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Maintenance Instruction Manual and

Spare Parts Lists


S 050.012 en
1 Safety regulations S 223.380 en
S 000.001 en
2 General & Technical information S 223.361 en

3 Installation S 223.362 en + enclosures

S 223.360.01 en 4 Electrical system S 223.392 en + enclosures

Maintenance Instruction 5 Starting up S 223.367 en


Manual and
Spare Parts Lists Lubrication system
for 1800-Series Hydrocones 6 S 223.363 en

7 Heat exchanger S 223.393 en


H2800 S2800

H3800 S3800 8 Hydroset system S 223.364 en

S 223.365 en
H4800 S4800 9 Lubricant recommendations

H6800 S6800 10 Topshell assembly & concave ring S 223.370 en

11 Spider bearing S 223.394 en

2003-06-10 12 Mainshaft assembly & mantle S 223.371 en

13 Bottomshell assembly S 223.372 en

14 Pinionshaft assembly S 223.373 en

15 Bevel gears S 223.374 en

16 Drive arrangement S 223.389 en

S 223.368 en
17 Routine maintenance S 223.405 en

18 Fault tracing S 223.369 en

S 223.375 en
19 Backing with plastic composition S 966.001 en

20 ASR According to order

21 Over-pressure dust sealing S 223.408 en

22 Operating in low temperatures S 223.410 en + enclosures

23
24 Optional extra equipment S 223.366 en

25 Motor instruction booklet

26
27 Spare Parts List – Crusher

28 Spare Parts List – Oil tank

29 Spare Parts List – ASR According to order

30 Declaration of Conformity S 058.039 en

31 Accumulator certificate
1800-Series Hydrocone crushers S 223.380.00 en 1 (6)

Safety Regulations for Hydrocone Crushers 2001-11-15

Safety Regulations for Hydrocone Crushers

These regulations must be studied in detail before a crusher is


Warning!!! put into operation. If you disregard these regulations there is a
risk of serious injury to personnel.

Field of use
Hydrocone crushers are intended for use as size reduction machines for rocks, minerals and
similar materials within the aggregates and mining industries. All other use is forbidden.

Handling materials

Backing with plastic composition


The unhardened components of the plastic composition can with some people cause skin
irritation and allergic reactions. See Section 19 for information on how to avoid such
problems.

Flame cutting
When cutting manganese steel and plastic composition with a gas torch there is a risk of
gases and dust which are dangerous to health. A breathing mask with a filter must be used.
Make sure that there is good ventilation at the work-place.

Oil products
Oil products present environmental and fire risks and can cause injury if inhaled or brought
into contact with the skin. Follow your lubricant supplier’s instructions and safety
directions when handling oils and greases.

Fluorinated rubber
H-type and S-type 4800 Hydrocones incorporate radial seals made of fluorinated rubber in
the pinionshaft housing assembly. If such seals have been subjected to extreme
temperatures (i.e. they are burnt) they must be handled in the same way as corrosive acids.

Accumulator
To avoid the risk of an explosion, use only nitrogen gas (N2) in the accumulator(s). Do not
subject the accumulator(s) to mechanical or thermal damage (impact, welding, etc.)
1800-Series Hydrocone crushers S 223.380.00 en 2 (6)

Safety Regulations for Hydrocone Crushers 2001-11-15

Dust
Crushing always creates dust. Such dust can be more or less dangerous to health,
depending on the type of material. Use a breathing mask.
To reduce the risks caused by dust, the plant should be dust encapsulated and fitted with a
dust-extraction system.
(Dust encapsulation, dust extraction and/or water-spraying equipment are not included in
the crusher’s standard specification).

Stones in motion
In any crushing operation it is possible that individual stones have such a size, shape or
surface texture that they are not properly gripped by the crushing liners. Such stones can be
ejected upwards out of the crushing chamber at high speed and then fall back close to the
crusher. Falling stones can also cause injury to personnel at transition points – for example
where a conveyor or a feeder discharges into a crusher. Provide adequate guarding against
such ejected or falling stones and place warning signs at appropriate places around the
danger area.

Use safety glasses and a safety helmet! This is especially important if the crusher’s feed
hopper is open (unencapsulated) since this is an area where falling stones and stone
fragments may be encountered.

The feed hopper has inspection doors. These must not be opened during crushing. If an
inspection door is to be opened while the crusher is idling, open it carefully and make sure
that no material can fall down whilst the inspection is being carried out.

There are inspection holes in the crusher’s bottomshell. Do not remove the covers over
these holes during crushing. Do not put a hand inside the crusher while it is running.

Pipes and hoses must be protected against falling material to avoid damage and subsequent
leakage.

Material spillage over the top of the feed hopper can be prevented by installing a level
monitor which stops the feed to the crusher if the level of material in the feed hopper is too
high.
(A level monitor is not included in the crusher’s standard specification).

Dust encapsulation reduces the risk of ejected and falling stones.


(Dust encapsulation is not included in the crusher’s standard specification).
1800-Series Hydrocone crushers S 223.380.00 en 3 (6)

Safety Regulations for Hydrocone Crushers 2001-11-15

Guarding
Fixed guarding must be used over the moving parts of the crusher’s drive. The crusher is
normally driven with V-belts and in such a case there should be a possibility of checking
the tension in the belts. The guarding must be constructed in such a way that it conforms to
the applicable regulations for access guarding.
(The V-belt guard is not included in the crusher’s standard specification).

Risk of pinching 35

When the crusher is mounted on rubber vibration


dampers there can be a risk of pinching between the
oscillating parts of the crusher and the stationary frame.
During normal operation the crusher will oscillate
horizontally up to ±15 mm. During starting and stopping
the movement is greater – up to ±35 mm.

Falling objects
35
Do not stand inside the crusher when concaves are being
removed.

Explosion risk
Do not use explosives to loosen wearing parts. Do not use explosives to break up stone
blockages in the crusher’s feed opening.

Lifting
Use lifting equipment with sufficient capacity. Lifting eyes and lifting tools are supplied
with the crusher.
Follow the instructions for assembly and disassembly.
Information about lifting weights is given in Section 2.
For information on the weights which must be lifted when the crusher is installed, see
Section 3.

Electrical installation
(The electrical components inside the oil tank unit are wired up before the crusher is
delivered. All components are wired to a connection box on the outside of the tank. Other
electrical equipment is not included in the crusher’s standard specification).
Follow the applicable regulations when installing electrical equipment. The necessary
interlocks are shown in the circuit diagrams – see Section 4.
1800-Series Hydrocone crushers S 223.380.00 en 4 (6)

Safety Regulations for Hydrocone Crushers 2001-11-15

Access
The person in charge of the crusher’s installation is responsible for the provision of access
to the crusher and that guarding is provided to prevent people and animals falling into the
crusher. Walkways, stairs and (step)ladders must be constructed in accordance with the
applicable regulations.
(Walkways, stairs and (step)ladders are not included in the crusher’s standard
specification).

Noise
Dangerous noise levels occur during crushing.
Use ear protection!
Vibration dampers and dust encapsulation result in lower noise levels.
(Dust encapsulation is not included in the crusher’s standard specification).

