure that it is not blocked, which may lead to pressure build-
up inside the cartridge; breakdown of grease inside, etc.
Excessive build-up of grease

Excessive build-up of grease may cause an overflow of grease onto the
drive belts, causing premature failure of the drive belts.
WARNING!


7. Rotor servicing
OM Sandvik CV215-CV229 7. Rotor servicing
The rotor assembly is the main wearing component of the crusher, and
regular and timely inspection of wear parts will extend the life of the rotor. If
wear parts are not replaced when required, severe damage or even total
destruction of the rotor body may result.
7.1 Access
While wear patterns and wear rates can be observed with the rotor in place, it
may be necessary or desirable to remove the rotor from the crusher to replace
any worn wear parts.
In this manual we have assumed that the parts are being replaced with the
rotor in the machine. The major problem with this can be the removal of the
build-up of material in the rotor around the wear parts.
7.2 Cleaning out rotor

The most successful method of removing the build-up is by using water. If a
hose pipe is available at the crusher it is quite in order to "wash out" the
build-up by inserting the hose pipe into the rotor, via the Chamber Inspection
Door.
If a hose pipe is not available near the crusher it may be possible to remove
build-up with a scraper bar or chipping hammer. If this is not possible, it may
be necessary to remove the rotor from the crusher for the removal of the rotor
wear parts.
Please observe the correct shut-down procedures. See section 5. Shut down
procedure. Prior to any internal inspection/service ensure that the Safety
Interlock System is activated. See section 2.3.2 Safety interlock system

7.3 7.3 Rotor tip assembly

7.3.1 HP & LP / EP Rotor Tip Assembly
1 Rotor Tip
2 Back-Up Tip
3 Washer
4 Tip Locating Domed Nut
1 2 3 4
7.3.2 Rotor Tip Assembly

Rotor Tips
Rotor tips must be checked to determine the amount of wear on the inserts.
Tips need to be replaced once 95% of the insert has been removed at the
centre of the wear track. Ensure that the rotor tips are tightly held and not
broken, cracked or badly chipped.
HP Rotors LP / EP Rotors
95% of the
95% of the insert worn
insert worn
95% of the insert worn

7.3.3 Rotor Tip Assembly

Rotor Tips
Normal Wear
The rotor tips are wearing normally. Replace when less than 3mm [1 /8 in.]
of insert remains at the centre of the wear, or if tip will not last another shift.
Cracked or Chipped Inserts
Tramp iron in feed. Remove tramp iron.
Oversize feed material. Investigate cause of oversize. Reduce maximum feed
size.
Off Centre Wear
The rotor tips are wearing at the top or bottom not in the centre. Trail plates
may require adjustment.
7.3.4 Selection Of Rotor Tips

A range of rotor tips are available to suit differing feed material
characteristics, operating conditions and type of rotor (LP / EP or HP). The
rotor tips supplied with your machine have been carefully chosen to suit your
requirements. However, changing feed material can require the re-selection
of the rotor tips.
For information regarding rotor tip options, contact your Sandvik
representative.

7.3.5 Removal / Installation Removal

Unscrew the Tip Locating Domed Nuts by two turns and impact the head of
the nuts with a hammer. This will break away build-up that holds the Tip
Plate in place. Fully release the location nuts and washers. The worn Tip Plate
can now be pulled forward from the Tip Carrier and removed from the rotor.
(Access is through the Crushing Chamber Inspection Door.)
1 Crushing chamber
inspection door
1
1 Rotor Tip
2 Back-Up Tip
3 Washer
4 Tip Locating Domed Nut
5 Tip Carrier
1 2 3 4

7.3.6 Installation
Ensure that all mating surfaces on the Rotor Tip Plate and Rotor Tip Carrier
are free of any high spots (dirt, stones etc.).
Position the Tip Plate behind the Tip Carrier and align the two location studs
through the location holes in the rear of the Tip Carrier. Ensure that the Tip
Plate is flush with the mating face of the Tip Carrier and that the Tip Location
flange fit snuggly around the front face of the Tip Carrier.
Tighten the Tip Location nuts to the specified torque setting. When fitting
Rotor Tips into a HP type rotor, make sure that the ends of the tips abut to
each other. This can be achieved by loosely fitting all three tip sections and
placing a small wedged screwdriver under the bottom tip and also over the top
tip and then securing in place. Ensure that tip assembly is pulled up tight and
that there is no movement in the parts. See bolt torque settings section
15. Bolt torque reference chart.
NOTE! Rotor tips must be changed as sets (in the case of HP rotors, it is
permissible to change three middle section tips or three top section tips etc.).
Do not replace single tips or a rotor out-of-balance condition may result.

7.4 Upper and lower wear plates removal

Replace upper and lower wear plates when it is obvious that they will not last
another shift.
Replace once there is less than 3-5 mm. [1 /8 - 3 /16 in.] of plate remaining at
the centre of the wear path at the discharge edge or inside edge.
Removal of the wear plates can be achieved by:
1 2
1 - 2.Tap the wedge inwards toward the centre of the rotor. This will help in
removal of any retained stone bed within the rotor, which must be cleaned
away before removal of the wedges and wear plates. See section 7.2 Cleaning
out rotor. Then remove the wedges.
3 3a
3 - 3a.Push the Upper and or Lower wear plates back towards the Trail Plates,
until they are released from the front rotor location clip.

4
4. The Wear Plates can then be removed from the rotor.
7.4.1 Upper Wear Plate

Rapid upper wear plate wear is an indication that either the Feed Tube is worn
or that excessive tonnage rotor throughputs are being experienced or large /
oversize feed is being processed.
Exposed to wear
Upper wear plates

The upper and lower wear plate
profiles shown above have been
used as examples only.
There are different profiles for different
rotors, but the principle is the same.
Lower wear plates
7.4.2 Upper & Lower Wear Plate Assembly

a) Ensure that all mating surfaces are clean and free of any dust / stone etc.
b) Place either the upper or lower wear plate into the rotor, with the long
straight side locating against the inner face of the rotor wall.
c) Pull the wear plate forward until it locates in the front rotor clip and
abuts against the tip carrier.
d) Fit the rotor wear plate location wedges and using a hammer tap the
wedges to firmly lock the wedges and upper or lower wear plates in the
rotor.

