05.CH660-04 Installation Instructions S223.1257-04 en

Original instructions
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Installation Instructions
CH660:04
This publication is copyright of Sandvik – © Sandvik 2015.
It must not be copied*, reproduced or otherwise made available in full or in part to any third party
without Sandvik's prior written consent.
All rights reserved.
* The maintenance checklists in the Maintenance Instructions and Operator's Instructions may be
copied solely for maintenance purposes of Sandvik equipment.
Document number: S 223.1257

Version: 4
Language: en-US
Issue: 09/03/2017
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
WARNING!
IGNORANCE HAZARD
You can sustain personal injuries or even die if you ignore instructions.
Follow the instructions in the manual when you carry out any work on the
equipment and when you operate it. If anything is unclear, please contact
your local Sandvik representative.
Copyright © Sandvik
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Table of contents
1. Installation preparations
1.1. General preparations................................................................... 10
1.2. Machine access........................................................................... 10
1.3. Crusher capacity and performance..............................................10
1.4. Installation preparations checklist................................................ 11
1.5. Placement....................................................................................12
1.5.1. Height differentiation in the return line............................. 12
1.5.2. Maximum allowed pressure in pressure line.................... 13
1.6. Foundation...................................................................................14
1.6.1. Foundation loads..............................................................15
1.6.2. Natural frequencies.......................................................... 15
1.6.3. Movement of the crusher................................................. 15
1.6.4. Using an existing concrete foundation............................. 16
1.6.5. Using a steel supporting structure....................................16
1.7. Installation alternatives................................................................ 17
1.7.1. Installation packages........................................................18
1.7.1.1. V-belt drive installation package.......................... 18
1.7.2. Rubber dampers.............................................................. 18
1.7.3. Crusher mounting feet......................................................19
1.8. Crusher arrangement...................................................................20
1.8.1. Electrical installation - general......................................... 20
1.8.2. Plant control system.........................................................20
1.9. Process material.......................................................................... 20
1.9.1. Dust protection................................................................. 21
1.9.2. Feed arrangement............................................................21
1.9.3. Feed arrangements for fine crushing............................... 23
1.9.4. Discharge arrangement....................................................23
1.9.5. Guards............................................................................. 24
1.9.6. Platforms and guard rails................................................. 24
1.10. Emergency stop (Customer's supply)........................................25
1.11. Operating in low temperatures...................................................25
1.11.1. Measures for easier starting and running in cold climate
................................................................................................... 25
1.11.2. Low temperature problems - symptoms and remedies...
25
1.11.3. Heater set - cold climate.................................................28
1.11.4. Diesel heating system (option)....................................... 28
1.11.5. Heating cables on oil line............................................... 29
1.11.6. Synthetic oils.................................................................. 29
1.11.7. Mineral oil for the winter season.....................................30
1.11.8. Continuous running of the lubrication oil pump.............. 30
1.11.9. Insulation of the oil tank..................................................30
1.11.10. Heating in the component section................................ 31
2. Transport handling
2.1. Goods data.................................................................................. 34
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Table of contents
2.1.1. Contents...........................................................................34
2.1.2. Loading and unloading goods signs.................................34
2.2. Lifting equipment......................................................................... 35
2.3. Gantry crane or mobile crane...................................................... 35
2.4. Fork lift......................................................................................... 36
2.5. Unpacking area............................................................................37
2.6. Inspection of goods......................................................................37
2.7. Moving and storage..................................................................... 37
2.7.1. Moving..............................................................................38
2.7.2. Storage of a non-assembled crusher............................... 38
2.7.3. Pre-delivery rust prevention treatment............................. 39
2.8. Unpacking the goods................................................................... 40
2.9. Disposal/return of packaging material......................................... 40
3. Mechanical installations and connections

3.1. General requirements.................................................................. 42
3.2. Crusher on a subframe with rubber dampers.............................. 42
3.3. Crusher on a concrete foundation – fixed installation..................45
3.4. Crusher with rubber dampers on a steel supporting structure.....45
3.5. Motor and V-belt drive..................................................................45
3.6. Installing the feed hopper............................................................ 46
3.7. Dust seal air pressure system..................................................... 47
3.7.1. Installing the dust seal air pressure system..................... 47
3.8. Platforms......................................................................................48
3.9. Lubricants.................................................................................... 49
3.10. Hydroset and lubrication systems..............................................49
3.11. Pipes and hoses - General........................................................ 49
3.11.1. Connections................................................................... 50
3.11.2. Oil tank unit.................................................................... 51
3.11.3. Air/oil cooler....................................................................52
4. Electrical installations
4.1. General requirements – Electricians............................................56
4.2. The electrical system................................................................... 56
4.3. Motors, pumps, and heating elements.........................................58
4.3.1. M1-M1 – Crusher motor................................................... 58
4.3.2. L1-M1 - Lubrication oil pump............................................59
4.3.3. L1-M2 - Oil cooler fan motor............................................ 59
4.3.4. K1-M1 - Hydroset pump................................................... 59
4.3.5. E - Oil heater/s................................................................. 59
4.3.6. L3-M1 - Dust seal air pressure fan...................................59
4.4. Interlock, start and stop conditions for consumers...................... 59
5. Final installation checks

5.1. Installation and connection checks.............................................. 64
5.2. Lubrication system and Hydroset checks.................................... 64
5.3. Electrical checks.......................................................................... 64
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Table of contents
5.4. Safety checks.............................................................................. 65

5.5. Start-up........................................................................................ 65
6. Preparations for commissioning

6.1. General........................................................................................ 68
6.2. General checks............................................................................68
6.3. Supply value checks.................................................................... 68
6.4. Function checks – Preparation.................................................... 68
6.5. Health and safety checks.............................................................69
6.6. Documentation.............................................................................69
7. Disassembly and removal

7.1. Moving the crusher...................................................................... 72
7.1.1. Short moves and short-term storage................................72
7.1.2. Long moves and long-term storage................................. 73
7.1.3. Draining procedure...........................................................74
7.2. Regular inspection during storage............................................... 74
7.3. Storage of an assembled crusher................................................74
7.4. Return to the manufacturer..........................................................75
7.5. Disposal....................................................................................... 76
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Table of contents
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1.1. General preparations

Ensure that the dimensions of the installation site and the positions of
connections correspond with the information given in the drawings.
Refer to the Mechanical Drawings and any site-specific installation
drawings.
NOTE! Check that the required service areas, as shown in the installation
drawings in the Mechanical Drawings, comply with the installation site.
Check that the installation site is accessible for spare part deliveries.
Check that the equipment meets the local legislation demands
regarding personnel safety, emissions or other legal aspects. In case of
doubt, please consult local authorities or local authorized personnel.
It is possible to prepare parts of the installation before the main
installation of the crusher, for example placement, foundation and
electricity.
If the site does not meet all of the specifications given in this manual,
please contact Sandvik.
Use the checklist in section Installation preparations checklist on page
11 as a guide and for documenting the installation procedure.
1.2. Machine access

Every machine requires access for personnel who carry out inspections
and/or maintenance work. Suitable access platforms and guard rails
must be installed. Walkways, stairs and ladders must be designed in
accordance with applicable regulations. Also make sure that they are
not overloaded by spillage and spare parts.
These parts are not included in the crusher’s standard specification. For
advice, contact Sandvik.
Areas where access is required are indicated on installations drawings,
see the Mechanical drawings.
1.3. Crusher capacity and performance

A crusher is normally a component in a crushing and screening
process. The performance of the crusher is dependent on the operation
and design of the whole process including conveyors, feeders, motors,
site design and structure, etc.
The following factors affect the capacity and performance of a crusher:
• Choice of crushing chamber

• Choice of eccentric throw
• Feed size distribution and moisture
• Feed rate
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• Discharge system design

• Screening capacity
• Automation controls (options), both SanRemo or ASRi, and main
control system for the crushing plant
The following factors are very likely to lower the capacity and
performance of a crusher:
• Adhesive or moist process material

• Excessive amount of fines (> 20% of process material smaller than
CSS value)
• Very tough process materials
• Uneven distribution in the crushing chamber
• Not choke feeding the crusher
• Insufficient feed control
• Incorrect feeding and screening arrangement
• Incorrect discharge design
• Motor power less than recommended
1.4. Installation preparations checklist
System Check Remark Date/

Signature
Placement Site access checked for crusher and oil
tank unit dimensions?
Smallest area through which the
crusher components must pass?
(W × H) ____ x ____
Available service space? (L × W × H) ____ x ____ x
____
Available lifting device on site? Type:
Length of oil hoses and pipes?
Length of V-belts (if applicable)?
Foundation Foundation constructed according to
drawings?
Electrical system All necessary cables arranged to the
crusher and the oil tank unit?
Cable lengths?
All necessary switchgear installed?
All necessary connections to plant
control system arranged?
Electrical power available?
Plant control system prepared for the
equipment (if applicable)?
Process material Process
material tested
by Sandvik?
Dust protection Dust protection complies with local
regulations?
Feed arrangement Feed arrangement designed correctly?
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System Check Remark Date/

Signature
Discharge Discharge arrangement is ready to be
connected to outlet of the crusher?
Guards Need for additional guards?
Guards designed and ready to be
installed?
Platforms and Comply with local regulations?
guard rails Designed so that they do not interfere
with the crusher’s or tank unit's
function?
1.5. Placement
• Mark the service areas in the vicinity of the crusher with paint.
• Fence in the site to avoid damage and unauthorized operation.
Make sure that there is easy access to the crusher. A well planned
installation will result in better overall performance, easier service, and
less down-time.
NOTE! The oil tank unit can be installed on any side of the crusher. This is
important to decide before the foundation is designed. Refer to the
installation drawings in the Mechanical Drawings.
Place the tank unit as close to the crusher as possible. The maximum
allowed total length of the oil lines is 15 m (49 ft) .Excessively long oil
lines as well as many or sharp bends will increase the flow friction and
lower the performance.
Place the tank unit below the level of the crusher. Return oil must run
back to the oil tank unit and be pumped to the crusher.
Make sure that there is sufficient room to drain out all oil.
Make sure there is access to a lifting device meeting the requirements
stated in chapter Transport handling on page 33.
All requirements for the service area must be met. Refer to the
Mechanical Drawings.
Consider additional clearance for the feed arrangement (for example
chute, feeder or other equipment) and for the discharge arrangement.
Consider the placement of the motor for a crusher with V-belts. There
are several possible installation arrangements for a crusher with V-belt
drive. If the optional Sandvik motor bracket is used, ensure that the
motor is correctly positioned and aligned.
1.5.1. Height differentiation in the return line