Noise levels and measuring conditions

Machine Test running in the factory Typical values when


(without material) crushing
dB(A) dB(A)
Hydrocone crusher ≤ 95 95 - 106

The values given above are equivalent continuous sound levels (Leq) measured during a
period of 60 seconds with an integrating sound level meter. The values are measured at a
distance of approx. 1 m from the machine and approx. 1.6 m above ground level or above a
platform alongside the machine.

The sound levels given are approximate values. The sound level depends on many factors,
e.g. whether or not the crusher has dust encapsulation, how the equipment is installed, how
the feed arrangement is designed, the size and impact strength of the feed material, the size
of the drive motor, etc.

Training
The plant personnel must be trained for their duties and must be given safety instructions.
1800-Series Hydrocone crushers S 223.380.00 en 5 (6)

Safety Regulations for Hydrocone Crushers 2001-11-15

Safety signs
To increase the safety of the personnel working on and around crushers, they carry warning
signs with the texts explained below.

Not to be opened/removed during operation.

See (A) in the figure on the next page.

This sign is placed adjacent to the inspection doors in the feed


hopper. See Section 3.1.

The same sign is also placed adjacent to the inspection holes in the
bottomshell. See section 13.2.

Guards must be in place before operating equipment.

See B in the figure on the next page.

This sign is placed on the bottomshell adjacent to the drive to


underline that the crusher must not be put into operation unless the
fixed guarding is in place over the moving parts of the drive.
See Section 16.

Read safety regulations in enclosed maintenance instruction


manual before operating equipment

See C in the figure on the next page.

This sign is placed on the bottomshell adjacent to the drive. The


purpose of this sign is to encourage the plant personnel to
familiarize themselves with the applicable safety regulations and
crusher maintenance procedures before putting the crusher into
operation.
1800-Series Hydrocone crushers S 223.380.00 en 6 (6)

Safety Regulations for Hydrocone Crushers 2001-11-15

Positions of safety signs


Safety Regulations - General S 050.012.02 en 1 (10)

2003-02-25

Contents Page

Introduction 2

Extra safety precautions 3

General safety precautions 4

Personnel safety 4

Work area safety 5

Electrical safety 6

Flammable and hazardous materials safety 7

Pressurized systems safety (air and hydraulic) 8

Welding safety 9

Ten safety rules 10


Safety Regulations - General S 050.012.02 en 2 (10)

2003-02-25

This manual must be studied in detail before the installation


Warning !!! work starts. If you disregard the instructions given in this
manual there is a risk of serious injury to personnel and/or
damage to your equipment.

Introduction

Sandvik Rock Processing manufacture crushers, screens and feeders as well as mobile
crushing and screening units for the mining and construction industries. During the design
and manufacture of the machines, a lot of effort is put into the avoidance of health and
safety risks.

Since Sandvik Rock Processing’s machines are used for the


Warning !!! handling and/or processing of minerals and other materials
which can give rise to health risks for human beings and
animals, it is the responsibility of the user to follow the relevant
rules and regulations intended to prevent health risks - for
example specific regulations applying to asbestos, quartzite,
radon, etc.

A single machine, delivered from Sandvik Rock Processing, will always be used as a
component in a mineral processing plant. It is therefore virtually impossible for us as
suppliers to provide operator instructions for every conceivable control system
configuration in which the machine could operate.

This manual gives information on safe installation, operation and maintenance. It is not
intended as a detailed manual for a specific machine. Its purpose is instead to alert
customers, operators and maintenance personnel to the general hazards and risks which
can be encountered in a crushing plant.

Our maintenance instruction manuals for individual machines give more detailed
information regarding your equipment. Despite this, additional training by Sandvik Rock
Processing may be necessary. Never hesitate to contact our service organization.

Historically, most injuries in crushing and screening plants occur during maintenance,
although some occur during the inspection of moving parts or while clearing material
blockages, so this safety manual emphasize safety precautions when these activities are
undertaken.
Safety Regulations - General S 050.012.02 en 3 (10)

2003-02-25

To avoid potential safety risks it is important that:

 The recommendations in instruction manuals are studied and followed.


 Personnel are regularly given training on maintenance and safety.
 General and official safety regulations are followed.
 Dangerous areas are marked with warning signs.
 The appropriate equipment and tools are available.
 The owner and management live up to their responsibility to make sure that effective
safety programmes and regulations are worked out and are followed by all personnel.

Extra safety precautions

Our instruction manuals and other documentation contain important information which
must be read and understood by all users before they operate the equipment. To make it
easier to notice information in our instruction manuals directly concerning USER SAFETY
and the avoidance of problems with the EQUIPMENT, we use the terms and symbols
shown below:

Important information which alerts you to a situation which


Warning !!! could lead to serious injury or death if you do not follow the
instructions given.

Important information which describes how you avoid damage


Caution !! to a machine and its systems or how you avoid a situation which
could cause personal injury.

Advice about operation, inspection and maintenance of a


Note ! machine and its systems.
Safety Regulations - General S 050.012.02 en 4 (10)

2003-02-25

General safety precautions

The following list of general safety precautions should be


Warning !!! considered as a guide only. There may be other conditions and
variations in the operation of this equipment that are not covered
in these general safety precautions. The purpose of these general
safety precautions is to make all personnel aware of the general
hazards and dangerous situations that exist around the
equipment and the work area.

Personnel safety

1. Read and understand each of the warnings, cautions and instructions in the
instruction manual and on all signs and information plates on and around the
equipment. If anything is unclear, make sure that all of your questions are answered
before work is started.

2. Report all accidents immediately to your supervisor. Consult a doctor or medical


personnel as soon as possible if personal injury is involved.

3. Keep a list of emergency telephone numbers close to the telephone and inform all
work area personnel about the location of the list.

4. Do not operate or work around equipment while under the influence of alcohol,
medicines, tranquilizers or other drugs that can make you less alert or affect your
judgement.

5. When moving about on or around the machine, use the hand grips, ladders, guard
rails and other safety equipment provided. Use a safety harness if this is required.

6. Take precautions to keep hair and loose fitting clothing from being caught on
moving parts or controls.

7. Wear safety glasses whenever there is any danger of flying debris, stone fragments,
objects or dust that could enter the eyes, and when required by operating regulations.
Be extra safe - always wear eye protection. Take good care of your eyes.

8. Wear gloves whenever possible to protect hands and fingers from cuts, scrapes,
burns and solvents.

9. Always wear a helmet and safety shoes when appropriate for the work being done
and always when required by local or national regulations. Around and beneath
material transfer points - between conveyors or feeders and crushers, for example -
there can be a risk of falling material. Make sure that suitable guards and warning
signs are provided.

10. Remove rings, watches, necklaces and bracelets before working in the plant.
Safety Regulations - General S 050.012.02 en 5 (10)

2003-02-25

11. In areas where noise levels are high, wear hearing protection devices.

12. Wear a breathing apparatus or mask whenever appropriate i.e. when painting or
working with chemicals, solvents and other substances that may be hazardous to
your health. Remember that there is a risk of silicosis when there is silicious dust in
the air.