7.5 Distributor plate

The distributor plate wears in three places initially, opposite each rotor port.
The wear then spreads out around the surface of the distributor plate as
shown below. (Maximum wear.)
Replace distributor plate once there is only 3-5 mm.
[1 /8 - 3 /16 in.] of casting left at the thinnest point
Worn Section of Distributor plate
3-5 mm
Maximum wear
7.5.1 Premature Wear

Generally caused by oversize feed or material dropping from a conveyor or
screen chute directly onto the distributor plate.
7.5.2 Selection Of Distributor Plate

Different types and shapes of distributor plate are available. Please contact
your dealer for more information.
7.5.3 Distributor Plate

Removal/Installation

7.5.4 Removal
a) Clear away the stone bed within the rotor that covers the Distributor
Plate
b) Remove Distributor Location Pins.
c) With the aid of a screwdriver, lift the Distributor Plate from the Rotor
Top Plate.
d) Remove via the Feed Hole in the top of the rotor.
7.5.5 Refitting
a) Ensure the top plate surface is clear of obstructions before fitting the
distributor plate to ensure that it seats correctly and to ensure that the
Distributor Plate Location Pins will align with the fitting holes in the
sides of the Distributor Plate and Rotor Top Plate.
b) Ensure that the Distributor Locating Cap Screw is in place and tightened.
c) Place the Distributor Plate on the Rotor Top Plate, ensuring that the
counterbore in the base of the Distributor Plate fits easily over the cap
head of the Rotor Locating screw.
d) Align the Distributor Plate, so that one straight side aligns with the rotor
wall and that the location holes in the sides of the Distributor Plate align
with the holes in the rotor Top Plate.
e) Fit the Distributor Locating pins into the three sides facing each rotor
port. Ensure that the pins go fully into the rotor Distributor Plate and
tighten the screws securely.

7.6 Feed tube

Replace the Feed Tube just before the bottom lip is exposed by a maximum
of 6mm above the rotor Top Wear Plate. This wear can be checked by
looking through the viewing slot cut in the Feed Kit Holder Wear Skirt.
The feed tube should wear evenly up the casting.
Maintaining the correct position of the feed tube in the rotor will result in
increased life for the upper wear plates.
1 2
1 Wedge
2 Feed tube clamp plate
3 Feed Tube
4 Maximum permitted wear
3

7.6.1 Uneven Wear

Feed tube wearing on one side - feed tube not centralised. To centralise feed
tube, see section 14.1 Feed tube centralisation and height adjustment.
7.6.2 Cracking and Breakage

Feed tube cracking on bottom edge - excessive rotor build-up is rubbing on
feed tube and causing overheating. Adjust trail plates to reduce build-up.
Feed tube breaks - can be caused by excessive build-up in rotor, stones
wedging between feed tube and rotor feed hole and Rotor Top Wear Plate or
the feed tube coming loose (check feed tube clamp plate).

7.6.3 Removal
a) Open crushing chamber inspection door (1) after operation of time delay
interlock.
1 Crushing chamber inspection door
b) Remove wedge (2) and open door on feed kit assembly door
c) Remove the Feed Tube Clamp plate Wedges (2 off),
(will need to remove build-up within the Feed Kit Holder)
d) Remove the Feed Tube Clamp Plate (3).
e) Lift Feed Tube out (4).
2 Wedges
2
3 Feed tube clamp plate
4 Feed tube
5 Feed tube locating plate 3

7.6.4 Installation
a) Lower Feed Tube into Feed Tube Holder Location Plate, ensuring that
the holder is free from stones etc.
b) Refit Feed Tube Clamp Plate.
c) Lock Feed Tube Clamp Plate onto position with the two Location
Wedges and finally check the feed tube is centrally located.
d) Close feed kit assembly door and re-insert wedge.

7.7 Trail plates

Check trail plates regularly for signs of wear. Replace if badly worn. If the
rotor build up is not satisfactory, adjust the Trail Plates. Maintaining the
profile edge of the Trail Plates maximises rotor tip life and is very cost
effective.
HP Rotors LP/EP Rotors
1
1 Trail plates
2 Tip assembly
3 Build-up
2 3 1

The trail plates are the heart of the rotor. The position and profile shape of
the trail plate controls the size of the rotor build-up and the flow of material
through the rotor. Incorrectly positioned or worn trail plates can result in
premature wear on every rotor wear part. See section 9. Rotor tuning
Due to the importance of the Trail Plate within the rotor, all rotors are fitted
with Tungsten Carbide along the front profile edge, in order to achieve
maximum life of the Trail Plates, rotor and rotor wear parts.
P
Build up
The use of different sized trail plates (through uneven wear or uneven
fixing position) can create uneven build-up which may cause severe
WARNING! vibration. Ensure that trail plates are matched in size and shape and are
bolted into the same location positions.

7.7.1 Removal
a) Access through service door.
b) Remove trail plate retaining bolts. Take note of which position location
holes the Trail Plates are fitted to.
c) If trail plate is held in by the build-up, a sharp blow with a hammer will
break away the build-up and allow the trail plate to fall free.
7.7.2 Installation
a) Clean out any remaining build-up.
b) Position trail plate and insert bolts into the threaded holes in the Trail
Plates and tighten.

7.8 Rotor body

The following areas are subject to normal wear - the comments provide a
guide to causes of unusual rapid wear.
7.8.1 HP Rotors
2
1
1 Top Edge
2 Top wear plate
3 Streaming
4 Cavity Wear
5 Bottom edge
5
4
7.8.2 LP / EP Rotors
2
1
1 Top edge
2 Top wear plate
3 Streaming
4 Cavity wear
5 Bottom edge
5
4

7.8.3 Top wear plate

Feed tube too short and material is discharging over the top of the rotor.
Replace feed tube or remove dust build-up.
7.8.4 Top edge wear

Feed Kit Wear skirt and/or Cavity Ring are worn. Replace worn parts.
Seesection 14.2 Wear skirt and section 13.1 Cavity ring.
HP Rotors
LP/EP Rotors

7.8.5 Streaming Wear

This is more prevalent in wet and/or very abrasive fine applications, and is
caused by dust streamlining around the Tip and or Cavity Wear Plates.
Effects can be reduced by sealing the gap between the top and bottom edges
of these components with a silicone rubber or urethane sealant. If the rotor
has been in service for some time it is important to check possible wear on
Rotor Tip Carrier. If wear is severe, remove the rotor and repair.
HP Rotors
1 Check for wear here and seal if

necessary with silicone sealant
2 Check Tip Carrier for wear here
3 Check for wear here and seal if 2
LP / EP Rotors

2 Check Tip Carrier for wear here
2

7.8.6 Bottom edge wear

Can be a feature of high tonnage operation or indicative of excessive build-up
in the base that is rubbing on the rotor. Reduce build-up by reducing moisture
content of feed or introducing water spray system and Transmission non stick
liner kit.
HP Rotors LP/EP Rotor
7.8.7 Rotor wear protection plates – Top wear plate

The Top Wear Plate should not wear rapidly, but it should be inspected and
replaced before the rotor body is damaged.
If it is necessary to renew the Top Wear Plate, the rotor should be removed
from the crusher and the stone bed and wear parts removed. Remove the worn
Top Wear Plate, Fit the new Top Wear Plate and re-balance the rotor.

The remaining rotor wear parts can then be re-fitted as described previously
and the rotor re-fitted to the crusher.