For the oil to flow freely in the return line there must be a minimum
height difference between crusher and oil tank. The required height
difference depends on the pressure build-up created by the piping and
bends.
The tables below show how to calculate the minimum height difference.
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Minimum height difference in mm 1500 cSt (cold start), DN 100 new/clean

stainless steel pipes
Specified flow: 120 lit/min
Per meter pipe 130 mm
90° bend R=1×D 200 mm
90° bend R=2×D 110 mm
90° sharp turn 910 mm
Minimum height difference in " 1500 cSt (cold start), 4" new/clean stainless steel
pipes
Specified flow: 31.7 US gal/min
Per foot pipe 1.56"
90° bend R=1×D 7.87"
90° bend R=2×D 4.33"
90° sharp turn 35.83"
NOTE! The minimum height difference is directly proportional to oil viscosity, so

at 750 cSt viscosity the numbers in the table above should be reduced
by 50%.
NOTE! Place bends as far from the crusher as possible since they create a
relatively high pressure drop.
Example ISO units:

The specified flow is 120 l/min, and the return line consists of:
15 meters DN 100 piping 15 × 130 = 1950 mm

4 × 90° bends R=1×D 4 × 200 = + 800 mm
1 × 90° sharp turn 1 × 910 = + 910 mm
Minimum height difference needed = 3 660 mm
The crusher should be placed 4 m above the tank.

Example US units:
The specified flow is 31.7 US gal/min, and the return line consists of:
49 ft 4" piping 49 × 1.56 = 76.44"

4 × 90° bends R=1×D 4 × 7.87 = + 31.48"
1 × 90° sharp turn 1 × 35.83 = + 35.83"
Minimum height difference needed = 143.75"
The crusher should be placed 12 ft above the tank.
1.5.2. Maximum allowed pressure in pressure line

To prevent the lubrication pump from being overloaded there is a
maximum allowed pressure in the pressure line. The pressure build-up
depends on the components and piping dimensions, and on the height
difference between crusher and oil tank.
Pressure drop in piping 800 cSt (cold start), DN 38 new/clean stainless steel
pipes
Specified flow: 120 lit/min
Per meter pipe 27.9 kPa
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Pressure drop in piping 800 cSt (cold start), DN 38 new/clean stainless steel
pipes
90° bend R=1×D 14.0 kPa
90° bend R=2×D 7.0 kPa
90° sharp turn 69.6 kPa
Pressure drop in piping 800 cSt (cold start), 1.5" new/clean stainless steel pipes
Specified flow: 31.7 US gal/min
Per foot pipe 1.23 psi
90° bend R=1×D 2.03 psi
90° bend R=2×D 1.02 psi
90° sharp turn 10.09 psi
NOTE! The viscosity value at cold start is usually lower in the pressure line than
in the return line since the oil is warmed by the oil heaters.
NOTE! If you measure the pressure ahead (upstream) of filter/s and/or cooler/s
on the pressure line to the crusher, you must add the pressure drop for
these components to the values above.
The height difference between crusher and oil tank will add to the
pressure build-up with 10 kPa per meter (0.44 psi per foot) difference.
Example ISO units:
The oil tank unit is placed 4 m below the crusher with 15 m DN 38
piping and 10 × 90° bends R=2×D. Specified flow is 120 l/min.
15 meters DN 38 piping 15 × 27.9 = 418.5 kPa

10 × 90° bends R=2×D 10 × 7.0 = + 70.0 kPa
4 meters height difference 4 × 10.0 = + 40.0 kPa
Pressure build-up in oil line = 528.5 kPa
Crusher minimum oil pressure + 300.0 kPa
Minimum required pump pressure 828.5 kPa
The required pump pressure will be approximately 850 kPa.

Example US units:
The oil tank unit is placed 13.1 ft below the crusher with 49 ft 1.5" piping
and 10 × 90° bend R=2×D. Specified flow is 31.7 US gal/min.
49 ft 1.5" piping 49 × 1.23 = 60.27 psi

10 × 90° bends R=2×D 10 × 1.02 = + 10.2 psi
13 ft height difference 13 × 0.44 = + 5.72 psi
Pressure build-up in oil line = 76.19 psi
Crusher minimum oil pressure + 43.51 psi
Minimum required pump pressure 119.7 psi
The required pump pressure will be approximately 123 psi.
1.6. Foundation
The crusher equipment must have a stable, adequately dimensioned
foundation. A well designed and level foundation is of the utmost
importance for the successful operation of the crusher equipment. The
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foundation can be either a cast concrete foundation or a steel

supporting structure.
The design and construction of the concrete foundation or steel
supporting structure must be undertaken by qualified and experienced
personnel.
NOTE! The concrete foundation or steel supporting structure must be designed
and constructed in accordance with the applicable national and local
engineering regulations and building codes, etc.
The foundation must be designed to accommodate the static and
dynamic loads generated by the crusher, with an adequate safety factor.
Refer to the Mechanical Drawings.
Anchor plates and foundation bolts must be sufficiently strong and must
be well anchored.
NOTE! Anchor plates and foundation bolts for casting into the concrete
foundation are not included in the delivery.
The foundation must be constructed to accurate dimensions. The
crusher's mounting points must be level, that is, max ±1 mm (±0.04")
deviation at load application points. The tank's mounting points must
also be level.
NOTE! It is important to decide on the placement of the drive motor and the oil
tank unit before the foundation is designed. The oil tank unit can be
installed on either side of the crusher. For a crusher with a V-belt drive it
is possible to install the motor on either side of the crusher.
Contact Sandvik to discuss any questions about the way in which you
plan to install the crusher.
1.6.1. Foundation loads

Refer to the Mechanical Drawings for information on the static and
dynamic forces transmitted to the foundation via the crusher's mounting
points.
1.6.2. Natural frequencies

It is important that the foundation/supporting structure has no natural
frequencies close to the normal operating speed (frequency) of the
crusher's eccentric. Refer to the Mechanical Drawings for information
on this frequency.
1.6.3. Movement of the crusher

If the crusher is mounted on a subframe with rubber dampers, the
subframe and crusher will oscillate horizontally during normal operation.
During starting and stopping the movement is greater. Refer to the
Mechanical Drawings for the displacements of the subframe. Make sure
that there is room for the displacements of the subframe and crusher all
around.
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The feed hopper is bolted to the crusher's topshell and thus moves with
the crusher. Do not attach any chute or conveyor to the feed hopper, as
this would subject the crusher and the other attachment points to
abnormal loads.
Hoses and cables attached to the crusher and motor will also move.
Provide adequate space for this movement and protect hoses and
cables from falling stones and dust.
1.6.4. Using an existing concrete foundation

If you intend to utilize an existing concrete foundation that has
previously been used for another type of crusher, it is essential to check
that it can cope with the dimensions and loads of the crusher, with due
regard paid to the condition of the concrete and reinforcement.
• Thoroughly clean and inspect the top surface of the foundation.

• If the foundation is in good condition, make sure that the attachment
points for the crusher (support pads) are level and firmly anchored.
NOTE! It is essential that the support pads are firmly anchored so
that they can withstand the loads generated by the crusher.
• If the existing foundation is damaged or has cracks on the top, it must
be repaired in an appropriate way.
• It is often convenient to install a large installation plate on top of the
old foundation (>30 mm (>1.2") thick steel plate), but it is essential
that it is properly anchored. If the old crusher's foundation bolts are
still in place and are in good condition, it may be possible to use them
to anchor the new installation plate. Make sure that the upper ends of
the old bolts are cut off at the correct level so that they do not
interfere with the new installation.
• If you are using one of Sandvik's standard installation packages,
make sure that anchor plates are provided in the correct positions for
the rubber dampers. Also make sure that the rubber dampers are
level. See section Installation alternatives on page 17 for more
details.
1.6.5. Using a steel supporting structure

If the crusher equipment is to be placed on a steel supporting structure,
the structure must be carefully designed for the duty. Take the following
points into consideration:
• Design the steel supporting structure so that it is strong enough to

accommodate the loads to which it will be subjected. Refer to section
Foundation loads in the Mechanical Drawings.
• When using one of Sandvik's standard installation arrangements,
note that the rubbers dampers are level, regardless the size of the
dampers beneath the motor and the crusher.
• Make sure that the crusher's mounting points are level (max. ±1 mm
(±0.04") deviation at load application point).
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Make sure that the structure is mounted horizontally and rests on a firm
foundation. If the foundation is not sufficiently stable, the supporting
structure will vibrate and thus be subjected to abnormal stresses.
1.7. Installation alternatives

The crusher can be installed in different ways:
• On a new foundation or on an existing foundation, previously used for

another crusher
• On a concrete foundation or on a steel supporting structure
• On rubber dampers or directly on the foundation or supporting
structure
• With a V-belt drive
NOTE! If the crusher is mounted directly on a foundation without the rubber
dampers, the dynamic loads transmitted to the foundation or supporting
structure will be higher. Consult Sandvik for advice.
In this manual, Sandvik provides installation drawings and detailed
descriptions of the installation sequence for the installation alternative,
for which Sandvik can supply a standard installation package:
• Crusher with V-belt drive and rubber dampers – crusher and motor
mounted on common sub-frame - on a concrete foundation (see
section V-belt drive installation package on page 18 and section
Crusher on a subframe with rubber dampers on page 42.
In the Technical Specifications and Mechancial Drawings you will find
information that will be useful for the design of other installation
alternatives:
• Crusher on a concrete foundation – fixed installation (see section

Crusher on a concrete foundation – fixed installation on page 45.
NOTE! If the crusher is fixed rigidly to the foundation, the dynamic
forces transmitted to the foundation will be higher than when
rubber dampers are used. Make sure that the foundation is
designed accordingly.
NOTE! As the motor is installed directly on the foundation, there is
no machined structure (sub-frame or motor bracket) between
the motor and the crusher. It is therefore extremely important
that the alignment of the motor is very carefully checked.
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• Crusher with rubber dampers on a foundation, and with motor fixed