13. Do not take chances with your back. Use lifting and moving devices to help you with
your work. Always lift with your legs, not with your back.

Work Area Safety

1. Keep the general work area clean and free of debris. Avoid stone or other material
build-ups on walkways, platforms, ladders and under conveyors.

2. Do not allow unauthorized personnel in or around the work area. Keep a constant
check on who is in your work area. If necessary, keep a list.

3. Keep equipment surfaces that will be touched by hands and feet clean, dry and free
of oil or grease.

4. Keep parts and tools in the designated places when not in use.

5. Keep safety equipment in a designated place and ensure that work area personnel
know the location and the proper use of the safety equipment.

6. Make a daily check of starting alarms and warning devices in the work area, and
ensure that each device is working properly before starting or operating the
equipment.

7. Do not stand under or allow anyone else to stand under equipment that is being
hoisted or suspended. Use a safety hook or hook with a safety latch when hoisting
equipment and use spreader bars when necessary.

8. Learn the weight limitations and clearances in and around your work area and for the
equipment in use.

9. Do not overload walkways. They are intended for personnel, not equipment.

10. Be alert to conditions that may obscure vision in and around your work area.

11. Always isolate the drive motor(s) of equipment before removing guards or carrying
out any inspection or maintenance work.

12. Ensure that the machine and the working area are sufficiently well illuminated.
Safety Regulations - General S 050.012.02 en 6 (10)

2003-02-25

Electrical safety

1. Permit only trained and competent personnel to work on


Warning !!! electrical components, in the plant or on any equipment.

2. Always assume that an electrical circuit is live until it is proven dead by proper
testing procedures.

3. Lock out the appropriate safety isolating switch or the main breaker, and display the
”Work in progress” warning sign in an appropriate place before performing any
inspection, maintenance, lubrication or adjustment procedure on a machine.

4. Repair or replace electrical wires, cables and connectors that are broken or damaged
in any way.

5. Check that electrical earth wires, motor and power cable connections are properly
and securely connected before starting any equipment.

6. Make sure you know the location of all power lines and underground cables. Use
extreme caution when working around these areas. Memorize the location of all main
electrical isolating switches.

7. Never work on electrical equipment while it is raining or while standing in water or


on wet surfaces unless you know that the power is disconnected.

8. Be alert when working around or with electricity. Report any electrical hazard
immediately to your supervisor.
Safety Regulations - General S 050.012.02 en 7 (10)

2003-02-25

Flammable and Hazardous Materials safety

1. Store flammable, combustible or hazardous materials in a safe place and in


containers specifically designed for that purpose and clearly marked in accordance
with the relevant regulations.

2. Store used and oily cleaning rags in a properly designed container as required by
national and local rules and regulations, and away from flammable and combustible
materials.

3. Do not store flammable or combustible materials in, on or around the equipment,


electrical installations or personnel facilities.

Do not permit smoking or an open flame around fuel tanks or


Caution !! other storage facilities for combustible materials.

4. Keep several fully charged fire extinguishers located throughout the work area.
Make sure that all personnel know their location and how to operate them. Have
them readily available during fueling operations or when other fire hazards are
present. Check the charge on each fire extinguisher at least once a month or when
otherwise specified.

5. Shut down all engines and motors when fueling or transferring flammable,
combustible or hazardous materials. Follow the recommended fueling and transfer
procedures for the substance or material being worked with.

6. Fill fuel storage tanks and other combustible materials storage facilities in a well
ventilated area, well away from equipment which can cause sparks and thus ignite
flammable materials.

7. When refueling or transferring flammable or combustible materials, ground the


nozzle or spout to prevent sparks caused by static electricity.

8. Never start a diesel or gasoline engine in an enclosed area unless there is adequate
ventilation.

Exhaust fumes can kill !


Warning !!!

9. Do not use flammable or combustible substances such as gasoline, kerosene or diesel


fuel for cleaning parts, unless specifically mentioned in our instruction manual. In
other cases, always use a nonflammable solvent for cleaning.
Safety Regulations - General S 050.012.02 en 8 (10)

2003-02-25

10. When using epoxy-resin based materials, follow the manufacturer's recommended
procedures and precautions.

Mix and pour epoxy materials in an open or well ventilated area.


Warning !!! Do not burn cured resin without adequate ventilation. Avoid
skin contact with uncured epoxy-resin materials.

11. Always inspect and charge batteries in an open or well ventilated area. Do not permit
smoking or open flames near batteries.

Remember that batteries can contain explosive gas.


Warning !!!

12. Properly dispose of waste, drained fluids and hazardous materials with due regard to
and in full accordance with all national and local environmental, safety,
transportation, and other regulations and ordinances. Make sure that all personnel are
familiar with these regulations.

13. Wear the appropriate clothing and protection devices, and follow the recommended
procedures when working with hazardous, flammable and combustible materials.

Pressurized Systems (Air, Hydraulic)

1. Do not perform maintenance on pressurized system


Caution !! components without first relieving ALL pressure in the
system.

2. Do not make internal checks on pressurized oil or fluid system reservoirs or levels
until ALL pressure in the system has been relieved. Pressurized oil and air are
dangerous if released incorrectly. Oil and air under pressure can get very hot; use
extreme caution and allow the system to cool before working on it.

3. Do not attempt to disconnect an air line or hydraulic line from a cylinder or other
component unless ALL pressure in the system has been relieved.

4. Do not operate pressurized systems with worn or damaged hoses, valves or fittings.
Replace defective components before pressurizing the system.

5. Do not attempt to remove an air or hydraulic cylinder clevis from its attachment
unless ALL pressure in the system has been relieved. Do not attempt to disassemble
air or hydraulic cylinders unless you have been trained and authorized for such
maintenance.
Safety Regulations - General S 050.012.02 en 9 (10)

2003-02-25

6. Never adjust pressure relief valves beyond the


Caution !! recommended values.

7. Follow the manufacturer's recommended inspection and maintenance procedures for


pressurized systems to ensure that safe operating conditions exist at all times.

8. Take extreme care when working with hydraulic


Warning !!! accumulators. They must never be heated or subjected to
welding or mechanical damage.

Welding Safety

1. Any welding or cutting operations should only be performed by experienced


welders who are familiar with the welding equipment and the materials to be welded.

2. Take all necessary precautions to avoid dropping sparks or welding splatter on belts,
hoses, tanks or other parts of equipment, or on personnel in the work area. Always
keep the risk of fire in mind.

3. Attach the welding earth cable as close as possible to the


Caution !! piece being welded to avoid damage to the equipment and
potential injury to personnel.