1 1
1 Top wear plate

7.8.8 Cavity Wear Plates

The cavity wear plates should be replaced before wear progresses to the body
of the rotor. Remove the bolts holding the wear plate to the rotor body and
replace. Always replace the Cavity Wear Plates in sets, e.g. either all Tops,
Bottoms or for HP rotors all middles with new sets to maintain balance.
HP Rotors LP / EP Rotors
1
1
1 Cavity Wear Plate


8. Rotor build-up
OM Sandvik CV215-CV229 8. Rotor build-up
8.1 Primary function

The build-up in the rotor needs to protect the internal walls of the rotor and
most importantly protect the rotor tip from direct wear and impact.
8.2 Secondary function

The build-up in the rotor can influence the wear patterns of the wear parts in
order of importance:
• Rotor tips
• Cavity wear plates
• Upper and lower wear plates
• Distributor plate
While large build-ups tend to assist in the protection of the above wear parts
- particularly the rotor tips - they can greatly increase feed tube wear.
See section 9. Rotor tuning

9. Rotor tuning
OM Sandvik CV215-CV229 9. Rotor tuning
9.1 General information

9.1.1 Rotor
The success of the crusher is centred on its rotor. If the rock build-up within
the rotor is ideal, then wear on the upper and lower wear plates will be even,
the rotor tips fully utilized, and the lowest consumable cost per tonne of
product will be achieved.
9.1.2 Different material characteristics
Unfortunately, the build-up characteristics are never the same for any two
materials, indeed the nature of the build-up will vary with rotor speeds, rotor
sizes, feed rates, feed sizes, and feed moisture.
9.1.3 Tuning on site
It is normal that some tuning will be required as each rotor is placed into
service. Tuning relates to controlling the build-up of material within the
rotor. This is done by altering the size, position, shape, or style of the trail
plates.
9.1.4 Primary function
The main purpose of tuning is to ensure that the build-up within the rotor
extends from the trail plate to the inserts in the rotor tip, and that the wear is
centralized across the rotor tips.
Insufficient build-up will result in tip exposure. This will lead to early failure
of the rotor tips through the chipping of the inserts by direct contact with the
larger stones in the feed. Insufficient build-up of material will expose the
supporting metal of the rotor tips. This will also lead to premature failure of
the inserts by direct abrasion from the stone flow through the rotor. This can
also result in the rotor tips wearing in front of the inserts which will eventually
lead to their falling out of the carrier plate.
9.1.5 Basic principles
In tuning the rotor one should try to maximise the build-up within the rotor to
achieve:
• A build-up of rock within the rotor to protect the wear parts and not
restrict the feed path through the crusher.
• A build-up that clears the side and bottom of the feed tube, preventing
premature feed tube wear.
• An equal flow through each rotor port, equalising the wear on the rotor
tips.

9.2 Adjustment of rotor build-up

The width and position of the trail plates will control the amount and
characteristics of the build-up in the rotor.
The following is meant only as a guide, as rotor build-up is dependent on
many factors: material type, moisture content, rotor speed, etc., and trial and
error will have to be employed to determine the correct trail plate position for
each application.
Generally:
• Wide trail plates make the material build-up deeper
• Narrow trail plates make the material build-up shallower.
2
1 Build-up too low
2 Trail plate
1
(Continued)

If build-up is not up to rotor tip - Increase trail plate width until build-up
approaches rotor tip and covers the centre distributor.
2
1 Ideal build-up
2 Trail plate
If build-up is rubbing on feed tube - Reduce trail plate width until build-up
starts to pull back from rotor tip
9.2.1 Adjustment Of Rotor Build-Up
Increasing the width of the trail plate increases the depth of the rotor build-up.
Decreasing the width of the trail plate decreases the depth of the rotor build-
up. Increasing or decreasing the effective width of the Trail Plate is achieved
by the positioning of the Trail Plate against the Trail Plate Holder in the rotor.
Two location positions are available, giving either wide or narrow Trail Plate
positions whilst using the same profile shaped tungsten edged Trail Plate.
NOTE! All Trail Plates should be the same size and shape or an out-of-balance
situation may result.
9.2.2 Rotor servicing
P
Premature failure
Do not attempt to weld on rotor while it is in the machine or arcing
damage will cause premature failure of the bearings.
WARNING!

9.2.3 Rotor Rebuilding

a) Remove rotor. See section 10. Rotor removal.
b) Clean out all wear parts and build-up.
c) Do not weld on balance machine.
d) Spin rotor on balance machine to check for low spots on periphery.
Mark them.
e) Build-up top edge to original diameter and roundness
f) Build-up bottom edge to original diameter and roundness.
g) Replace top plate as required.
h) Effect any internal repairs
i) Balance rotor
1 2
1 Hardface flush with top

edge
2 Build-up to original
diameter with mild steel
(low hydrogen)
3 Hardface inside edges
with 1 layer of hardface 3
to 2.5 mm (0.10")
4 Hardface plate edges with
3 runs of hardface 5 mm
(0.20") deep
5 Hardface bottom edge with 4
1 layer of hardface to
2.5 mm (0.10") deep
2.5mm
5mm 5
21mm
NOTE! Use hardface wire/pin Filarc P26154 or ESAB OK 852 or equivalent

(550 HB). Frequent minor rebuilding is cheaper than infrequent major
rebuilding work.


10. Rotor removal
OM Sandvik CV215-CV229 10. Rotor removal
10.1 Removal
a) Remove hydraulic rotor throttle control pipes, via quick release
hydraulic couplings.
b) Remove hopper and crusher roof in one lift.

NOTE! The hopper may be removed from the roof first if the lifting equipment does
not have sufficient capacity to lift both assemblies together. Disconnect the
Hydraulic Rotor Feed Throttle from the hydraulic ram and slide back as far
as possible. This will allow the hopper to be removed.
c) Remove Feed kit holder
(Continued)

.
HP Rotors
d) Remove Distributor Plate.
d
e) Remove the Distributor Locating Cap
Screw.
f) Remove the top plate bolts and the top
plate.
e
g) Attach the Rotor Lifting Plate.
f
Bolt down with four bolts and tighten bolts
in series until fully screwed in to force
rotor off taper lock
LP/EP Rotors
d
g f
(Continued)

Top Plate for 73LP and 73EP rotors
.
NOTE! The cut out slot in the outside diameter of the Top Plate is to permit the fitting
of the Top Plate through the feed hole in the 73LP and 73EP rotors (rotor top
and top wear plate fit between this slot on assembly).