(see section Crusher with rubber dampers on a steel supporting
structure on page 45.
NOTE! If the crusher is mounted on rubber dampers it will gyrate
(see section Movement of the crusher on page 15). If the
motor is fixed to the foundation, there will be relative
movement between the crusher and the motor. This normally
means that a V-belt drive will be used in such a case. If so,
make sure that the center line of the motor's shaft is within
15° of the vertical plane through the center line of the
crusher's pinionshaft. Otherwise there is a major risk of
problems with the V-belt drive.
Sandvik recommends that the motor is mounted on a frame, similar to
the arrangement used in Sandvik's standard V-belt drive installation
package. See section V-belt drive installation package on page 18.
Other installation arrangements are possible, to suit the individual
requirements of the plant in question. Please contact Sandvik to discuss
the way in which you intend to install your equipment.
1.7.1. Installation packages

The installation components supplied by Sandvik depend on what has
been ordered in each individual case.
1.7.1.1. V-belt drive installation package
The crusher is mounted on four rubber dampers fixed to the top of the
dust sealing frame, which incorporates a sponge rubber sealing strip.
The crusher has two normal mounting feet and two connector-type
mounting feet, to which the motor bracket is attached. Two additional
rubber dampers are installed beneath the motor bracket.
Mounted on the motor bracket is a motor frame that carries the motor
and a jack shaft assembly. Between the motor and the jack shaft is a
flexible coupling, with a guard. The jack shaft carries a V-belt pulley. A
set of V-belts transmits power to the crusher's drive pulley, protected by
a guard. Pulleys and V-belts have either SPC or 8V profiles.
The entire V-belt drive assembly can be fitted to either side of the
crusher (viewed from the outer end of the pinionshaft) and the
components are delivered from the factory set up for the desired side.
Refer to the Mechanical Drawings and Motor and V-belt drive on page
45 for more details of the V-belt drive installation.
1.7.2. Rubber dampers

To reduce the stresses in the concrete foundation or steel supporting
structure, it is advisable to install the crusher's sub-frame on anti-
vibration compression mountings which absorb the vibrations generated
when the equipment is running. If the crusher is delivered without a sub-
frame, no anti-vibration compression mountings should be used.
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Moving and fixed parts hazard

If the crusher is mounted on rubber dampers you can sustain
crush injuries if body parts get caught between the crusher
WARNING! and the frame.
Only stay on the equipment if it is necessary for inspections
and maintenance work.
Following rubber dampers are used:
• Dampers (Type A) are used on the sub-frame beneath the crusher,

when the crusher and motor are mounted on a common sub-frame.
• Dampers (Type B) are used on the sub-frame beneath the motor,
when the crusher and motor are mounted on a common sub-frame.
For details of the rubber dampers, see the figures below.
To ensure that the crusher's motion is harmonic, the rubber dampers
must be adjusted vertically to the correct level(s), as shown on the
appropriate drawing. Refer to Mechanical Drawings.
A 1 B
4
2
3 5
Type A Fitted to sub-frame
1 Sub-frame
2 Rubber compression mounting
3 Lower fixing plate
Type B Fitted to sub-frame or motor bracket

NOTE! The crusher can also be mounted directly on the foundation without the
rubber compression mountings, but dynamic loads will in this case be
higher. Consult Sandvik for advice.
1.7.3. Crusher mounting feet

The crusher has four mounting feet, bolted to the bottomshell. The
crusher is mounted on a sub-frame (as in the case of Sandvik's direct
drive and V-belt drive installation package), on four rubber dampers
(without a sub-frame or a motor bracket) or directly on the foundation
(i.e. a fixed installation), the four mounting feet are all of the normal
type.
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The crusher is delivered with the mounting feet already fitted, so if either
of Sandvik's installation packages is ordered, the mounting feet will be
correct.
Tighten the attachment bolts to the correct torque.
Tightening torque:
572 Nm (422 lbf ft)
1.8. Crusher arrangement
1.8.1. Electrical installation - general

Make sure all local requirements are fulfilled, also the ones that are site
specific.
NOTE! The crusher must be installed in such a way that it can be operated as a
standalone unit during maintenance sessions. Secure that any power
shutdown related to crusher activity does not interfere with other site-
critical operations.
It is prohibited to modify the electrical equipment. Modification may lead
to malfunction or breakdown.
External cables, disconnecting switches and fuses are not provided by
Sandvik. Appropriate cables, switches and fuses must be purchased
before installation. In case of doubt, please consult local authorized
electrical personnel. See chapter Electrical installations on page 55
for further information.
1.8.2. Plant control system

At most sites a plant control system is used to control the process. The
plant control system must be prepared for the addition of the equipment.
1.9. Process material

To select the correct liner, Sandvik recommends testing the process
material quality prior to using the crusher. Process material wears the
crusher and the adjacent equipment in varying ways. Sandvik can assist
with such testing.
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1.9.1. Dust protection

The inhalation of dust from the process material can be unhealthy with
many types of material. Dust can cause death or severe injuries.
Sandvik recommends installing dust protection equipment to prevent
dust spreading from the process equipment. Such equipment is not
included in the crusher's standard specification.
1.9.2. Feed arrangement

The efficiency of the crusher is dependent on the design of the feed
arrangement. To achieve maximum crusher capacity, the following
parameters must be met:
• The material is fed into the crusher at a sufficiently high rate

• The material is evenly distributed around the crushing chamber
• The material fed to the crusher is not segregated
However, it is important to design the infeed so that the construction is
removable to facilitate easy maintenance of the equipment. The crusher
can be delivered with a feed hopper and without a distributor to control
the distribution of the process material into the crusher. The feed hopper
is divided so that the machine can be disassembled without the need to
remove the feed conveyor or feeder. If a belt conveyor or a chute is
used to feed the crusher, coarser material will tend to separate from the
finer material (segregation).
The feed arrangement must be electronically connected and interlocked
in such a way that it cannot be started before the crusher and the
discharge system are running.
Sandvik recommends the following:
• mount a level monitor in the crusher feed hopper to stop the feed to
the crusher if the material level rises too high. Another method is to
use a variable speed drive for the feeder to maintain a constant
material level in the feed hopper.
• install a surge bin ahead of the crusher. The surge bin should have a
high and a low level monitor connected to the control system to
ensure choke feed condition.
• install a screen ahead of the crusher to remove fine material before
crushing to increase the performance and capacity of the crusher.
• install a magnet conveyor ahead of the crusher to remove magnetic
metal from the process material and a metal detector to prevent metal
objects from entering the crusher.
The drawing below shows a crusher without a distributor. The spider
arms should be aligned with the feeder or the conveyor.
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Crusher without a distributor
The process material should be de-segregated before it is fed into the

crushing chamber. This can be accomplished in different ways, for
instance with a distributor. The drawing below shows a crusher with a
distributor. The spider arms are at right angles to the feeder or
conveyor.
Crusher with a distributor
Regulate the feed so that there is a build-up of process material in the

feed hopper (choke feed). The process material should be level with the
top of the spider cap. Choke feeding will create a better result in the
form of a finer and more uniform product size. This will also make the
crusher run more smoothly and lower the power consumption.
If a distributor is not used, it is important to optimize the feed
arrangement as far as possible. This can be accomplished with a feed
box above the crusher's feed hopper, as shown below. The feed box
must be designed so that it can be moved longitudinally to correctly
guide the material.
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Feed from a belt conveyor Feed from a chute. The chute Feed from a feeder without a feed
can be attached to a belt box. The feeder must be adjustable
conveyor
1.9.3. Feed arrangements for fine crushing

Fine crushing gives rise to the highest loads on the crusher. To obtain
correct feeding, always use a splitter for feed sizes up to 80 mm (3.1")
This part is not included in the normal scope of supply from Sandvik.
The splitter prevents segregation and also distributes the material
evenly around the crushing chamber.
For installation dimensions of the feed hopper, see the installation
drawing. Refer to the Mechanical Drawings.
NOTE! The topshell arms must be correctly oriented relative to the splitter and
the material must not be segmented to the sides.
1.9.4. Discharge arrangement

Design the discharge arrangement so that there is no possibility for
material to build up beneath the crusher and damage the crusher’s dust
seal ring. Protect the lubrication and Hydroset lines from falling material.
• The diameter of the crusher’s discharge opening is

1 970 mm (77.6 in).
• Concrete foundations or discharge arrangements below the crusher
must be constructed with a larger inner diameter than the diameter of
the crusher’s discharge opening to minimize wear.
The volume of the discharge below the crusher must be larger than the
volume of the process material in the crusher and the feed hopper
together. This volume is approximately 4 m3 (140 ft3). If a discharge
conveyor stops, the feed arrangement must stop and allow the process
material in the crusher to pass out from the crusher.
The discharge arrangement must have an inspection door for cleaning
and inspection. The Hydroset cylinder must be easily accessible.
A ledge or shelf inside the discharge compartment will absorb the
impact of the material falling onto the discharge conveyor.
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A chute should have a slope angle of at least 45° to avoid material build
up. In some cases, the inclination needs to be steeper. Contact Sandvik
for further information.
Crusher mounted on concrete foundation where

the foundation forms two sides of the discharge
Crusher mounted on a concrete foundation or hopper. The two remaining sides and the hopper
steel supporting structure with discharge hole bottom are attached to anchor plates cast into
in floor. Openings are blanked off. the foundation.
1.9.5. Guards
All moving and rotating parts on the machine must be covered with
guards. The belt drive and coupling or direct drive coupling must be
equipped with guards.
Conveyors and feed arrangements always present a potential risk of
falling process material. Design overhead conveyors and feed
arrangement so that guards protect walkways and platforms from falling
process material.
1.9.6. Platforms and guard rails