4. Always consult with the manufacturers of the equipment to be welded before any
welding operation.

5. Never weld vessels or pipework which are pressurized.

6. If a radio control system is installed, disconnect the radio system – including the
antenna – before starting any welding work. This is in order to avoid damage to the
radio equipment.
Safety Regulations - General S 050.012.02 en 10 (10)

2003-02-25

TEN SAFETY RULES


1. Support all efforts to make your work-area safe and healthy.

2. Act responsibly and with concern for the safety of others, as well as yourself.

3. Check all tools and protective equipment frequently, to make sure they are in safe
working order.

4. Educate yourself and others in the hazards associated with your job so that they can
be avoided in a safe manner.

5. To avoid injury and damage, familiarize yourself in advance with the risks and safety
aspects of procedures which are new to you.

6. Think over accident and injury possibilities before starting on any project. Take
appropriate precautions to protect yourself and others. Revise and improve working
procedures regularly.

7. Warn others of the possibility of accidents and injuries if you see them working
unsafely or creating potential hazards.

8. Be alert for changes in working conditions and process characteristics.

9. Report unsafe acts and conditions immediately to your supervisor. Don't assume that
someone else will do it.

10. Keep your work area and your tools clean. Pick up tools and materials after use and
return them to the appropriate storage place.
Maintenance Instruction Manual S 000.001.04 en 1 (2)

General information 2001-11-15

General maintenance conditions

The person who carries out maintenance work on this machine must be well acquainted
with its design.

The person who is responsible for the operation of the machine must have good
knowledge of the machine and must know when and how adjustments should be made.
He must also be familiar with the machine's permissible load limits.

For this reason you should read carefully through this maintenance instruction manual
and study the spare parts list and the drawings included therein before you install or
operate the machine. In addition, make sure that the operator responsible for the machine
has a copy of this manual.

It is especially important to read the safety regulations included in the instruction manual.

Guarantee and spare parts policies

Guarantee policy

In addition to the information given in the general delivery conditions, we should like to
point out the following:

Sandvik Rock Processing undertakes to correct faults in machines sold by us, under the
condition that:

- the fault is due to defective design, material or manufacturing.

- the fault is reported to Sandvik Rock Processings' representatives within the


applicable guarantee period.

- the machine is used only in accordance with the operating conditions specified by
us and in applications for which it is intended.

- maintenance work and repairs are carried out by competent service personnel, in
accordance with Sandvik Rock Processings' recommendations.

- only genuine Sandvik Rock Processing parts are used.


Maintenance Instruction Manual S 000.001.04 en 2 (2)

General information 2001-11-15

Our obligation thus does not cover faults caused by the use of non-genuine parts,
inadequate maintenance, incorrect installation, incorrect operation, incorrectly carried out
repairs or normal wear.

Sandvik Rock Processing takes no responsibility for damage beyond what is mentioned
above - neither injuries to people, damage to property nor consequential damage.

We reserve the right to alter the design and specifications of our products without prior
notice.

Spare parts policy

In order to achieve optimal reliability and operating economics throughout the entire life
of the machine, only genuine Sandvik Rock Processing original parts may be used.

The use of genuine Sandvik Rock Processing parts automatically gives access to the
development and quality advances constantly made by Sandvik Rock Processing.

Sandvik Rock Processing guarantees that spare parts will be available for at least 10
years after the cessation of manufacture of the machine in question.

To ensure that spare parts deliveries are correct, consult the applicable spare parts list and
with all orders, specify the following:

* machine type
* serial number/SW-number
* description, part number and quantity required.

Service assistance

Service work or service personnel can be ordered through the nearest


Sandvik Rock Processing company, agent or representative or directly from:

Sandvik SRP AB Telephone + 46-40-409000


Service Dept. Telefax + 46-40-409264
S-233 81 SVEDALA
Sweden
1800-Series Hydrocone crushers S 223.361.00 en 1 (22)

2. General technical information 2001-11-15

2. General technical information

Contents Page
2.1 Introduction 2
2.2 Important notes 12
2.3 Damage during transport 12
2.4 Pre-delivery rust prevention treatment 13
2.5 Storage of assembled crusher 13
2.6 Storage of partly assembled crusher 14
2.7 Starting up 15
2.8 Tightening threaded fasteners 15
2.9 Welding 17
2.10 Weights 19
1800-Series Hydrocone crushers S 223.361.00 en 2 (22)

2. General technical information 2001-11-15

2.1 Introduction

Type designation

Hydrocone is a trade name - registered by Sandvik Rock Processing - for our crushers of
the type known as "cone crushers". These are manufactured in two versions – H-type and
S-type respectively.

Another trade name registered by Sandvik Rock Processing is Hydroset, the name used to
describe the safety and setting adjustment system which is incorporated in the two types.

H-type and S-type Hydrocone crushers have different cone angles on the crushing mantle.
The mantle of an S-type has a smaller included angle than the mantle of an H-type crusher.
This means that the downward crushing force is larger in an H-type than in an S-type
crusher.

Pivot point

S-type H-type

Figure 2.1.1
1800-Series Hydrocone crushers S 223.361.00 en 3 (22)

2. General technical information 2001-11-15

Size designation

The 2800, 3800, 4800 and 6800 Hydrocones are crushers of different sizes in the so-called
“1800-Series". The designation H2800 merely indicates the crusher's position in this series.

The H4800, for instance, has larger dimensions and higher performance than the
H2800.

The designation system shown below is used to describe the type, size and main data of the
crusher.

Table 2.1.2 Designation system

H4800-MC/A/MC-16/20/24/13:01
TYPE OF CRUSHER MARK NUMBER
H=H-type
S=S-type

SIZE
ECCENTRIC THROW
2800
(mm)
3800
4800
CONCAVE RING
6800
EF=EXTRA FINE
F=FINE FILLER RING
MF=MEDIUM FINE MANTLE MF, M, MC, C
M=MEDIUM A, B, HC
MC=MEDIUM COARSE
C=COARSE
EC=EXTRA COARSE
1800-Series Hydrocone crushers S 223.361.00 en 4 (22)

2. General technical information 2001-11-15

1. Wearing plate 8. Concave ring 15. Eccentric bushing


2. Locating bar 9. Mantle 16. Step bearing
3. Headcentre 10. Topshell 17. Hydroset piston
4. Head nut 11. Bottomshell 18. Pinionshaft
5. Spider bushing 12. Dust seal ring 19. Pinionshaft housing
6. Spider cap 13. Bottomshell bushing 20. Crusher pulley
7. Mainshaft 14. Eccentric 21. Filler ring

Figure 2.1.3 H2800 Hydrocone: Crusher nomenclature


1800-Series Hydrocone crushers S 223.361.00 en 5 (22)

2. General technical information 2001-11-15

1. Crusher pulley 8. Spider cap 15. Bottomshell bushing


2. Locating bar 9. Spider bushing 16. Eccentric bushing
3. Dust seal ring 10. Concave 17. Eccentric
4. Mantle 11. Concave ring, lower 18. Step bearing
5. Headcentre 12. Topshell 19. Hydroset piston
6. Mainshaft 13. Bottomshell 20. Pinionshaft
7. Head nut 14. Wearing plate 21. Pinionshaft housing

Figure 2.1.4 S2800 Hydrocone: Crusher nomenclature


1800-Series Hydrocone crushers S 223.361.00 en 6 (22)