10.2 Rotor installation

The life of the bearing cartridge is greatly reduced when the rotor is running
with excessive vibration for long periods. When this vibration is extreme,
there is potential for catastrophic failure, i.e. shaft breakage. One factor
which has a direct influence on the smooth running of the crusher is the fit
between bearing cartridge and rotor. The correct procedure for securing a
rotor to a bearing cartridge is as follows:
1. Preparation
Thoroughly clean the shaft, key, taper lock, rotor boss and top seal plate. Coat
these surfaces with light oil or dewatering fluid and wipe down prior to
assembly. Ensure the key screw is not proud of the outer face of the key.
2. Taper lock fitting

Place a small wedge or screwdriver in the split on the top of the taper lock to
expand it slightly. Place the taper lock, large end downward, on the shaft so
that it sits hard down on the top seal plate, and over the taper lock location pin.
Remove the wedge or screwdriver and remove any burrs on the taper lock left
behind.
1 Top seal plate 1 3
2 Taper lock
locating pin
3 Rotor taper lock
NOTE! Do not expand the taper lock any more than necessary to achieve a snug
sliding fit onto the shaft. Excessive expansion of the taper lock can break it.
3. Rotor taper check

If the rotor being fitted has just been repaired and/or reconditioned around
the taper area (i.e. has undergone extensive welding that may cause
distortion), it is recommended that the fit between rotor and taper lock be
checked prior to final fitting. To do this, blue the bore of the rotor boss and
lower onto the taper lock on the shaft. (Use the rotor lifting plate). Ensure the
taper is properly seated under the weight of the rotor and then remove. You
should see a blue mark on the taper lock indicating contact with the rotor
boss. This mark should cover at least 80% of the circumference and 80% of
the length of the taper.

4. Rotor fitting
Fit the Rotor Location Pin into any hole in the Rotor Taper Lock.
Fit the rotor lifting plate to the rotor boss and lower the rotor onto the taper
lock, guiding the hole in the Rotor Lifting Plate, over the Rotor Locating Pin.
NOTE! The rotor must be lowered square to the shaft onto the taper lock. Failure to do so
may result in a poor mating of the tapered surfaces and hence vibration problems.
Check the 2 mm [1 /16 in.] difference in height between the rotor boss and taper
lock to ensure that the rotor has seated on the taper lock squarely. Remove the
lifting plate bolts evenly, allowing the rotor to slide onto the taper lock under its
own weight. Remove the Rotor Locating Pin. With the rotor firm on the taper lock
there must be at least 2 mm [1 /16 in.] between the top of the taper lock and the
top of the rotor boss.
Rotor installation
Rotor locating pin
Min 2mm

5. Securing bolts
Insert the bolts through the top plate into the taper lock and tighten evenly.
This pulls the taper lock up tight on the shaft and rotor boss. Fit the additional
4 outer bolts through the top plate into the rotor boss and tighten. This fills the
holes that are necessary for removal and provides positive drive between
taper lock and rotor boss in addition to the friction fit of the taper. Torque to
250 Nm [190 ft lbs]
Top plates
6. Final check
Stand on top of the rotor (if possible) and try to rock it from side to side. If
there is excessive movement or if you feel the rotor "settle" at all, recheck the
torque on all bolts. Note that there will be a small movement of the shaft
within the bearings. This is normal. This check simply confirms that the rotor
is properly seated on the taper lock.
7. Distributor plate fitting

The distributor plate must now be fitted to protect the taper assembly. First
locate and tighten the Distributor Location Cap Screw, and then fit the Centre
Distributor Plate as previously described.
8. Replace and centralize the Feed Kit Holder assembly.
9. Replace the Roof assembly and Hopper.
10. Reconnect hydraulic rotor throttle control pipes.


11. Rotor balancing
OM Sandvik CV215-CV229 11. Rotor balancing
11.1 Assembly of Rotor Balance Machines

(For both HP / LP and EP Rotors)
These machines require full assembly as follows:
a) Assemble the two side plates of the frame with the joining plates, bolts,
washers and nuts supplied.
b) For 85 rotors only, fit the adapter sleeve to the balance shaft
c) Clean the bearings in solvent to remove all traces of dirt, grease, oil, etc.
Fit the bearings to the balance shaft.
d) Rest the shaft assembly on the frame. The shaft should rotate freely.
1 2 3 4 5 6
1 Bearing
2 Taper to suit either 73EP,
73LP or 85HP and 85LP
3 Clamp Plate 7
4 Bolt and Washer
5 Balance Shaft 8
6 Bearing
7 Side Plate
8 Bolt, Nut and Washer
9 Joining Plate
e) Ensure the balance frame is level.

f) Remove bearing from the end of shaft that passes through the rotor
g) Insert the balance shaft through the rotor.
(Continued)

h) Locate rotor on taper, ensure that the two tapers fit evenly, fit rotor clamp
plate, washers and bolts and tighten.
i) Fit bearing back onto shaft and tighten grubscrew.
j) Using suitable lifting apparatus position the rotor and balance shaft on the
support frame.
1 Clamp Plate
2 Washer
3 Bolt 1 2 3 4
4 Bearing

11.2 Balancing procedure

a) Thoroughly clean out rotor of all rock, dirt, old wear parts and any old
welded on weights from a previous balance, see figure 3. Check for
perforations in the inner and outer walls.
b) Check taper in rotor boss is clean and free from damage
c) Remove weights from previous balance and set rotor up level in rotor
balancing frame.
d) Gently rotate the rotor and allow it to wind down to a stop. The heaviest
point on the rotor is now at the bottom.
e) With chalk mark the blades A, B and C, see figure 1.
f) Add weights to the blade A (fig. 1) until blade B is at top dead centre.
Each time a weight is added give the rotor a gentle push in the direction
you are working and allow the rotor to settle to the new balance point.
This helps overcome bearing friction.
g) When blade B has settled at Top Dead Centre, pull it around 90 ° and
hold it steady there by hand (fig. 2)
h) Add weights to the blade you are holding down (B) until it doesn't try to
go up or down.
i) Sometimes the blade B won't take enough weights to balance the rotor. If
this is the case cut a piece of 50 mm × 12 mm [2 in. × ½ in.] flat bar
200 mm [8 in.] long and weld it onto the B section where indicated
(figure 3). Use a small tack weld so the weight is easy to remove for the
next balance. Repeat the whole balancing exercise.
j) When you think the rotor is balanced, rotate the rotor in 90° steps four
times. If the rotor does not move from each stop, it is balanced.
k) Tighten the balance bolts.
l) Keep spare weights in a safe place.