All equipment need inspection and maintenance. It is important to
design suitable platforms for this purpose. The standard scope of supply
for a crusher from Sandvik does not include platforms and guard rails.
A well-designed platform never relies on the crusher for support as
vibrations and movement of the crusher make it unsuitable. The floor of
the platform should preferably be “solid” (instead of wire mesh) to avoid
the risk of falling tools or equipment accidentally falling and hitting
someone below. Use kicking boards and wire mesh on the sides under
the handrails for the same reason.
NOTE! Never use conveyors as walkways. Always design walkways along the
conveyors with guard rails, and ensure sufficient carrying capacity to
meet local rules and legislation. Take into account the build-up of stone
and dust, as well as the weight of tools and parts for service work. Make
sure overloading is not possible.
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1.10. Emergency stop (Customer's supply)

When installing the crusher install an emergency stop. The emergency
stop must be installed in accordance with the regulations and in such a
way that it will instantly cut off all power to the crusher, causing it to
stop.
NOTE! When the power to the crusher is cut off by an emergency stop there will
be a delay before the crusher stops due to the inertia of the crusher
when it is in motion.
1.11. Operating in low temperatures

The crusher's oil tank unit needs special preparations for reliable
operation in low temperatures. The following section describes
recommended methods.
The accompanying flow chart Low temperature problems - symptoms
and remedies on page 25 can be used to determine which method to
use.
NOTE! If it is difficult to start the crusher even when the appropriate
recommendations have been followed, contact Sandvik for further
assistance.
1.11.1. Measures for easier starting and running in cold

climate
The following methods will increase the oil flow at low temperatures.
The order in which these methods are applied should be judged in each
individual case. A combination of several methods may be necessary.
• Heating cables on oil lines

• Additional oil heater
• Diesel heating system
• Synthetic oils
• ISO VG 100 mineral oil for the winter season
• Continuous running of the lubrication oil pump
A crusher that is fitted with “low temperature equipment” will normally be
equipped with:
• Additional oil heater
1.11.2. Low temperature problems - symptoms and

remedies
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26
1. Start the oil pump. 2. Yes: Has the crusher started and 4. Yes: Start crushing when the crusher
Does the “Crusher continued to run normally? has warmed up.
ready for start” signal

5. No: Does the crusher stop due to 8. Yes: Check the pressure in the main
appear within 60 s?
interruptions in return oil flow? lubrication system. If it exceeds 15 bar,
insulate the pipes/hoses.
3. No: Stop the oil pump. Has oil run back 6. Yes: Oil returns to the tank, but not in
through the oil line to the return oil flow sufficient quantity. Wait 3.5 min. to drain
switch? the crusher and then make a new
attempt to start up.
7. No: Has oil overflowed the dust collar? 9. Yes: During long periods with very low
temperatures, the crusher should be heated
during the night to avoid excessive cooling.
Position a fan heater beneath the crusher and
cover the feed opening. In addition, the
lubrication oil pump should run continuously.
10. Yes: There is a blockage in the return oil
line. Clean out the blockage. If necessary,
install heating cables on the return oil line.
Does the oil flow back to the tank?
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11. No: Install low temperature equipment in See boxes 12 and
the tank. Does the oil flow back to the tank? 13.
12. Yes: Under very low temperatures the
radiator coil can be "thawed out" with a fan
heater.
Yes: See box 6.
13. No: Change to synthetic oil (alternatively, 14. Yes: See box 6.
use an ISO VG100 oil).
15. No: Install heating cables on the oil 16. Yes: See box 6.
Does the oil flow back to the tank?
lines. Does the oil flow back to the tank?
17. No: Insulate the oil tank. Does the oil flow 18. Yes: See box 6.
back to the tank?
19. No: Sometimes
it can be advisable
to run the lubrication
oil pump
continuously to
minimize starting
problems
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27
1.11.3. Heater set - cold climate

In order to heat the oil to the correct temperature, it can be necessary to
install an extra heater. Installation is easiest if this equipment is ordered
together with a new crusher, but the extra heater can also be ordered
afterwards.
The component section of the oil tank unit is normally open at the
bottom to provide good ventilation and cooling of the oil pumps. In a
cold climate it might be necessary to insulate the tank to keep the oil at
working temperature and prevent pressure drop.
1 Heater
1.11.4. Diesel heating system (option)

In plants without 24-hour electrical power, a timer-controlled diesel
heating system can be used. The system starts heating the oil up to
three hours before electrical power is available.
The diesel heating system uses a 12 V DC supply.
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1 Diesel heater
2 Coil in tank
1.11.5. Heating cables on oil line

At low temperatures, the oil in the lines between the tank unit and the
crusher can solidify and block the lines. This problem can be minimized
by insulating the oil lines and installing heating cables.
It is preferable to use a heating cable of the self-regulating type which
needs no thermostat. The heating cable should have a rating of 8-10 W/
mand 40 mm (1.6") insulation.
Install the heating cable on the underside of the oil line and use
insulating tape to keep the cable in place. If possible, increase the slope
of the return oil line before installing heating cables.
If the oil lines are more than 50 mm (2") in diameter, or if the oil needs
to be heated to a temperature of 50 ºC (122 ºF) above the ambient
temperature, the heating cable can be led backwards and forwards on
the same line.
Heating cables are in many countries considered as high voltage
equipment and must therefore be installed by an authorized electrician.
The heating cable can be purchased from a local supplier who usually
also can install it.
1.11.6. Synthetic oils

Synthetic oils will allow for trouble-free starting at about 10 ºC lower
temperature than a mineral-based oil, and are in all respects superior to
mineral-based oils:
• Longer change intervals due to high stability

• Easier starting at low temperature
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• Lower energy consumption due to lower friction

• Wider temperature range
• No oxidation and “coking”
The synthetic oil shall meet the same requirements as for mineral oil.
For further information about lubricant requirements, refer to the
Technical specifications.
The recommended synthetic oils can be mixed with mineral-based oils,
but should be diluted as little as possible.
NOTE! Empty the crusher and oil tank carefully before refilling with synthetic oil.
To reduce the risk of dilution of a synthetic lubricating oil, the Hydroset
oil should also be synthetic. A grade with a viscosity down to 30 cSt at
40 °C can be selected for the Hydroset system.
Risk of equipment or property damage
NOTICE It must be possible to mix the lubrication and Hydroset oils
used in the crusher. Consult the oil supplier if in doubt.
1.11.7. Mineral oil for the winter season

In ambient temperatures below 0 ºC, an ISO VG 100 oil can be used,
refer to section Lubrications systems in the Technical Specifications.
1.11.8. Continuous running of the lubrication oil pump

NOTE! If the oil is severely cooled after it leaves the tank, the oil can overflow
the dust collar.
Running the oil pump continuously while the crusher is stopped will
prevent the oil from solidifying in the lines and crusher.
Leave the oil tank heater/s switched on. Cover the crusher’s feed
opening to prevent excessive cooling by cold air passing through the
crusher chamber.
1.11.9. Insulation of the oil tank

Insulating the oil tank will reduce the overnight drop in oil temperature at
low ambient temperatures. In warmer weather the insulation should be
removed to prevent overheating.
Insulation can easily be installed by the plant personnel. A suitable
material is Paroc Pro Slab 35, 50 mm (2") thick. The insulation material
must be protected from moisture, as it will otherwise lose its insulating
properties.
Insulation kits are not supplied by Sandvik.
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1.11.10. Heating in the component section

If you want to use a fan heater, you must first install a bottom in the tank
unit. This is not supplied by Sandvik.
Extra heating in the tank unit can be provided by a standard fan heater
with a rating of about 600 W. The fan heater must have a thermostat
which prevents overheating.
NOTICE Position the fan heater so that oil cannot drip onto it.
Sandvik does not supply modification kits with fan heaters. Select a
suitable fan heater from any supplier.
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2.1. Goods data

The equipment is delivered in sections. Some basic measurements are
given in the table below to indicate the space required by the equipment
during transportation. The number of sections delivered may vary,
depending on the crusher variant and auxiliaries.
Crusher
Part name Option Mass kg (lbs) Measurements

L x W x H (")
Crusher No 26 600 kg (58 643 lbs) 2 850 × 2 440 × 3 430 mm (112.2 × 96.1 ×
135.0 in)
Tool box etc. No 650 kg (1 433 lbs) 1 170 × 1 170 × 920 mm (46.1 × 46.1 × 36.3 in)
Feed hopper No 1 400 kg (3 087 lbs) 2 450 × 2 200 × 1 250 mm (96.5 × 86.6 × 49.2
in)
Feed hopper No N/A N/A
cone
Frame Yes 1 700 kg (3 448 lbs) 4 800 × 2 800 × 450 mm (189.0 × 110.2 × 17.7
in)
Motor Yes 1 900 kg (4 189 lbs) 1 750 × 1 050 × 1 400 mm (68.9 × 41.3 × 55.1
in)
Motor frame Yes 550 kg (1 213 lbs) 2 800 × 800 × 900 mm (110.3 × 31.5 × 35.4 in)
Tank
Part name Mass kg (lbs) Measurements

L x W x H (")
Tank unit 700 kg (1 543 lbs) 1 950 × 1 350 × 1 220 mm (76.8 × 53.1 × 48.0 in)
Cooler assembly 210 kg (463 lbs) 1 260 × 860 × 1 080 mm (49.6 × 33.9 × 42.5 in)
2.1.1. Contents
A Package Inventory List is attached to one of the packages in the
delivery.
NOTE! If the equipment is collected from the factory, check before
transport that the equipment corresponds with the items in the
Package Inventory List.
If the equipment is delivered by Sandvik to a harbor or to the
site, check immediately after arrival that the equipment
corresponds with the items in the Package Inventory List, and
that the equipment is not damaged in any way.
2.1.2. Loading and unloading goods signs

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

The following types of equipment can be used to lift and move the
goods:
• overhead gantry
• mobile crane
• fork lift
Make sure that the lifting equipment and the lifting capacities of the
equipment and tackle comply with the value given in the table:
NOTE! The lifting capacity of a mobile crane varies with the lifting radius. Make
sure that the lifting capacity is sufficient at the appropriate lifting radius.
Recommended Equipment and tackle Nominal load to be lifted

Overhead gantry 27 000 kg (59 525 lbs)
Mobile crane
Lifting chains, cables, ropes or slings
Fork lift (only for goods on pallet/platform)
2.3. Gantry crane or mobile crane