2. General technical information 2001-11-15

1. Locating bar 8. Topshell 15. Eccentric


2. Filler ring 9. Bottomshell 16. Eccentric bushing
3. Head nut 10. Mantle 17. Step bearing
4. Spider cap 11. Headcentre 18. Hydroset piston
5. Spider bushing 12. Dust seal ring 19. Pinionshaft
6. Mainshaft 13. Wearing plate 20. Pinionshaft housing
7. Concave ring 14. Bottomshell bushing 21. Crusher pulley

Figure 2.1.5 H3800 Hydrocone: Crusher nomenclature


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2. General technical information 2001-11-15

1. Locating bar 8. Topshell 15. Eccentric


2. Head nut 9. Bottomshell 16. Eccentric bushing
3. Spider cap 10. Mantle 17. Step bearing
4. Spider bushing 11. Headcentre 18. Hydroset piston
5. Mainshaft 12. Dust seal ring 19. Pinionshaft
6. Concave 13. Wearing plate 20. Pinionshaft housing
7. Concave ring, lower 14. Bottomshell bushing 21. Crusher pulley

Figure 2.1.6 S3800 Hydrocone: Crusher nomenclature


1800-Series Hydrocone crushers S 223.361.00 en 8 (22)

2. General technical information 2001-11-15

1. Locating bar 8. Topshell 15. Eccentric


2. Filler ring 9. Bottomshell 16. Eccentric bushing
3. Head nut 10. Mantle 17. Step bearing
4. Spider cap 11. Headcentre 18. Hydroset piston
5. Spider bushing 12. Dust seal ring 19. Pinionshaft
6. Mainshaft 13. Wearing plate 20. Pinionshaft housing
7. Concave ring 14. Bottomshell bushing

Figure 2.1.7 H4800 Hydrocone: Crusher nomenclature


1800-Series Hydrocone crushers S 223.361.00 en 9 (22)

2. General technical information 2001-11-15

1. Locating bar 8. Topshell 15. Eccentric


2. Head nut 9. Bottomshell 16. Eccentric bushing
3. Spider cap 10. Mantle 17. Step bearing
4. Spider bushing 11. Headcentre 18. Hydroset piston
5. Mainshaft 12. Dust seal ring 19. Pinionshaft
6. Concave 13. Wearing plate 20. Pinionshaft housing
7. Concave ring, lower 14. Bottomshell bushing 21. Crusher pulley

Figure 2.1.8 S4800 Hydrocone: Crusher nomenclature


1800-Series Hydrocone crushers S 223.361.00 en 10 (22)

2. General technical information 2001-11-15

1. Locating bar 8. Topshell 15. Eccentric


2. Filler ring 9. Bottomshell 16. Eccentric bushing
3. Head nut 10. Mantle 17. Step bearing
4. Spider cap 11. Headcentre 18. Hydroset piston
5. Spider bushing 12. Dust seal ring 19. Pinionshaft
6. Mainshaft 13. Wearing plate 20. Pinionshaft housing
7. Concave ring 14. Bottomshell bushing 21. Crusher pulley

Figure 2.1.9 H6800 Hydrocone: Crusher nomenclature


1800-Series Hydrocone crushers S 223.361.00 en 11 (22)

2. General technical information 2001-11-15

1. Locating bar 9. Topshell 17. Eccentric bushing


2. Head nut 10. Bottomshell 18. Step bearing
3. Spider cap 11. Mantle 19. Hydroset piston
4. Spider bushing 12. Headcentre 20. Pinionshaft
5. Mainshaft 13. Dust seal ring 21. Pinionshaft housing
6. Concave ring, upper 14. Wearing plate 22. Crusher pulley
7. Convave ring, lower 15. Bottomshell bushing
8. Spider 16. Eccentric

Figure 2.1.10 S6800 Hydrocone: Crusher nomenclature


1800-Series Hydrocone crushers S 223.361.00 en 12 (22)

2. General technical information 2001-11-15

2.2 Important notes

Each crusher is checked and test-run before delivery. The crusher is only test-run without
load and is thus not run-in.

Normally, the crusher is delivered on a transport frame and the tank unit is shipped in a
crate.

Great care must always be taken when handling crusher


Caution !! components to avoid damaging bearing surfaces or other
machined surfaces. Always use timber supports and never place
components directly on the ground.

Never transport an assembled crusher unless the mainshaft is


locked. This is done by lowering the mainshaft to its lowest
position and driving in suitable timber wedges in the crushing
chamber. If the mainshaft is allowed to move up and down or if
the crusher is subjected to severe buffeting, the step bearing
components can be destroyed. For the same reason it is
important to use care when lifting the crusher. Never lay the
crusher on its side as the step bearing components will then be
disturbed from their correct positions.

Lifting equipment must be dimensioned for the lift which is to


be carried out. Weights of the various components are given on
the installation drawing and in Section 2.10 below.

If chains are used for lifting, protect machined surfaces.

If a travelling hoist is installed above the crusher, the hoist travel direction must coincide
with the axis of the pinionshaft. This will make it easier to remove the pinionshaft
assembly. There must also be a storage area beneath the hoist's track so that crusher
components can be set down.

2.3 Damage during transport

Since the shipping agent is responsible for loss or damage which occurs during shipment,
inspect the delivery carefully when it arrives and check it against the packing list. In the
event of any shortage or damage, send in a claim to the shipping agent at once and inform
us at the same time so that we can recheck the delivery. It is always the responsibility of the
consignee - and not of the supplier - to send in a claim to the shipping agent. Ensure that
the goods are immediately brought under cover or are otherwise protected from rain.
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2. General technical information 2001-11-15

2.4 Pre-delivery rust prevention treatment

Before delivery from the factory, the crusher is treated with rust preventatives sufficient for
approx. 30 days of transport and storage. In special cases, additional rust prevention
treatment can be specified in the order.

The crusher is normally delivered fully assembled.

Before delivery from the factory, all crushers are test-run for a number of hours with oil
circulating through the crusher. When test-running has been completed, the inlet and outlet
holes for lubrication and Hydroset oil are plugged. This means that the internal bearing
surfaces of the crusher are covered with oil and then sealed off from the outside
environment.

The same procedure is followed for the tank unit.

A completely assembled crusher which has been test-run before delivery will therefore
withstand about 30 days of transport and storage before installation and starting up, as long
as it is protected from the elements by covering it with a tarpaulin.

If the machine is not put into operation within 30 days after it has been dispatched from the
factory, follow the instructions given in Section 2.5, Storage of assembled crusher.

2.5 Storage of assembled crusher

When the crusher has arrived at the storage site, carry out the following:

1. Inspect the crusher and tank unit for external damage (see Section 2.3, Damage
during transport).

2. Inspect the rust prevention treatment and touch-up or repeat the treatment if
necessary.

3. Do not place heavy components directly on the ground. Use properly arranged timber
supports.

4. Inspect the stored crusher regularly and check that the rust prevention film is intact
and that no damage has occured.