Rotor balancing
T.D.C. T.D.C.
B A
B
A
C C
Figure 1. Typical rotor position after step 4. Figure 2. Step 6: 'B' is pulled around 90° from T.D.C.
Add weight to 'A' until 'B' moves to T.D.C. Add weights to 'B' until rotor does not try to turn.
Weight
Figure 3. Step 8: If you can't

get enough weights into position 'B', weld flat weight inside
rotor as shown and start again.
NOTE! To check that the rotor is now properly balanced, remove one balance
weight and confirm that the rotor is out-of-balance.
IF SO: Replace the weight. The rotor is now balanced.
IF NOT: There may be a fault with the balance machine. The balance
machine should be sensitive enough to detect an out-of-balance condition less
than the effect of one balance weight.
Refer to Troubleshooting, section 11.3 Rotor balancing troubleshooting

11.3 Rotor balancing troubleshooting

If the rotor fails to balance properly, check the following:
• Make sure there is no loose material in the rotor that could be moving as
the rotor is turned.
• Make sure the rotor balance machine is level and the bearings are totally
clean.
• Make sure the tapers are in good condition.
• Make sure the bearings are not damaged or worn.
After all checks have been made, attempt to balance the rotor again from
stage 1

12. Maintenance
OM Sandvik CV215-CV229 12. Maintenance
12.1 The rotor balance machine

The rotor balance machine is designed to give many years of trouble-free
operation. However, as with any precision machinery, proper care must be
taken to ensure this is the case.
• Wrap a cloth around the taper on the balance machine when not in use.
• Remove the bearings from the shaft and store in a container of light
machine oil.
• Store all components in a clean environment.
12.2 Crushing chamber build-up

• The chamber should have a full rock lining covering all items of the
• structure except for the faces of the chamber gussets (see below).
• The outer wall must not be exposed.
• The feed areas must be free of fines build-up and debris.
• Build-up should not be excessive, i.e. blocking material flow routes
or encroaching on moving parts.
Initially, the bottom crushing chamber gussets may protrude through the
build-up. These will soon wear to their ideal level. This is quite normal.
On stopping the crusher, if the time between shutting off the feed and the
rotor stopping is more than 5 minutes, air movement in the crusher may blow
away much of the lighter material from the stone bed, giving the impression
of insufficient build-up. In these cases, stone beds will be re-instated shortly
after starting to feed material again. This can be confirmed by 'crash-
stopping' the plant, to minimise the chance of air blowing material away.
Minimum
Ideal
Maximum
Bare steel
should not
show here.
ROTOR
Initially, the bottom crushing chamber gussets may protrude through the
build-up. These will soon wear to their ideal level. This is quite normal.

12.3 Chamber wall (low build-up)

Damage caused by large feed, very dry feed, or rounded feed. Tuning of the
gussets will assist in holding a build-up. Alternatively, the addition of fines
to a rounded or bony feed and or adding some water will enable the build-up
to form.
12.4 Excessive build-up

Feed moisture content too high and/or high fines content. Tuning of the
gussets will assist in reducing build-up. Alternatively, remove moisture and/
or reduce fines content.
Frequent operation of the crusher running light/empty may reduce stability
of the build-up and increase the likelihood of gusset and/or casing wear.
12.5 Chamber gussets

Chamber gussets can be added or removed as required. Add gussets to
improve poor build-up conditions. Remove gussets to reduce excessive
build-up. Gussets can be replaced when excessively worn.
1
1 Chamber gussets
2 4 Lifting points welded to
outside of crushing chamber.
2

12.6 Toe-board
The toe-board should be replaced when 12 mm [½"] remains as shown.
1 Toe-board ring
12 mm

13. Crushing chamber
OM Sandvik CV215-CV229 13. Crushing chamber
13.1 Cavity ring

The cavity ring is a secondary wear part and under normal conditions wears
little but needs checking. The cavity ring should be replaced when it has
worn to the level shown below (5mm).
If the Chamber Shield section of the Cavity Ring Assembly becomes worn it
must be replaced.
1 Chamber shield
13.2 Hopper Bi-Flow®

The opening of the Bi-Flow® port can be altered by moving the Bi-Flow
Adjuster Gates up or down. Adjust gates individually so that the Bi-Flow®
material passes through evenly over all ports.
Adjusting Bi-Flow® Adjuster Gate height
a) Remove build-up from hopper.
b) Lift shield up vertically and out toward centre of hopper.
c) Holding shield close to wall of hopper, lift to desired height.
d) Replace shield on brackets.
1 2
1 Slots for height
adjustment
2 Bi-Flow® port gate

13.3 Hopper body

It is important to check the general condition of the hopper. Material flow
from the conveyor/feeder and/or chute work may create wear in the hopper
structure. Adjust flow of material to correct.
13.4 Control plate

Once worn, this plate will need replacement. Note that various opening sizes
are supplied. Choose the size that allows the control gate to operate at the
middle of its adjustment when the rotor feed is at its optimum.
13.4.1 Removal
a) Clear away the build up of material in the hopper and lift out the Control
Plate.
b) Ensure that the locating surface is free from stone and dust.Assembly
13.4.2 Assembly
a) Place the Control Plate inside the three location blocks, welded to the
Feed Hopper Base.
b) Ensure that the Control Plate sits flat on the Feed Hopper Floor
c) Adjust the Hydraulic Rotor Feed Throttle to achieve desired operating
parameters.
1 Control plate

13.5 Hydraulic rotor feed throttle gate

13.5.1 Normal running adjustment
Adjustment of the Throttle Gate is done manually via a hydraulic hand pump
and double acting ram. The drawing below shows the position of the
hydraulic operating lever for either opening or closing the Throttle Gate.
Opening the gate increases the throughput of material to the rotor (increases
motor amp loading) and closing the Throttle Gate reduces the throughput of
material to the rotor (decreases motor amp loading).When not in use the
hydraulic Throttle Gate lever should always be in the neutral position.
CV228/CV229
Bi-Flow
Throttle
gate Motor 1 Motor 2
1 2 3 4 5 6 CV218/CV217/CV216/CV215
1 Grease Hand Pump

2 Lever for Bi-Flow throttle
3 Lever for motor 1
4 Distribution block with tell-tale
5 Lever for motor 2 (Dual Drive Crushers only)
6 Hydraulic Hand Pump
If the edges of the Throttle Gate are excessively worn, it is necessary to

replace it.

13.5.2 Removal
a) Remove hydraulic rotor throttle control pipes via quick release hydraulic
couplings.
b) Release Roof Swing Bolts and remove Hopper and Roof in one lift.
c) Remove clevis pin from the hydraulic ram assembly.
d) Slide Throttle Plate back to release from the retaining guides.
1 Throttle Gate

13.6 Cylinder
13.6.1 Removal
a) Remove ram cover (1) kit.
b) Remove R-clips (3) from clevis pin (2) at both ends of hydraulic ram
c) Remove clevis pins (2).
d) Remove ram.
1 Ram cover
2 Clevis pin
3 R-clip
4 Hydraulic cylinder
4
2
3