Suspended load hazard
A crusher weighs up to 27 000 kg (59 525 lbs). You
can sustain crush injuries, fall or even die if you are
WARNING! struck by the load.
Make sure that the load is secure. Stand clear of
suspended loads. Use ropes or poles to steady and
maneuver loads – never use hands or feet.
a) Make sure that the lifting equipment is in good condition and that it
has been maintained according to the manufacturer's instructions.
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b) Make sure that the lifting chains have the correct lengths for the
desired lifting angle.
c) Make sure that the lifting equipment has a sufficient SWL (Safe
Working Load) for the weight to be lifted and the method of lifting
the crusher.
d) Follow the applicable lifting standard for the equipment used.
e) Attach the lifting equipment according to the symbols, see section
Loading and unloading goods signs on page 34.
f) Make sure that all parts are properly seated.
g) Slowly take up the slack in the lifting equipment. Make sure that
the hooks are secure in the lifting eyes of the component. If
necessary, adjust the lifting equipment to distribute the load evenly.
h) Make sure that the lifting chains are not twisted.
i) Make sure that the destination is clear and able to support the
weight before lifting.
j) Lift, move and lower the load carefully and calmly. Avoid sudden
movements.
k) Use ropes or poles to steady and maneuver loads. Never use
hands or feet. Stand clear of suspended loads.
2.4. Fork lift

The oil tank unit must be placed on a pallet/platform when lifted with a
fork lift.
a) Make sure that the forks have the correct length and lifting
capacity.
b) Set the lifting forks to the correct width.
c) Make sure that the equipment is firmly attached to the transport
platform.
d) If the transport platform is fitted with fork tubes, use these.
e) Make sure that the destination is clear and able to support the
weight before lifting.
f) Lift, move and lower the load carefully and calmly. Avoid sudden
movements.
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2.5. Unpacking area

The required unpacking area should have the approximate dimensions
given below.
Crusher
Unpacking area required L × W × H

4.8 ×18 × 4.4 m (15.7 × 59.1 × 14.4 ft)
Tank unit
Unpacking area required L × W × H

3.7 × 3 × 3.8 m (12.1 × 9.8 × 12.5 ft)
NOTE! These dimensions result in approximately 1.0 m (3.3 ft) of free space
around and above the equipment.
2.6. Inspection of goods

NOTE! Sandvik is not responsible for the transport. If the delivery is damaged,
report this to the transport company.
Check the content against the Package Inventory List. If anything is
missing or damaged, report this to Sandvik. Please send photos of any
damage. Also check if the delivery corresponds to the order. If the
delivery differs from the order, contact Sandvik.
2.7. Moving and storage

Important notes
If the crusher components must be stored before installation, make sure
that the storage area meets the requirements given in section Storage
of a non-assembled crusher on page 38.
If installation starts immediately, check whether it is possible to move
the crusher components to the installation site/unit. Unpacking and
installation can be performed together.
When moving the crusher components to the installation site/unit,
deposit them so that they can be lifted out and positioned without being
turned around.
Wait until installation can start before unpacking the crusher
components.
Crusher and motor is mounted onto the sub frame and a special lifting
procedure for the entire assembly must be performed. Lifting lugs shall
not be used. Please contact your local Sandvik representative for
details how to perform this lifting procedure.
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2.7.1. Moving
a) Lift the crusher component only enough to clear the floor.

b) Make sure that the load remains stable on the lifting equipment.
c) Move the crusher component to the assembly destination.
d) Lower the crusher component gently to the floor. Leave enough
room for access to all sides.
e) Make sure that the load is stable before you remove the lifting
equipment.
f) Remove the lifting equipment.
g) If applicable, remove any screws holding the transport platform to
the crusher component.
2.7.2. Storage of a non-assembled crusher

Risk of equipment and property damage
Exposure to moisture or too high or too low
NOTICE temperatures can damage the crusher components.
Place the crusher components indoors if you store
them for more than 30 days.
NOTE! For an assembled crusher, see section NaN) on page .

a) Make sure that there is at least 1 m (3.3 ft) of free space around
and above the crusher for access and ventilation.
b) Make sure that the indoor storage environment meets the
conditions given in the table below.
Characteristic Value Notes

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

is uneven, place blocks or plates under the crusher components to
provide steady support.
d) Make sure that the crusher component is stable and remove the
lifting equipment.
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e) Cover the stored components with a protective covering that

matches the local conditions.
NOTE! Store seals and gaskets in a dark, dust-free, dry place.
Keep them in their packaging until they are required. Never
tie seals with steel wire or hang them on nails or pins
during storage. Rubber components must be stored free
from any stresses in order to avoid cracking and
deformation.
f) Inspect the rust-preventive coating and touch-up or repeat the
treatment if necessary.
g) Fasten the lifting eye bolt on the top end of the mainshaft. Lift the
mainshaft assembly out of its transport frame and put it down on
wooden blocks placed beneath the lifting eye and the lower edge
of the mantle. Avoid contact with the bearing surfaces on the two
ends of the mainshaft.
h) Inspect the stored components regularly and check that the rust-
preventive coatings are intact and that the components have not
been damaged.
Toxic hazard
Read the cleaning agent’s MSDS for information
about its health effects.
Handle cleaning agents with care and according to
the MSDS and local regulations.
Collect cleaning agents in suitable containers and
WARNING! dispose of them as recommended in the MSDS and
according to local regulations.
i) Remove all rust preventatives with a suitable cleaning agent before

you assemble the crusher after storage. Thoroughly inspect all
components to ensure that no corrosion or damage has occurred.
2.7.3. Pre-delivery rust prevention treatment

Before delivery from the factory, the crusher is treated with rust
preventatives that last approximately 30 days. The crusher's internal
bearing surfaces are covered with oil and then sealed off. Additional
rust prevention treatment can have been specified in the order.
The tank unit's and cooler assembly's packing contain rust
preventatives that last 12 months.
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2.8. Unpacking the goods

a) Remove all loose boxes and packages.
If using an overhead gantry or mobile crane, see section Gantry
crane or mobile crane on page 35.
If using a fork lift, see section Fork lift on page 36.
Risk of property damage
NOTICE Ensure that the crusher components are
supported evenly.
b) Use the Package Inventory List to check that nothing is missing

from the equipment delivery.
c) Inspect the crusher components for damage.
d) Inspect the crusher’s accessories for damage.
e) Open the boxes containing smaller components and inspect these
for damage.
f) Open the tool box and locate the Package Inventory List for the
contents.
g) Check the contents of the tool box.
h) Check that the data on the identification plate corresponds with the
data given in the Package Inventory List.
i) Store the additional spare and wear parts in the allocated
depository.
j) If needed, send a transport damage report to Sandvik
NOTE! If possible, document any damage with a camera.
2.9. Disposal/return of packaging material

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

connections
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3.1. General requirements

Contact Sandvik to discuss any questions you may have regarding your
installation plan for the crusher equipment.
Personnel
Installation must be carried out by personnel with appropriate
competence.
The installation area
a) Clear the installation site. If necessary, clean the areas where
equipment will be installed.
b) Make sure that there is sufficient room to move safely around the
installation. If any adjacent machines on the site cannot be stopped,
take measures to prevent accidental contact.
c) Make sure that lighting is adequate and arrange additional portable
lights if necessary.
Packing
Leave wrapping and ties on the parts until they are ready for use.
Leave the plugs in the connections until they are ready to be connected.
Red plugs are used where equipment should be connected.
Installation sequence
The sequence that should be followed when the equipment is to be
installed is determined by the relevant installation alternative.
In these Installation instructions, detailed assembly sequence
instructions are given for the two installation alternatives that are
described above, that is, the Sandvik standard direct drive installation
package or standard V-belt drive installation package.
3.2. Crusher on a subframe with rubber

dampers
See installation drawings in the Mechanical drawings
BG00533135 for V-belt drive
Preparatory checks
Check that the foundation matches the dimensions given on the
installation drawing, refer to Mechanical Drawings.
Make sure that anchor plates are provided in the correct positions – and
at the correct levels – for the larger (Type A) rubber dampers beneath
the sub-frame (below the crusher) and the smaller rubber dampers
(Type B) beneath the motor end of the sub-frame. Refer to the Crusher
Foundation Loads drawing in Mechanical drawings for more details.
NOTE! The maximum deviation is ±1 mm (±0.04") at each load application
point. If the deviation is >1 mm (>0.04"), use shims to level.
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Installation sequence
a) Carefully clean any dust and oil from the area where the crusher is
to be installed.
b) Place the rubber dampers on the foundation. Make sure that the
lower fixing plates (8) and (15) are attached.
c) Turn the rubber dampers to the positions shown on the installation
drawing.
d) Tack weld the six lower fixing plates (8), (15) to the anchor plates
on the foundation.
e) Lower the sub-frame into position on the rubber dampers.
f) Remove the locking nuts (2), (9) ,screws (4), (11), and
washers (3), (10) and then lift the sub-frame away from the
foundation.
g) Remove the six rubber dampers (5) and (12).
h) Weld all around the lower fixing plates (8), (15) to the anchor plates
in the foundation.
i) Put the rubber dampers back into position on top of the lower fixing
plates (8), (15) and fit the lower screws (6), (13) and the
washers (7), (14).
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j) Reinstall the sub-frame and fit the upper locking nuts (2),
(9) ,screws (4), (11), and washers (3), (10).
A 1 B 9 10 11
2 3 4
12
5 13 14
6 7
15
8
Type A Fitted to sub-frame
1 Sub-frame
2 Locking nut
3 Washer
4 Screw
6 Screw
7 Washer
Type B Fitted to sub-frame or motor bracket