If the assembled crusher is not to be put into operation within 30 days after it has been
dispatched from the factory, carry out the following:

- Use the crusher's oil system to fill the bottomshell with lubricating oil until a little oil
overflows over the dust collar. Plug the oil return line so that the oil cannot run out
from the crusher. Close the valve(s) between the tank and the pump to prevent oil
running back from the crusher through the pump.
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2. General technical information 2001-11-15

- Fill the spider bushing with grease to prevent condensation on bearing surfaces.

- Rotate the crusher pulley by hand through at least four revolutions every 14th day.

- Coat the exposed part of the mainshaft sleeve (between the spider and the head nut)
with grease.

- If the lubrication and Hydroset oil tank unit is stored separately from the crusher, fill
the pumps with oil.

These recommendations apply also for crushers which are taken out of operation for a
period of more than 30 days.

2.6 Storage of partly assembled crusher

When the crusher components have arrived at the storage site, carry out the following:

- Inspect the rust prevention treatment and touch-up or repeat the treatment if
necessary.

- Do not place heavy components on the ground. Use properly arranged timber
supports.

- Screw in the lifting eye in the top end of the mainshaft. Lift the mainshaft assembly
out of its transport frame and set it down on wooden blocks placed beneath the lifting
eye and the lower edge of the mantle. Avoid contact with the bearing surfaces on the
two ends of the mainshaft.

- Inspect the stored components regularly and check that the rust prevention film is
intact and that the components have not been damaged.

- Cover the oil tank unit with a tarpaulin if it is stored outdoors.

- Store seals and gaskets in a dark, dust-free, dry place. Keep them in their pack-
aging until they are required. If possible, keep the store area at normal room
temperature. 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.
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2. General technical information 2001-11-15

2.7 Starting up

Before the crusher is started up, drain out all oil from components which have previously
been filled. Carefully inspect all components to ensure that there is no corrosion or damage
which could interfere with the proper operation of the machine.

Install the crusher in accordance with the installation drawing and the instructions given in
this manual. Start-up the crusher with the help of service personnel from Sandvik Rock
Processing.

For more information about putting the crusher into operation, see Section 5, Starting up.

2.8 Tightening threaded fasteners

The threaded fasteners used in the crusher must be tightened to the correct torque for the
size in question, as given in Table 2.8.1. General requirements for ”normal” joints with
threaded fasteners are described in Section 2.8.2.

Sections 2.8.3 - 2.8.6 describe ”special joints” for which there are additional requirements
for spread of tightening torques in a joint, tightening method and working procedure.

Table 2.8.1 Tightening torques in Nm (foot pounds).

THREAD STRENGTH GRADE


M (SS-ISO 898/1)
(mm)
8.8 10.9 12.9
8 24 (18) 33 (24) 40 (30)
10 47 (35) 65 (48) 79 (58)
12 81 (60) 114 (84) 136 (100)
16 197 (145) 277 (204) 333 (246)
20 385 (284) 541 (399) 649 (479)
24 665 (490) 935 (690) 1120 (826)
30 1310 (966) 1840 (1357) 2210 (1630)
36 2280 (1682) 3210 (2368) 3850 (2840)
42 3640 (2685) 5110 (3769) 6140 (4529)
48 5450 (4020) 7660 (5650) 9190 (6778)
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2. General technical information 2001-11-15

2.8.2 General requirements for joints with threaded fasteners - "normal"


joints

- Steel screws of grade 8.8, with surface finish dependent on dimensions: (zink coated
or hot-dip galvanized).

- Hardened washers - at least HB200 (zink coated).

- Lightly oiled components.

- Threads in castings cleaned out.

- Tightening carried out with a torque wrench which can be calibrated, or with a
bolt/nut runner with a torque limiter.

- Max. permissible torque spread: + 30%.

Unless otherwise specified, joints are of "normal" type.

2.8.3 The Hydroset cylinder/bottomshell joint - a "special" joint


and
2.8.4 The Hydroset cylinder cover/Hydroset cylinder joint - a "special" joint.

- Grade 8.8 hot-dip galvanized steel screws.

- Hardened washers - at least HB200. (Zink coated).

- Lightly oiled screws.

- Threads in the bottomshell cleaned out.

- Tightening carried out with a torque wrench which can be calibrated, or with a
bolt/nut runner with a torque limiter.

- Screws are tightened in stages, and in diagonal rotation.

- Max. permissible torque spread: + 10%.


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2. General technical information 2001-11-15

2.8.5 The locating bar/dust collar joint - a "special" joint.

The tightening torque for this joint is calculated with the strength of the threads in the
locating bar taken into consideration, and is thus independent of the grade of screw used.

Before assembly starts, apply Loctite 243 (or an equivalent) to the threads.

- Tightening torque: 45Nm ( 33 ft lbs)


- Max. permissible torque spread: + 10%

2.8.6 The eccentric gear/gear carrier joint - a "special" joint

- Untreated grade 12.9 steel screws.


- Hardened washers - at least HB 400-470.
- Lightly oiled screws.
- Threads in the eccentric gear cleaned out.
- Tightening carried out with a torque wrench which can be calibrated, or with a
bolt/nut runner with a torque limiter.
- The screws are tightened in stages, in diagonal rotation.
- Max. permissible torque spread: + 10%.

2.8.7 Locking fluid for threaded fasteners

In some places in this instruction manual you will come across the recommendation to use
locking fluid. Unless otherwise stated, this normally means using Loctite 243 or an
equivalent. Use Loctite 577 or an equivalent to seal pipe threads in the lubrication system,
where no other sealing is used. For pipes up to 3/4" in size - and in the Hydroset system -
use Loctite 543, or an equivalent. When a previously used screw is to be reinstalled, it is
important to clean oil and Loctite from the threads first.

Follow the manufacturer's instruction for the application of locking fluid.

2.9 Welding

Under some circumstances it can be necessary to undertake welding during maintenance


work on the crusher. If good results are to be obtained, it is important that the welding
work is carried out by competent personnel and that the correct electrode is used. Below
we give instructions for some of the welding jobs which may be required.

Follow the welding instructions for the electrode being used and earth as close as possible
to the working area. Do not allow the welding current to pass through important bearing
components, etc.
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2. General technical information 2001-11-15

2.9.1 Welding manganese wearing liners to the crusher's topshell and


bottomshell etc.

Use an ESAB OK 63.35 or equivalent electrode.

Liners on bottomshell arms.


Fettle the liners and fit them in place. Weld to the inner surface of the bottomshell with
three runs of weld 50-100 mm long. Use an A-dimension of 4-6 mm for H & S 2800, 3800
and 4800 crushers, and 6-8 mm for the H & S 6800.

Liners on the topshell spider arms (H-type crushers).


Fettle the liners and fit them in place. Make a continuous weld around the attachment slots.
Use an A-dimension of 4-6 mm for H2800, 3800 and 4800 crushers, and 6-8 mm for the
H6800.

Liners on topshell spider arms and spider rim (S-type crushers).


Fettle the liner support pads and make a continuous weld all around each against the rear
side of the liner. Use an ESAB OK 63.35 electrode or an equivalent, with an A-dimension
of 4-6 mm for S2800, 3800 and 4800 crushers, and 5-7 mm for the S6800.