14. Crusher servicing

OM Sandvik CV215-CV229 14. Crusher servicing
14.1 Feed tube centralisation and height

adjustment
Every time the Feed Kit Assembly is refitted to crusher, it is important to
check that the feed tube is located centrally and at the correct height in the
rotor feed hole.
Height Adjustment
Add or remove shims from below the three arms of the Feed Kit Assembly to
set required height.
Centralisation
a) Loosen the Lock Nut on each of the three arms of the Feed Kit
Assembly.
b) By tightening one of the screws against the inner rolling of the Crusher
Roof Assembly, it is possible to move the Feed Kit Assembly
horizontally and thus centralize the Feed Tube within the Rotor Feed
Hole
c) When the Feed Tube is central within the Rotor Feed Hole, release all
three adjustment bolts on the arms of the Feed Kit Assembly.
d) Tighten by hand the three location bolts against the inner rolling of the
Roof Assembly, and then slacken back, to give 1mm clearance and then
lock the adjuster bolt with the lock nut.
NOTE! It is important that the Feed Kit Assembly is not held tightly within the Roof
Assembly by the three adjustment bolts. The adjustment bolts are for adjusting
horizontally only and not for retaining the Feed Kit Assembly..
Ensure feed tube is centralised in rotor
(Continued)

1
2
3
1 Shims
2 Lock nut
3 Adjustment bolt
4 Feed kit holder assembly
14.2 Wear skirt

Like the cavity ring, this is a secondary wear part and under normal
conditions wears little, but needs checking. It should be replaced when wear
on the rotor top edge increases
Check for wear

14.2.1 Removal
a) Remove hydraulic rotor throttle control pipes via quick release
hydraulic couplings.
b) Release Roof Swing Bolts and remove roof and hopper in one lift.
c) Lift Feed Kit Assembly out of chamber.
d) Remove bolts and Spacer Washers holding wear skirt in place.
e) Remove wear skirt, noting the position of the Feed Tube Viewing
port cut into the Wear Skirt.
14.2.2 Installation
a) Bolt wear skirt into place (ensuring that the Feed Tube Viewing Port is in
the same position as previous) using wear skirt bolt set and spacer
washers.
b) Replace Feed Kit Assembly
c) Replace the Roof Assembly and re-fit the Roof Swing Bolts
d) Reconnect hydraulic rotor throttle control pipes

14.3 Safety interlock

Regularly check that the safety interlock device is offering the operator or
maintenance staff adequate protection. Ensure that the Dust Caps are in place
over the locks and that they are secured to prevent dust entry. Check the
operation of the Time Delay Unit. Replacement components can be sourced
via your local Sandvik dealer.
14.4 Vibration switch

It is very important to check regularly that the vibration switch is operating.
For detailed information refer to the Vibration Switch manual provided with
the machine for instructions.
14.5 Inspection doors and hatches

• Ensure all inspection hatches, doors, guards and locks are secure.
• Ensure safety pin is in inspection door.
1 Safety pin

14.6 Crusher base and discharge chutes

It is very important that material does not build-up under the rotor. This can
cause severe wear and possibly damage bearings and/or the main shaft.
Build-up should not impede flow of material to the discharge chutes.
Discharge chutes must be kept clear. In moist feed applications the discharge
chutes need to be checked for possible build-up. Check if external discharge
chutes design restricts the flow, i.e. size or angle.
1
1 Excessive Build-up
2 Maximum Build-up
3 Ideal Build-up
2
3
Excessive Build-up
Excessive build-up can be caused by:
(1) Moisture content of feed too high
(2) High percentage of fine material in feed
(3) A combination of 1 and 2
Low friction liners are fitted as standard to the Base and Discharge Chutes, in
order to prevent the above problems occurring. However, if the problem
persists it may be necessary to fit a Base Water Spray System and possibly
Transmission Base Liners. Please contact your local Sandvik dealer for
further information.
In cases of high tonnage and/or abrasive material, (mining applications etc.),
hardened steel base and chute liners can be fitted as an option to the above
low friction liners.

14.7 Base liners

Non-stick Hi-Flow liners are fitted as standard. High wearing hardened steel
liners can be fitted as an option. Both types of liners are fitted and removed in
the same way
14.7.1 Removal
a) Remove rotor as previously described.
b) Remove R clip retaining pins from the location wedges.
c) Use a hammer to tap the wedges clear of the locating brackets.
d) Fit a clamp to the top edge of the liner and lift clear.
e) Repeat the above process for the remaining liners.
14.7.2 Assembly
a) Ensure all mating surfaces are clean and free from grit and dirt, paying
special attention to the locating blocks in the bottom of the crusher base.
b) Lower the liner into the base and locate the bottom edge behind the
locating blocks in the bottom of the crusher base.
c) Remove the lifting straps and push the liner over the locating bracket
situated around the top edge of the crusher base.
d) Re-fit the wedges and tap home with a hammer.
e) Re-fit the R-clips to the wedges, ensuring that the head of the R-clip faces
the rotation of the rotor.
f) Repeat the process for the remaining liners

14.8 Gusset wear castings

Check wear castings on bearing cartridge gusset. Replace as required.
1 2 3
1 Gusset wear castings

2 Base Liners
3 Wedges and R-clip
(Base Liners)
14.9 Grease discharge chute

Check weekly that the grease discharge chute is not building up with grease.
Clean out as required. Seesection 6. Inspection and servicing.
P
Premature failure
Excessive build-up of grease may cause an overflow of grease onto the
drive belts, causing premature failure of the drive belts.
WARNING!
14.10 Belt guards

Ensure that all guards are in place and secure.
14.11 Motors
Check for missing bolts, bearing noise, excessive shaft float or damage and
obstruction to fan cover. Grease according to motor manufacturer's
instructions.

14.12 Bearing cartridge
1 Grease filled Labyrinth Seal 1

2 Radial Bearing
2
3 Grease Retaining Ring
4 Radial Bearing 3
5 Thrust Bearing
6 Grease Hose Connections
4
5
6
The bearing cartridge is a grease filled, sealed bearing assembly which can
be removed in one piece (shaft, bearings, seals and housing) for overhaul and
inspection. When the new bearing cartridge has run between 100 and
150 hours, begin a series of routine checks on the run down time of the rotor
(time from power being cut to rotor stops turning). A significant decrease in
the run down time over a period will indicate that the bearings (crusher or
motor) are deteriorating. Once the time falls below two minutes the bearings
should be checked at the next routine service time. Operators should become
familiar with the sound of the bearings running. If this noise changes,
especially if it begins rumbling, this will also indicate that the bearings are
deteriorating.
If, when standing on top of the rotor during servicing, the shaft can be rocked
from side to side with excessive float, then the radial bearings are worn. If no-
load current begins to increase slowly over a period of time, this is an
indication that the crusher bearings are worn.
Upper seals should be replaced and labyrinth repacked with grease at yearly
intervals.