9 Locking nut
10 Washer
11 Screw
13 Screw
14 Washer
k) Lower the bottomshell onto the sub-frame.
Figure1. V-belt
NOTE! Make sure that the pinionshaft is pointing in the correct

direction.
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l) Tighten the screws at the connection points between the

bottomshell and the sub-frame.
Tightening torque:
2 800 Nm (2 065 ft lbs)
For information about the installation of the motor and the V-belt
drive, see section Motor and V-belt drive on page 45.
3.3. Crusher on a concrete foundation –

fixed installation
Refer to the corresponding installation drawing in the Mechanical
drawings.
The installation sequence for a crusher that is to be fixed on a concrete
foundation steel supporting structure must be tailored to suit the design
of the installation in question. You should therefore draw up a new
installation sequence, using the directions given in the relevant parts of
this installation manual.
3.4. Crusher with rubber dampers on a steel

supporting structure
Refer to the corresponding installation drawing in the Mechanical
drawings.
Assuming that rubber dampers are used, the installation of a crusher on
a steel supporting structure follows – in principle – the sequence
described in section Crusher on a subframe with rubber dampers on
page 42, although it must be tailored to the design of the structure in
question. You should therefore draw up a new installation sequence,
using the directions given in the relevant parts of the instructions in the
section Crusher on a subframe with rubber dampers on page 42.
3.5. Motor and V-belt drive

Install V-belt drive motor
Refer to section Installing V-belt drive motor in the Maintenance
Instructions for further information.
Install V-belts
Refer to section Installing the V-belts in the Maintenance Instructions for
further information.
Speed monitor for V-belt drive
Refer to section Setting the V-belt speed monitor in the Maintenance
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V-belt guards
Refer to section Installing the V-belt guards in the Maintenance
3.6. Installing the feed hopper

The crusher can be installed with or without a distributor.
• If the crusher is installed without a distributor the spider arms must be

aligned with the feeder or the conveyor.
Cone crusher without a distributor
• If the crusher is installed with a distributor the spider arms are at right
angles to the feeder or conveyor.
Cone crusher with a distributor
a) Arrange the lifting equipment.

b) Put lifting hooks to the lifting eyes (1).
A feed hopper weighs up to 2 100 kg (4 630 lbs). You
c) Carefully lift the feed hopper (2) onto the rim of the topshell.
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d) Install the screws, washers and lock nuts (3, 4, 5) to attach it to the
topshell.
3, 4, 5
1 Lifting eye
2 Feed hopper (lower)
3 Screw
4 Washers
5 Lock nut
3.7. Dust seal air pressure system

The crusher is equipped with a dust seal air pressure system to exclude
dust from the equipment. A correctly functioning dust seal air pressure
system is important for the performance of the crusher.
For further information refer to the Mechanical Drawings.
3.7.1. Installing the dust seal air pressure system

For installation drawings, refer to the Mechanical Drawings.
NOTE! Hoses, pipes and pipe fittings are supplied by Sandvik.
Minimum and maximum length of hoses 2-15 m (7-50 ft)

Minimum and maximum pressure 600-1000 Pa (0.087-0.0145 psi)
Minimum blower capacity 0.3 m3 (793 US gall./min)
The length of the hoses depends on the position of the air supplier and
the tank.
It is important to install the fan in a dust free
NOTICE environment. Dust will damage the blower and result
in malfunction of the equipment
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a) Install the dust seal air pressure system:

• Install the dust seal air pressure system (dust seal air
pressure fan or regulator for compressed air) or at least
0.5 m (20") above the tank and the pinionshaft to prevent oil
from running into them.
• The dust seal air pressure fan can be mounted horizontally or
vertically. When the fan motor is connected, check that the
direction of rotation is the same as shown by the arrow on the
fan housing. If the rotation isn’t correct, the output of the fan
will be insufficient.
• The regulator L3-RV1 with filter unit L3-FU2 (3) must be
mounted horizontally and if possible, installed in a heated
space.
b) Measure the hose length between the air supplier’s coupling (2)
and the T-connection (2) on the pinionshaft.
c) Cut the appropriate length from the hose coil supplied with the oil
tank unit.
d) Connect one hose (1) between the air supplier’s coupling (5) and
the T-connection (2) on the pinionshaft housing. Use hose clamps.
4
5
3
1 Hoses
2 Coupling to the pinionshaft housing
3 Coupling to the air supplier
4 Filter to air regulator L3-FU2
5 Compressed air regulator L3-RV1
3.8. Platforms
Sandvik recommends installing platforms so they are located at least
50 mm (2") away from the crusher to avoid contact. Allowance must be
made for this. When the crusher is mounted on rubber compression
mountings there is a risk of pinching between the oscillating parts of the
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crusher and the stationary structure. The horizontal displacements

during normal operation and during start and stop are stated in the
Installation drawings, refer to the Mechanical Drawings.
See section Platforms and guard rails on page 24 for further
information.
3.9. Lubricants
Fill the required amounts of oil into the tanks.
For further information, refer to the Technical specifications.
Keep some extra oil within easy reach. It may be necessary to add
some oil after start-up due to the length of the hoses.
3.10. Hydroset and lubrication systems

Oil is supplied to the crusher through three lines – one two-way line
from the Hydroset cylinder, one to the main lubrication system and one
to the pinionshaft lubrication system.
The oil returns to the oil tank unit through two lines – the Hydroset two-
way line and the compound main/pinionshaft return oil line.
For general information on placement of the equipment, see section
Placement on page 12.
3.11. Pipes and hoses - General

NOTE! Pipes are not supplied by Sandvik.
The hoses that are installed on the crusher at delivery are plugged with
red plugs, showing where connections are needed. The hoses are long
enough to give service friendly connection points just outside the sub-
frame. If pipes are connected to the hoses, the hoses will compensate
for the crusher's movement during crushing.
If all parts of the Hoses and adapter kit are to be used, then all hoses
from the crusher must be connected.
Route all pipes and hoses to and from the crusher along the same path.
All pipes and hoses to and from the crusher must be carefully sealed
and tightened to avoid leakage and prevent the pipes and hoses to
come loose from the connections.
The inclination of return lines is critical. Refer to Oil tank unit on page
51.
For a description of hoses, pipes and connections on the tank unit and
crusher, refer to the installation drawing in Mechanical drawings.
NOTE! When starting the pumps the first time, make sure that there are
no leakages. If there are leakages, use a suitable sealing
compound.
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3.11.1. Connections
Hoses are not provided by Sandvik.
1 2 3 4
6 7
Callout Description Connection Hose Placement Connection

designation designation BSPP 60° cone JIC 37° cone
adapter kit adapter kit
1 Hydroset oil from tank N K1-H12 Tank unit BSPP 60° Cone G JIC 37° Cone 1 1/16
unit to crusher 3/4 Male - 12 Male
Crusher BSPP 60° Cone G JIC 37° Cone 1 1/16
3/4 Male - 12 Male
2, 7 Lubrication oil from tank U L1-H3 Tank unit BSPP 60° Cone G JIC 37° Cone 2 1/2 -
unit to cooler assembly 2 Male 12 Male
Cooler BSPP 60° Cone G JIC 37° Cone 2 1/2 -
assembly 2" Male 12 Male
3 Lubrication oil from tank Q L2-H4 Tank unit BSPP 60° Cone G JIC 37° Cone 1 1/16
unit to pinion housing 3/4 Male - 12 Male
Pinion housing BSPP 60° Cone G BSPP 60° Cone G
3/4 Male 3/4 Male
4 Lubrication oil from L L1-H6 Crusher BSPT R 4 Male NPT 4 - 8 Male
crusher to tank unit
Tank unit BSPP G 4 Female NPT 4 - 8 Female
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Callout Description Connection Hose Placement Connection

designation designation BSPP 60° cone JIC 37° cone
adapter kit adapter kit
6 Lubrication oil from M L1-H7 Cooler BSPP 60° Cone G JIC 37° Cone 2 1/2 -
cooler assembly to assembly 2" Male 12 Male
crusher
Crusher BSPP 60° Cone G JIC 37° Cone 2 1/2 -
2 Male 12 Male
3.11.2. Oil tank unit

An oil tank unit without cooler weighs up to
710 kg (1 566 lbs). You can sustain crush injuries, fall
WARNING! or even die if you are struck by the load.
a) Install the tank unit in a suitable location, see section Placement on

page 12.
1 Lifting lugs
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b) Connect the oil lines to the tank unit, refer to the installation
drawings in Mechanical Drawings.
NOTE! The connections are already fitted to the crusher. Pipes
and pipe fittings are not supplied by Sandvik.
• Make sure that there are no kinks in the return oil hoses and
pipes.
• Avoid pipe elbows. Use large-radius pipe bends instead to
reduce resistance in the piping.
• Run the piping so that it is protected from falling stones.
• Make sure that the piping is securely supported to avoid
vibration.
• Make sure that the piping is free from burrs, metal shavings
and dirt before it is connected to the crusher and tank unit.
• Use normal oil piping and hoses for lubrication oil lines.
c) Inspect and clean the lubrication oil tank.
d) Connect the Hydroset oil line to the oil tank unit with high-pressure
piping or hoses with minimum pressure rating 8 MPa (1160 psi).
• Make sure that there are no kinks in the oil hoses/pipes.
• If pipes are used, avoid pipe elbows. Use large-radius pipe
bends instead to reduce resistance in the piping.
• Run the piping so that it is protected from falling stones.
• Make sure that the piping is securely supported to avoid
vibration.
• Make sure that the piping is free from burrs, metal shavings
and dirt before it is connected to the crusher and tank unit.
e) Inspect and clean the Hydroset tank.
3.11.3. Air/oil cooler

Refer to the installation drawings in Mechanical drawings.
If the crusher equipment is installed at high altitude
NOTICE and/or extremely high or low ambient air
temperature, a special cooling system is required.
Consult Sandvik for advice.

The wrong thermostatic element can lead to failure of
the eccentric and bottom shell bushings.
NOTICE The thermostatic element as well as the setting of the
temperature switches L1-TS1, L1-TS2 and L1-
TS3must correspond to the viscosity grade of the oil
you use.
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NOTICE The air must pass through the cooler's matrix.
1 Air flow direction
The cooler assembly must be shielded from direct sunlight.