2.9.2 Welding liner plates to the inside of the bottomshell

After fettling the plates, weld them to the inside of the bottomshell in the holes provided.
Use an ESAB OK 48.00 electrode or an equivalent, as directed on the drawing in the spare
parts list. Use an A-dimension of 5-6 mm for H & S 2800, 3800 and 4800 crushers, and 6-
8 mm for the H & S 6800.

2.9.3 Welding the head nut and the mantle

See Section 12.3.

2.9.4 Lifting lugs on mantles and concave rings

If lifting lugs are to be welded on crushing liners, use an electrode suitable for welding to
manganese steel, for example ESAB OK Selectrode 67.45 (or an equivalent).
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2. General technical information 2001-11-15

2.10 Weights

Table 2.10.1 gives details of the weights of components which can require handling during
normal maintenance and repair work.

The weights given here are intended for the selection of lifting equipment etc. and must not
be considered to be exact. The weights given for concave rings, for example, apply for the
heaviest concave ring for each model.

Table 2.10.1 Lifting weights (kg)

Cat. No. Component H2800 S2800 H3800 S3800 H4800 S4800 H6800 S6800
4175-0 Mantle 240 460 480 760 775 1300 1160 2210

6005-0 Concave ring 360 - 590 - 860 - 1290 -

6390-0 Concave, upper - 45 - 80 - 100 - -

6305-0 Concave ring, - 400 - 600 - 1050 - 2000


lower

6395-0 Concave ring, - - - - - - - 1900


upper

5650-0 Spider cap 75 75 130 130 160 300 370 370

5660-0 Protective cap - - - - - - - 420

4205-0 Head nut 15 15 25 25 50 50 85 85

6050-0 Support ring 45 - - - 135 - 180 -

- Mainshaft 1180 1600 1840 2730 3500 5100 6000 7900


assembly with
mantle
-
Topshell assembly, 1800 - 2900 - 4700 - 7400 -
with filler ring and
concave ring
-
Topshell assembly 1600 2300 2520 5100 4100 8100 6800 9600
with concave ring

6006-0 Filler ring 210 - 620 - 500 - 1000 -

5150-0 Arm liner, topshell - 55 - 270 - 290 - 525

5110-0 Liner plate, 15 - - 30 - 65 - 60


topshell

- Feed hopper 120 260 310 340 330 840 750 1800
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2. General technical information 2001-11-15

Table 2.10.1 Lifting weights (kg) – Continued

Cat. No. Component H2800 S2800 H3800 S3800 H4800 S4800 H6800 S6800
1400-0 Dust collar 70 70 110 110 180 180 265 265

1200-0 Bottomshell bushing 45 45 60 60 100 100 180 180

Eccentric bushing
1810-0 40 40 75 75 130 130 250 250
Eccentric wearing
1880-0 plate 15 15 15 15 30 30 20 20

Mainshaft sleeve
4025-0 15 15 30 30 45 45 85 85
Dust seal ring
4305-0 5 5 10 10 15 15 20 20
Retaining ring for
4350-0 dust seal ring 25 25 55 55 70 70 95 95

Mainshaft step
4075-0 10 10 15 15 25 25 40 40
Step washer
2280-0 10 10 15 15 25 25 45 45
Piston wearing plate
2260-0 10 10 15 15 25 25 35 35
Hydroset piston
2205-0 85 85 110 110 185 185 345 345
Hydroset cylinder
2505-0 cover 50 50 85 85 130 130 265 265

Hydroset bushing
2050-0 21 21 30 30 50 50 85 85
Spider bushing
5675-0 15 15 35 35 70 70 90 90
Pinion
3050-0 10 10 15 15 20 20 40 40
Crusher pulley
8875-0 50 50 80 80 100 100 150 200
Topshell assembly
- with spider, liners 16 000
and concave rings

Spider assembly
- with liner plates 6100

Eccentric assembly
- incl. eccentric 260 260 410 410 700 700 1170 1170
bushing

Hydroset assembly
- with step bearing 360 360 520 520 610 610 1380 1380

Pinionshaft
- assembly, excl. 120 120 180 180 280 280 420 420
crusher pulley

Oil tank excl. oil


- 270 270 270 270 520 520 520 520
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2. General technical information 2001-11-15

Table 2.10.2 Lifting weights (lbs)

Cat. No. Component H2800 S2800 H3800 S3800 H4800 S4800 H6800 S6800
4175-0 Mantle 525 1010 1050 1670 1700 2860 2550 4860

6005-0 Concave ring 790 - 1290 - 1890 - 2840 -

6390-0 Concave, upper - 95 - 175 - 220 - -

6305-0 Concave ring, - 880 - 1320 - 2310 - 4400


lower

6395-0 Concave ring, - - - - - - - 4180


upper

5650-0 Spider cap 165 165 285 285 350 660 810 810

5660-0 Protective cap - - - - - - - 925

4205-0 Head nut 30 30 55 55 110 110 185 185

6050-0 Support ring 95 - - - 290 - 390 -

- Mainshaft 2590 3520 4050 6010 7700 11230 13200 17400


assembly with
mantle
-
Topshell assembly, 3960 - 6380 - 10350 - 16290 -
with filler ring and
concave ring
-
Topshell assembly 3520 5060 5550 11230 9030 17840 14970 21140
with concave ring

6006-0 Filler ring 460 - 1360 - 1100 - 2200 -

5150-0 Arm liner, topshell - 120 - 590 - 630 - 1150

5110-0 Liner plate, 30 - - 65 - 140 - 130


topshell

- Feed hopper 260 570 680 740 720 1850 1650 3960
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2. General technical information 2001-11-15

Table 2.10.2 Lifting weights (lbs) – Continued

Cat.No. Component H2800 S2800 H3800 S3800 H4800 S4800 H6800 S6800
1400-0 Dust collar 150 150 240 240 390 390 580 580

1200-0 Bottomshell 95 95 130 130 220 220 390 390


bushing

1810-0 Eccentric bushing 85 85 165 165 280 280 550 550

1880-0 Eccentric wearing 30 30 30 30 65 65 40 40


plate

4025-0 Mainshaft sleeve 30 30 65 65 95 95 185 185

4305-0 Dust seal ring 10 10 20 20 30 30 40 40

4350-0 Retaining ring for 55 55 120 120 150 150 205 205
dust seal ring

4075-0 Mainshaft step 20 20 30 30 55 55 85 85

2280-0 Step washer 20 20 30 30 55 55 95 95

2260-0 Piston wearing 20 20 30 30 55 55 75 75


plate

2205-0 Hydroset piston 185 185 240 240 405 405 755 755

2505-0 Hydroset cylinder 110 110 185 185 285 285 580 580
cover

2050-0 Hydroset bushing 45 45 65 65 110 110 185 185

5675-0 Spider bushing 30 30 75 75 150 150 195 195

3050-0 Pinion 20 20 30 30 40 40 85 85

8875-0 Crusher pulley 110 110 175 175 220 220 330 440

- Topshell assembly 35 200


with spider, liners
and concave rings

- Spider assembly 13 400


with liner plates

- Eccentric 570 570 900 900 1540 1540 2575 2575


assembly incl.
eccentric bushing

- Hydroset 790 790 1140 1140 1340 1340 3030 3030


assembly with
step bearing

- Pinionshaft
260 260 390 390 610 610 920 920
assembly, excl.
crusher pulley

- Oil tank excl. oil 590 590 590 590 1140 1140 1140 1140
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3. Installation 2001-11-15