14.13 Bearing cartridge seals

Many premature bearing cartridge failures can be attributed to the condition
of the Top Seal Plate labyrinth seals within the cartridge. It is recommended
these upper labyrinth seals are renewed at intervals of 2000 hours. The
inspection/replacement can be achieved with the Bearing Cartridge
Assembly remaining in the base of the crusher and with the rotor removed.
Every care should be taken during inspection to ensure that the Bearing
Cartridge Assembly remains free of dust. The lower seals cannot be
inspected or replaced and are very unlikely to cause a premature failure.
To inspect/replace upper seals:
a) Remove the top key and slide top seal plate vertically off the Main Shaft
(a screwdriver inserted in the gap between the Upper Bearing Retaining
Ring and Top Seal Plate will assist this operation)
b) Remove the o-ring from within the top seal plate. This is a static seal and
may have a flat surface from contact against the shaft. If the seal is not
broken or obviously damaged in any other way, it can be re-used.
(Continued)

c) Inspect the labyrinth between the bearing and the outermost seal. This
should always be fully packed with clean grease. If the grease is not
clean, the v-ring seals are not effective and must be replaced. If the
labyrinth is not completely packed with grease, there could be a problem
with the grease supply to the bearing cartridge (check hoses, etc.) or with
the lubrication schedule. See section 6. Inspection and servicing.
1
2
1 Taper Lock Locating Pin
3
2 Top seal plate
3 O-Ring 4
4 V-Ring Seal, Outer
5
5 V-Ring Seal, Inner
6
6 Top Key
(Continued)

d) Remove the two v-ring seals from the Top Seal Plate.
These should not be worn, cracked or broken.
NOTE! CV218,228 and 229 Bearing Assemblies have only one top V ring seal fitted to the
Top Seal Plate and one fitted to the upper bearing retaining ring.
Sharp Broken
edge edge
Normal Condition Worn
Cracked Broken
e) Refit/replace seals as necessary, pack the labyrinth with grease,

refit top seal plate, pin and key.
f) Refit the rotor and start the crusher. Apply twice the normal amount of
grease to each grease point and continue with normal operation.
P
Crusher
Do not run crusher without rotor fitted.
WARNING!

14.14 Bearing cartridge removal from base

a) Remove hopper and crusher roof in one lift.
b) Remove the rotor. See section 10. Rotor removal
c) Loosen off belt tension using the Hydraulic Motor Mount Tensioning
system, see section 13.5 Hydraulic rotor feed throttle gate, and remove
drive belts.
d) Remove crusher pulley. In larger models, use a threaded rod (in the
threaded hole in shaft) and use a support to assist in lowering pulley.
1 Lock Nut
2 Nut
3 Support
4 Threaded Rod
1 3
5 Allow room to undo taper lock
6 4×¾" UNC threaded holes for 2 4
jacking off taper lock
5
6
(Continued)

e) Remove grease hoses and grease chute

f) Release bottom taper rings by removing the taper ring bolts in the
outer bottom taper ring.
g) Refit 4 of these bolts back into the tapped extractor holes to extract
the outer taper ring.
h) Remove the bottom taper rings.
i) Remove the top flange bolts.

j) Insert lifting eye bolt into the top of the shaft.
k) Lift out bearing cartridge.

14.15 Bearing cartridge refitting in base

a) Remove all traces of grease, protective coatings, dust, etc., from
machined surfaces using thinners or similar solvent.
b) Ensure all mating surfaces are free from rust, dents, scratches, etc.
c) Apply a thin layer of heavy machine oil to the mating surfaces of the
bearing housing, cartridge housing and taper rings.
d) Lower bearing cartridge into top of cartridge housing and check to see
that the three grease points are clear, full of grease and free of debris.
e) Check orientation of cartridge. The grease discharge slot must align with
the grease discharge chute.
f) Locate bearing cartridge centrally with top flange and loosely fit by hand
the bolts / nuts.
g) Fit bottom taper rings (inner and outer) and lightly screw in bottom taper
ring bolts.
h) Refer to Bearing Cartridge Bolt Torque Settings.
See section 15. Bolt torque reference chart.
i) Starting on top flange, torque down bolts top and bottom in a "star"
sequence (Fig.1) in two stages. Torque bolts in order from 1 to 8. Repeat
for bottom taper ring.
j) Refit grease hoses, making sure they are not twisted or blocked.
section 6. Inspection and servicing for identification of grease points on
bearing housing. Ensure that grease hoses are not able to fall onto drive
belts during operation.
(Continued)

k) Refit pulley and drive belts and tension using the Hydraulic Motor.
l) Refit rotor.
Figure 1

14.16 Drive belt tensioning

Correct tensioning is the most important factor necessary for long,
satisfactory drive belt operation. Too little tension will result in slippage,
causing rapid belt and pulley wear, and poor efficiency.
Too much tension results in excessive strain on belts, bearings (especially
motor bearings), and shafts. In order to ensure trouble free and rapid
operation of this maintenance procedure, the crusher is fitted with a
Hydraulic Motor Mount Adjuster.
This system makes adjustment of the drive belt tension very quick and easy.
14.16.1 Procedure for Adjustment and/or Removal of

wedge belts
a) Slacken the Motor Mounting Plate Location Bolts on either side
of the Motor Mounting Plate
(two Motor Mounting Plates for dual drive machines).
b) Position the hydraulic operating lever for Motor 1 in the release position.
See section 13.5 Hydraulic rotor feed throttle gate.
c) Pump the hydraulic hand pump to slacken the drive belts on motor 1.
d) Position the hydraulic operating lever in the neutral (central) position.
e) For dual drive machines, position the hydraulic operating lever for motor
2 in the release position.
f) Pump the hydraulic hand pump to slacken the drive belts on motor 2.
g) Remove the worn wedge belts.
14.16.2 Re-fitting and tensioning of wedge belts

a) Refit matched set of wedge belts.
b) Position the Hydraulic operating lever for Motor 1 in the tension position.
c) Pump the hydraulic hand pump to tension the drive belts on Motor 1.
d) Check belt tension through the belt tension inspection panel and when at
correct tension, tighten the Motor Mounting Plate Location Bolts.
e) Return the hydraulic operating lever for Motor 1 to the neutral (central)
position.
f) For dual drive machines, position the hydraulic operating lever for Motor
2 in the tension position.
g) Pump the hydraulic hand pump to tension the drive belts on Motor 2.

h) Check the tension through the belt tension inspection panel and when at
correct tension, tighten the Motor Mounting Plate Locating Bolts.
i) Return the hydraulic operating lever for Motor 2 to the neutral (central)
position.
14.16.3 Measuring
a) Select the second belt from the bottom.
b) Measure the force required to deflect the belt the distance as set out
below:
Apply force on belt through V-belt

inspection hatch towards centre of
belt span
Specified deflection distance
Force and deflection for each model and belt type can be found
on the Belt Tension/Deflection Chart, overleaf
c) For measuring the force and deflection, Sandvik recommends the use of a
tension gauge (supplied in the Toolkit as standard) similar to the one
represented. Using the belt tension gauge at the centre of the belt span,
follow these instructions:
– Set the large 'O' ring on the designated deflection as per the Belt
Tension/Deflection Chart.
– Push the belt tension gauge against the second to bottom belt until the
large 'O' ring is even with the top of the next belt. Ensure that the gauge
is in the centre of the belt section, and always test the belts on the tight
(or driven) side of the belts.
– Remove the gauge and observe that the small 'O' ring has moved from
its original setting at zero to the number of kg [lb] required to deflect
the belt.