The air/oil cooler can be installed in a suitable place close to the oil tank
unit. Piping and hoses can be used to connect to the oil tank unit. The
cooler must always be installed in the crusher lubrication system.
If the ambient air contains a lot of dust, it is advisable to lead fresh air to
the cooler through a duct from a dust-free place. The duct must be
correctly dimensioned so that air flow is not restricted, and it must not
be rigidly connected to the air/oil cooler.
To reduce the amount of dust which settles in the radiator matrix, the
air/oil cooler is best placed so that the fan blows towards the crusher.
NOTE! Pipes or hoses between the tank unit and the cooler assembly
are not supplied by Sandvik. Nor the pipes or hoses between the
cooler assembly and the crusher.
a) Check the sign on the thermostatic element (1). If it does not
correspond to the viscosity grade of the oil you use, the
thermostatic element must be changed. Refer to Replacing the
thermostatic element in the Maintenance instructions. The
thermostatic valve installed at delivery is ISO VG 150 - 35C/95F.
b) Install the air/oil cooler close to the oil tank unit.
c) Remove the red transport plugs and install the adapters included in
the adapter kit.
d) Connect the hoses to the cooler.
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e) Connect piping or hoses to the tank unit.
IS
O
VG
15
0-
35
C
1 Thermostatic element sign
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4.1. General requirements – Electricians

Electricians must be certified according to local regulations and have
experience of similar types of installations, proven skills in reading and
working from drawings and cable lists, and knowledge of local safety
regulations regarding power and automation circuits. Work with
electrical equipment must be performed only by skilled or instructed
technicians. For more information, refer to Personnel in Safety and
Environmental instructions.
Complete electrical drawings are found in the Electrical documentation.
4.2. The electrical system

The purpose of the electrical system is to power the crusher with its
auxiliary systems and to control the operation of the crusher.
The crusher must be interlocked with the surrounding equipment for safe
operation and reliable functionality. Stop crusher use immediately if
interlock does not operate properly.
Complete electrical drawings are collected in Electrical documentation
for the crusher and for the tank unit. External cables, disconnecting
switches and fuses are not provided by Sandvik. Appropriate cables,
switches and fuses must be purchased before installation. In case of
doubt, please consult local authorized electrical personnel.
The tank unit has been prepared with cable trays and signs for all
motors and sensors to make it easy for the customer to route cables to
them. There is a cable entry plate on the left side of the tank unit.
Motors and heater/s are connected directly. For equipment in the tank,
route the high voltage (motor) cables along the lower cable tray (marked
with Main voltage, 380-690VAC) and low voltage (sensor) cables along
the upper cable tray (marked with 24VDC/Sensors).
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2 3 4 5
1 Low voltage (sensor) cable tray

2 High voltage (motor) cable tray
3 Lubrication motor
4 Hydroset motor
5 Cable duct
6 Ground point
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Sensors overview *)
*) This illustration shows tank for crusher with basic equipment.
4.3. Motors, pumps, and heating elements

Starting equipment for the motors, pumps and heating elements are
normally not part of the supply from Sandvik. Fuses, relays, motor
protectors and control units must be installed in the appropriate switch
gear cabinets. Starting and stopping can be made possible either by
buttons or via software.
4.3.1. M1-M1 – Crusher motor

The main drive motor of the crusher can be started in several different
ways, depending on the power supply available:
• Direct on-line starter

• Electronic soft starter
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NOTE! The crusher drive motor’s (M1-M1) relay must be interlocked with the
lubrication oil pump motor L1-M1, so that it is only possible to run the
crusher when the lubrication pump L1-M1 is in operation.
4.3.2. L1-M1 - Lubrication oil pump

Risk of equipment or property damage.
The crusher drive motor’s (M1-M1) relay must be interlocked
NOTICE with the lubrication oil pump motor L1-M1, so that it is only
possible to run the crusher when the lubrication pumpL1-M1
is in operation.
4.3.3. L1-M2 - Oil cooler fan motor

Every crusher has an air/oil cooler in the lubrication system. The
temperature is controlled by the temperature switch L1-TS2. For further
information about the temperature switches, refer to the Technical
specifications.
4.3.4. K1-M1 - Hydroset pump

Starting and control equipment for the Hydroset pump is normally
delivered by Sandvik. The delivered electrical cabinet L3 contains a
fuse, a relay and a motor protection for operation of the Hydroset pump.
4.3.5. E - Oil heater/s

The temperature switch L1-TS1 controls the heater/s.
4.3.6. L3-M1 - Dust seal air pressure fan

The power supply to the dust seal air pressure fan must incorporate the
necessary fuse, relay and motor protection built into an appropriate
switch gear cabinet.
4.4. Interlock, start and stop conditions for

consumers
For further information, refer to the Electrical Documentation.
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Interlock conditions
Consumer Designation Start allowed Interlock stop

Main motor M1-M1 The return oil flow switch L1-FS1 must send The return oil flow switch L1-FS1 stops
the signal that there is a sufficient return oil sending the signal that there is a sufficient
flow. return oil flow.
Only for ASRi or no control system Only for ASRi or no control system
The temperature switch L1-TS3 must send the The temperature switch L1-TS3 stops
signal that the return oil temperature is not too sending the signal that the return oil
high. temperature is not too high.
The contactor for starting the lubrication pump The contactor for starting the lubrication
motor L1-M1 must send the feedback signal pump motor L1-M1 stops sending the
that the lubrication pump motor is running. feedback signal that the lubrication pump
motor is running.
Only for SanRemo for Crushers Only for SanRemo for Crushers
Cone Cone
The interlock signal Main Drive - OK to Start The interlock signal Main Drive - OK to Start
from the control system must send the signal from the control system stops sending the
that the main motor is ready to be started. signal that the main motor is ready to be
started.
Lubrication L1-M1 The return oil flow switch L1-FS1 must not The return oil flow switch L1-FS1 stops
Pump Motor send the signal that there is a sufficient return sending the signal that there is a sufficient
oil flow. return oil flow 60 seconds after the start of the
lubrication pump.
The level switch L1-LS1 must send the signal N/A
that the oil level in the lubrication tank is not
too low.
Only for SanRemo for Crushers Only for SanRemo for Crushers
Cone Cone
The interlock signal Lubrication - OK to Start The interlock signal Lubrication - OK to Start
from the control system must send the signal from the control system stops sending the
that the lubrication pump is ready to be started. signal that the lubrication pump is ready to be
started.
Air Cooler Motor L1-M2 The contactor for starting the lubrication pump The contactor for starting the lubrication
motor L1-M1 must send the feedback signal pump motor L1-M1 stops sending the
that the lubrication pump motor is running. feedback signal that the lubrication pump
motor is running.
Tank Unit L1-E1, L1-E2, The level switch L1-LS1 must send the signal The level switch L1-LS1 stops sending the
Heaters L1-E3 that the oil level in the lubrication tank is not signal that the oil level in the lubrication tank
too low. is not too low.
Crusher Material The pinion oil flow switch L2-FS1 must send The pinion oil flow switch L2-FS1 stops
Feed the signal that there is a lubrication oil flow to sending the signal that there is a lubrication
Arrangement the pinion housing. oil flow to the pinion housing.
The level switch K1-LS1 must send the signal The level switch K1-LS1 stops sending the
that the oil level in the hydroset tank is not too signal that the oil level in the hydroset tank is
low. not too low.
The level switch L1-LS1 must send the signal The level switch L1-LS1 stops sending the
that the oil level in the lubrication tank is not signal that the oil level in the lubrication tank
too low. is not too low.
Only for ASRi or SanRemo for Only for ASRi or SanRemo for
Crushers Cone Crushers Cone
The interlock signal Feed Allowed from the The interlock signal Feed Allowed from the
control system must send the signal that the control system stops sending the signal that
crusher is ready to receive material feed. the crusher is ready to receive material feed.
Start and stop conditions

NOTE! Setpoints vary depending on which lubrication oil you use.
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Consumer Designation Start condition Stop condition

Tank Unit Heaters L1-E1, L1-E2, L1- The temperature switch L1-TS1 sends the The temperature switch L1-TS1 stops sending
E3 signal that the oil temperature in the the signal that the oil temperature in the
lubrication tank is too low. lubrication tank is too low.
Air Cooler Motor L1-M2 The temperature switch L1-TS2 sends the The temperature switch L1-TS2 stops sending
signal that the oil temperature in the the signal that the oil temperature in the
lubrication tank is high enough for cooling lubrication tank is high enough for cooling to
to be needed. be needed.
Dust Seal Air L3-M1 The lubrication pump motor L1-M1 starts The lubrication pump motor L1-M1 and the
Pressure Motor or the discharge conveyor starts. discharge conveyor has both been shut down
for at least 180 seconds.
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5.1. Installation and connection checks

See Mechanical drawings for further details on the following checks.
No. Checks Done

1 The crusher is level, transversely and longitudinally (±1 mm/m)
Also make sure that the tank unit is level
2 The crusher is secured to the foundation or steel support structure
3 The discharge system is sufficient and connected/positioned
4 The feed arrangement is connected/positioned
5 The drive arrangement have been correctly installed.
6 All transport and packing materials have been removed from the parts
5.2. Lubrication system and Hydroset

checks
No. Checks Done

1 Brand name and type of oil and grease are recorded.
2 The oil tank unit is placed in relation to the crusher according to instruction and is
properly installed.
3 The Hydroset and lubrication systems are correctly installed.
4 Air/oil cooler is installed properly.
5 Thermostatic element corresponds to viscosity grade of oil.
6 Piping and hosing has been installed according to the recommendations in this
manual.
5.3. Electrical checks

See Mechanical drawings for further details on the following checks.
No. Checks Done

1 All electric cables are correctly connected.
2 Make sure that the rotation directions of the motors are correct, see the illustration
below
3 ASRi/SanRemo for Crushers is installed properly (option)
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5.4. Safety checks
No. Checks Done

1 Make sure that all accessible moving parts are correctly protected by guards
2 Make sure that all emergency stop buttons engage and release correctly.
3 Check that all threaded fasteners have been tightened to the correct torque values.
5.5. Start-up
No. Checks Done

1 Prepare the equipment for production.
Refer to section Starting up the crusher in the Maintenance instructions, and the
Operator's instructions for further details.
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6. Preparations for
commissioning
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6.1. General
Perform the following checks even if an actual commissioning test is not
required.
NOTE! Commissioning covers only the functioning of the individual machine. A
line performance test is required to check the functioning of the crusher
and the oil tank unit as parts of a complete production line. Check with
the local service organization about arrangements for a line performance
test.
6.2. General checks
No. Checks Done

1 The data on the machine identification plate corresponds with the machine
specification document.
2 The ordered wear and spare parts have been delivered and stored in the spare part
depository
3 All the documents correspond to the specific crusher:
• Complete manual suite
• Factory acceptance test report
• Machine specification document
• Machine deviation report (if relevant)
4 Sufficient process material is available for commissioning purposes
6.3. Supply value checks
No. Checks Done

1 Electrical power supply:
• Voltage
• Max voltage fluctuation
• Frequency
• Fuse rating
2 Hydroset and lubrication systems:
• Systems have been thoroughly cleaned
• Lubricants of the correct types are available
6.4. Function checks – Preparation

Start the crusher and the oil tank unit according to the instructions in
Starting up the crusher in the Maintenance instructions. Perform the
following checks:
No. Checks Done

1 There are no unusual noises which could indicate misaligned parts or faults
2 There is no contact between oscillating crusher and stationary structure.
3 The hydroset pressure is within limits (see Technical specifications).
4 Oil heating elements operate correctly.
5 Dust seal air pressure system functions correctly
6 Return lubrication oil temperature is within limits for the chosen oil.
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6.5. Health and safety checks
No. Checks Done

1 All necessary guards are in place.
2 The crusher and the oil tank unit stop when any emergency stop button (if
applicable) is pressed. The test must be performed with the crusher in operation.
3 The crusher stops when the Stop button is pressed
4 The oil tank unit stops after a short delay when the Stop button for the crusher is
pressed
6.6. Documentation
a) Compile the Installation report. List all work, besides the
installation work, that was performed to ensure correct functioning.
The installation work covered by this manual is now complete.
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7.1. Moving the crusher
7.1.1. Short moves and short-term storage

The storage is considered short-term if it is shorter than 30 days.
Preparation for moving
Electrical hazard
You can get an electric shock or even be
electrocuted if you come into contact with live parts.
DANGER! Only electricians working according to European
Standard EN 50110 or equivalent are permitted to
access electrical cabinets and to perform electrical
operations on the equipment.
You must regard all electrical equipment as live until
it is proven dead by proper testing procedures.
a) Shut off utilities connected to the crusher:

• Electrical power
• Process material
b) Disconnect the following connections:
• Electrical power
• ASRi/SanRemo for Crushers (option)
c) Plug or protect all open connections.
d) Check that the doors to the cabinet are closed and locked with the
handle.
e) Check that the main lubrication tank cover as well as the Hydroset
tank cover are fit to the tank, closed and that all nuts are tightened.
f) Disassemble the crusher and the oil tank unit to the extent
necessary for the planned transport/storage. See section Draining
procedure on page 74 and refer to the Maintenance Instructions
for information on how to disassemble.
g) Prepare a storage area large enough to store the components with
at least 1 m (3.3 ft) of free space around and above them for
access and ventilation. Make sure that the storage area
environment meets the conditions in the table below:
Characteristic Value Notes

Min. - max. temperatures 5–40 °C (41–104 °F)
Max. relative humidity 80% Non-condensing
The main shaft can damage the dust collar if the
NOTICE main shaft hits the dust collar.
Place wooden blocks between the main shaft and the
dust collar before transport.
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h) Place three wooden blocks (1) between the main shaft

assembly (2) and the dust collar (3).
1
1
1 Wooden block
2 Main shaft assembly
3 Dust collar
i) Move the crusher and the oil tank unit to the new position
according to section Moving and storage on page 37.
Risk of property damage
NOTICE Protect the sensitive machined parts' surfaces. Treat
them with anti rust agent.
j) Level the crusher and the oil tank unit roughly.

k) Cover the crusher and the oil tank unit with suitable protective
covering.
l) Store the crusher and the oil tank unit according to section Storage
of a non-assembled crusher on page 38.
7.1.2. Long moves and long-term storage

The storage is considered long-term if it is for more than 30 days.
a) Perform the instructions a) to j) listed in section Short moves and
short-term storage on page 72.
b) Wrap all loose components in bubble wrap or other suitable
wrapping to prevent damage.
c) Pack the equipment in suitable packing, crates and transport
platforms. Use original packing, crates and transport platforms if
possible. Make sure that all parts are adequately protected.
d) Fix small boxes to each other to prevent them from moving during
transport.
e) If there is no oil left in the pumps, fill with oil to keep all surfaces
inside lubricated.
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f) Perform the instructions k) to l) listed in section Short moves and

short-term storage on page 72.
7.1.3. Draining procedure

If the crusher and the oil tank unit are to be transported, or not to be
used for a longer time it is necessary to drain the oil circuits.
The crusher and the oil tank unit cannot be moved without being
drained.
Drain the oil circuits, refer to section Changing the main lubrication oil in
the Maintenance Instructions.
Disconnect the oil inlet hose for the pinionshaft oil system, refer to
section Removing the pinionshaft housing assembly in the Maintenance
Instructions.
7.2. Regular inspection during storage

The following checks should be carried out regularly during the storage
period:
• Inspect the oil tank unit for damage and make sure that it is
protected from rust and contamination.
• If the oil tank unit has not been in operation before being stored,
check that the rust prevention packing is undamaged, and renew it
if necessary.
7.3. Storage of an assembled crusher

If an assembled crusher is taken out of operation for a period of more
than 30 days, carry out the following:
a) Plug the oil return line so that the oil cannot run out from the
crusher.
b) Close the valve(s) between the tank and the pump to prevent oil
running back from the crusher through the pump.
c) Plug the over-pressure air connections.
74 S 223.1257 - 4 en-US 09/03/2017 15:36:41
d) Use the crusher's oil system to fill the bottomshell with lubricating
oil until a little oil overflows over the dust collar (1).
1 Oil level = top of dust collar
e) Fill the pinionshaft housing with oil and plug the inlet and outlet
holes.
f) Fill the spider bushing with grease to prevent condensation on
bearing surfaces.
g) NOTE! Before putting the crusher into operation, check that the
ventilation hole and the breather are not blocked with
grease.
Coat the exposed part of the mainshaft sleeve (between the spider
and the head nut – see arrows) with grease. Make sure that this
area is protected from contamination.
h) If the lubrication and Hydroset oil tank unit is stored separately

from the crusher, fill the pumps with oil.
i) Rotate the crusher pulley/drive shaft by hand through at least four
revolutions every 14th day.
7.4. Return to the manufacturer

a) Prepare the equipment for transport, see section Draining
procedure on page 74.
b) Contact the local service organization for further instructions on
arranging transport.
S 223.1257 - 4 en-US 09/03/2017 15:36:41 75
7.5. Disposal
a) Drain the crusher, see section Draining procedure on page 74.
b) Follow the steps in section Moving on page 38, but instead of
moving the crusher continue with the steps below.
Toxic hazard
You can suffer damage to the lungs, eyes, liver,
kidney and central nervous system and you are at
WARNING! risk of cancer if you inhale flame cutting fumes.
Use a suitable welding helmet and a respirator that is
approved for the emissions that are released.
Remember that some parts of the crusher contain
manganese.
Make sure that the area is well ventilated.
Follow the instructions provided by the flame cutting
equipment supplier/s.
c) Disassemble the equipment as far as possible and separate the

following parts and material:
• Stainless steel
• Cast steel
• Cast manganese steel
• Carbon steel
• Alloy steel
• Bronze
• Rubber
• Nylon and other plastics
• Electrical cables
• Electrical components
• Pumps and motors
• Oil filters
• Lubricants
Toxic hazard
Long-term storage of disposed crusher parts can
leach heavy metals and other potentially hazardous
WARNING! substances into subsoil water and soil.
Recycle crusher parts in compliance with local
regulations.
d) Recycle or dispose of all material and components in compliance

with local regulations.
76 S 223.1257 - 4 en-US 09/03/2017 15:36:41

05.CH660-04 Installation Instructions S223.1257-04 en

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05.CH660-04 Installation Instructions S223.1257-04 en

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3. Mechanical installations and connections

5. Final installation checks

5.4. Safety checks.............................................................................. 65

6. Preparations for commissioning

7. Disassembly and removal

This page is intentionally left blank

1.1. General preparations

1.2. Machine access

1.3. Crusher capacity and performance

• Choice of crushing chamber

• Discharge system design

• Adhesive or moist process material

1.4. Installation preparations checklist

System Check Remark Date/

System Check Remark Date/

1.5.1. Height differentiation in the return line

Minimum height difference in mm 1500 cSt (cold start), DN 100 new/clean

NOTE! The minimum height difference is directly proportional to oil viscosity, so

Example ISO units:

15 meters DN 100 piping 15 × 130 = 1950 mm

The crusher should be placed 4 m above the tank.

49 ft 4" piping 49 × 1.56 = 76.44"

The crusher should be placed 12 ft above the tank.

1.5.2. Maximum allowed pressure in pressure line

15 meters DN 38 piping 15 × 27.9 = 418.5 kPa

The required pump pressure will be approximately 850 kPa.

49 ft 1.5" piping 49 × 1.23 = 60.27 psi

The required pump pressure will be approximately 123 psi.

foundation can be either a cast concrete foundation or a steel

1.6.1. Foundation loads

1.6.2. Natural frequencies

1.6.3. Movement of the crusher

1.6.4. Using an existing concrete foundation

• Thoroughly clean and inspect the top surface of the foundation.

1.6.5. Using a steel supporting structure

• Design the steel supporting structure so that it is strong enough to

1.7. Installation alternatives

• On a new foundation or on an existing foundation, previously used for

• Crusher on a concrete foundation – fixed installation (see section

• Crusher with rubber dampers on a foundation, and with motor fixed

1.7.1. Installation packages

1.7.2. Rubber dampers

Moving and fixed parts hazard

Following rubber dampers are used:

• Dampers (Type A) are used on the sub-frame beneath the crusher,

Type A Fitted to sub-frame

Type B Fitted to sub-frame or motor bracket

4 Rubber compression mounting

1.7.3. Crusher mounting feet

1.8. Crusher arrangement

1.8.1. Electrical installation - general

1.8.2. Plant control system

1.9. Process material

1.9.1. Dust protection

1.9.2. Feed arrangement

• The material is fed into the crusher at a sufficiently high rate

Crusher without a distributor

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

Crusher with a distributor

Regulate the feed so that there is a build-up of process material in the