14.16.4 Adjustment
a) Slightly loosen off motor mount bolts
b) Tighten (or loosen) tension by adjusting hydraulic belt tension
cylinders as described above.
c) Adjust belt tension as per the Belt Tension/Deflection Chart.
(For dual drive, adjust both exactly the same).
Model Normal running tension n (kgf) Deflection distance mm (in.)
CV229 96 (9.7) 27 (1.06)
CV218/CV228 96 (9.7) 27 (1.06)
CV217 76 (7.8) 24 (0.94)
CV216 76 (7.8) 24 (0.94)
CV215 69 (7.0) 20 (0.78)
Deflection in mm Setting force in kgf
NOTE! The above maximum belt tension/deflection values relate to QXPC belt
sections, and have been formulated to accommodate the various centre
distances that motor frame sizes or sheave diameters will provide on each
model.
Tension Range
Belt tension should be monitored regularly (at least weekly), but does not
need adjustment if within 10% of the above stated figures.
Running In New Belts (This includes the initial commissioning of the
crusher).
After 30 Minutes
After thirty minutes running it is recommended that the tension should be
checked and re-tensioned if necessary, to the above Tension / Deflection
values.
After 4 Hours
If necessary re-tension to the above Tension / Deflection values

14.16.5 Dual Drive
Belt Tension/Balanced Motor Amps
On dual drive machines, one motor may draw less current than the other, i.e.
it appears lazy. For the motors to do equal work the belt drives must be set up
with equal tension. On dual drive machines, a small difference in belt tension
between drives can make a big difference in motor amps.
Follow the normal static adjustment procedure as explained above, but make
special effort to adjust the two drives to exactly the same values.
Motors amperes should be within approximately 10% of each other
Some possible causes of unbalanced motor amperes if the motors will not
draw similar amps by altering belt tension, check:
a) The motor or starter electric terminals. Have a qualified electrician check
motor or starter terminals. If dirty they will need cleaning and re-fitting.
b) The starter has a fault. To confirm starter fault exists, have a qualified
electrician check the following:
With the machine under load:
– Read both ammeters and record amps on ammeter 1 and ammeter 2.
– Stop the machine.
– Swap motor wiring over at starter contactors.
– Restart the machine. The ammeter readings should have swapped, i.e.
No. 1 should read what No. 2 used to, and vice versa. If this doesn't
happen, the electrician must check the function of the starter components
c) Belt alignment - Make sure sheaves are in line using a straight edge or
string line.
d) Motors - They should be of the same brand and type and preferably be
manufactured in the same batch (check with motor manufacturer or
agent). Different manufacturers and sometimes different batches of
motors have different winding specifications.
(Continued)

e) Belts - The belts should be matched, i.e. all the same brand at least, and a
matched set if possible.
Pulleys:
– Check pulley axes are parallel and grooves are properly aligned
with one another - any dust build-up entering under the motor mount will
cause the pulleys to be out of parallel, with higher tension on belts at one
end of the pulley.
X 
– Check pulley diameters. For equal power transmission, the pitch

diameters of the driving pulleys must be within 0.5mm [0.02"] of each
other. This can be checked by measurement as shown. Check grooves at
each end of the pulley - any taper in pulley length will cause problems.
Vernier Caliper / Ground bar

stock to suit groove
Check
each
end


15. Bolt torque reference
chart

OM Sandvik CV215-CV229 15. Bolt torque reference chart
15.1 Bolt Torque Settings Nm (ft lbs)

Model Rotor size Rotor tip plate Rotor top, Distributor plate Bearing cartridge Bearing cartridge
Cavity wear plate plate bolts Centralising bolt Top flange Bottom taper
Trail plate bolts ring bolts
CV229 85HP 50 (37) 250 (184) 250 (184) 250 (184) 130 (96)
CV218/ 85HP 50 (37) 250 (184) 250 (184) 250 (184) 130 (96)
CV228
CV217 73LP 50 (37) 250 (184) 250 (184) 250 (184) 130 (96)
CV216 73LP 50 (37) 250 (184) 250 (184) 250 (184) 130 (96)
CV215 73EP 50 (37) 250 (184) 250 (184) 250 (184) 130 (96)
Note: All threads must be lightly lubricated before assembly.

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operation & maintenance manual S 226.051.

Serial no. / Machine no. Sign.

© Copyright 2010 Sandvik SRP AB.

Document number: S 226.051.en

© 2010 Sandvik SRP AB S 226.051.en-02 3

5. Shut down procedure

6. Inspection and servicing

4 S 226.051.en-02 © 2010 Sandvik SRP AB

7.5.1 Premature Wear..................................................... 57

© 2010 Sandvik SRP AB S 226.051.en-02 5

10. Rotor removal

11. Rotor balancing

13. Crushing chamber

6 S 226.051.en-02 © 2010 Sandvik SRP AB

14. Crusher servicing

15. Bolt torque reference chart

© 2010 Sandvik SRP AB S 226.051.en-02 7

This page is intentionally left blank

8 S 226.051.en-02 © 2010 Sandvik SRP AB

10 S 226.051.en-02 © 2010 Sandvik SRP AB

1.1 Control of crushed product sizes

1.2 Rotor speed

© 2010 Sandvik SRP AB S 226.051.en-02 11

Sieve size Sieve size

Feed gradation Screen aperture

1.4 Vibration protection

12 S 226.051.en-02 © 2010 Sandvik SRP AB

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

14 S 226.051.en-02 © 2010 Sandvik SRP AB

2.1.3 Prohibition signs

Do not remove Do not clear crusher Do not open

2.1.4 Mandatory signs

Disconnect current Read the manual

2.1.5 Other signs

Point where the whole

© 2010 Sandvik SRP AB S 226.051.en-02 15

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 respirator

16 S 226.051.en-02 © 2010 Sandvik SRP AB

2.3 General safety precautions

2.3.1 Machine safety guards

© 2010 Sandvik SRP AB S 226.051.en-02 17

2.3.2 Safety interlock system

2.3.3 Crusher safety inspection procedure.

Safety interlock system

18 S 226.051.en-02 © 2010 Sandvik SRP AB

2.3.4 Vibration protection

Recommended position for Vibration Switch

© 2010 Sandvik SRP AB S 226.051.en-02 19

2.3.5 Electrical safety

2.3.7 Hydraulic system

20 S 226.051.en-02 © 2010 Sandvik SRP AB