3. Installation

Contents Page
3.1 Installation, general 2
3.2 Erection 3
3.3 Feed and discharge arrangements - general information 3
3.4 Feed arrangements for H-type Hydrocone crushers 5
3.5 Feed arrangements for fine crushing 7
3.6 Feed arrangements for S-type Hydrocone crushers 8
3.7 Discharge arrangements 9
3.8 Drive arrangement 12
3.9 Lubrication system 12
3.10 Hydroset system 13
3.11 Electrical system 13
3.12 Over-pressure dust sealing equipment 13
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3. Installation 2001-11-15

3.1 Installation, general

For every crusher we supply an installation drawing with installation instructions.

The installation drawing gives details of the space required for dismantling and also gives
information about the weights of the heaviest components. Information on weights can also
be found in Section 2.10. Install lifting gear so that the installation and removal of wearing
parts can be carried out quickly. Ensure that there is sufficient space beneath the crusher to
remove components from the Hydroset cylinder.

To reduce the stresses in the foundation or supporting structure, it is advisable to install the
crusher on anti-vibration compression mountings which absorb the vibrations generated
when the crusher is running.

To ensure that the crusher's motion is harmonic, the compression mountings should be
adjusted vertically so that they are equally loaded. When running normally, the crusher will
gyrate up to + 15 mm in the horizontal plane, but during starting and stopping the
movement is larger. A clearance of at least 35 mm should therefore be provided all around
the crusher.

There is a risk of pinching fingers etc. when the machine is


Warning !!! running, especially when starting and stopping.

If the crusher is delivered on a supporting structure or transportable frame, make sure that
it 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.

The crusher has a divided feed hopper so that the machine can be disassembled without the
need to remove the feed conveyor or feeder.

The feed hopper has inspection doors. Never open these when
Warning !!! the machine is crushing. If a door must be opened when the
machine is running empty, open it carefully and make sure that
no material can fall from chutes etc. while the inspection is
being carried out. Use protective glasses and a helmet. This is
especially important in the case of an open (unencapsulated)
feed hopper where stones and stone fragments may be thrown
out of the machine.

When the crusher is operating - even when it is idling -


Warning !!! occasional stones which are not properly gripped in the crushing
chamber can be thrown violently up out of the crusher and fall
down in the vicinity of the machine. Falling material can also
cause injury in the vicinity of transfer points - between
conveyors or feeders and crushers, for example. Provide suitable
guards to give protection against these ejected or falling stones.
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3. Installation 2001-11-15

3.2 Erection

On a steel supporting structure

Make sure that the crusher mounting points are level and attach the rubber compression
mountings to the crusher. Lower the crusher into place and weld the lower fixing plates to
the supporting structure.

If the compression mountings are instead to be bolted to the supporting structure, mark the
positions of the fixing holes. Lift the crusher out of the way, drill the holes for the fixing
bolts and then lower the crusher back into place and install the fixing bolts.

On a concrete foundation

The concreting work should be carried out by experienced personnel.

Anchor plates (not supplied with the crusher) must be cast into the foundation.

Carefully clean any dust and oil from the concrete areas around the anchor plate pockets.
Put the anchor plates into position in the foundation.
Fix the rubber compression mountings to the crusher/sub-frame and lower the crusher until
it is just above the foundation.
Position four blocks between the crusher/sub-frame and the foundation so that the bottoms
of the mountings are at least 25 mm above the foundation.
Make sure that the crusher is level.
Lift the anchor plates and weld the lower attachment plates of the mountings to the top
surfaces of the anchor plates.
Grout around the anchor plates with a grouting mortar.
Keep these areas wet for at least 24 hours.

The crusher can also be mounted directly on a foundation without the rubber compression
mountings. In such a case, use foundation bolts (not supplied with the crusher).

3.3 Feed and discharge arrangements - general information

One of the most important factors for long crusher life and low operating costs is that the
feed arrangement is designed so that the material is evenly distributed around the crushing
chamber and the crushing chamber is full. If you have any doubts about the feed and
discharge arrangements you intend to use, contact Sandvik Rock Processing for advice.

The feed system must be amply dimensioned so that the crusher


Caution !! can receive a sufficient quantity of material. The material should
be level with the top of the spider cap.

A metal detector should be installed to prevent uncrushable


objects from falling into the crusher.
1800-Series Hydrocone crushers S 223.362.00 en 4 (13)

3. Installation 2001-11-15

A level monitor should be mounted in the feed hopper to stop the


feed to the crusher if the material level rises too high.

The feeder or feed conveyor should be electrically connected in


such a way that it cannot be started before the crusher and the
discharge system are running.

Depending on the size of the feed material, feed hoppers with conical guide plates or a feed
distributor can be fitted.

As can be seen in Fig. 3.3.1, the topshell of an S-type or an


Note ! H-type Hydrocone without a feed distributor should always be
turned so that the spider arms are aligned with the feeder or feed
conveyor.

An H-type Hydrocone with a feed distributor should have the


topshell turned so that the spider arms are aligned at 90° to the
axis of the feeder or feed conveyor. See Fig. 3.3.2.

Figure 3.3.1 S-type Hydrocone (left) and H-type Hydrocone


without feed distributor (right)

Figure 3.3.2 H-type Hydrocone with feed distributor


1800-Series Hydrocone crushers S 223.362.00 en 5 (13)

3. Installation 2001-11-15

The crusher must not be put into full-scale operation until you have established that the
feed material is correctly distributed around the crushing chamber, at all rates of feed.

If the feed is not evenly distributed around the crushing chamber, or if the finer material
enters on one side whilst the coarser material enters on the other side, uneven loads will
result. This can lead to bearing failure or shortened bearing life. In addition, the manganese
liners will be worn unevenly, thus reducing manganese life.

Incorrect feeding arrangements cause:

- Higher power consumption = higher bearing loads


- Lower capacity
- Higher manganese wear
- Lower reduction
- Poorer product shape
- Higher costs

If a belt conveyor or a chute is used to feed the crusher, the coarser material will tend to
separate from the finer material (segregation). It is thus important to homogenize the feed
before it reaches the crusher. This can be accomplished with a feed box above the crusher's
feed hopper, as shown in figs. 3.4.1 and 3.4.2. The feed box should be so designed that it
can be moved longitudinally to correctly guide the material.

A feed box can also be used when a feeder is installed. See Fig. 3.4.3.

3.4 Feed arrangements for H-type Hydrocone crushers

Figure 3.4.1 Feeding from a belt conveyor


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3. Installation 2001-11-15

Figure 3.4.2 Feeding from a chute. The chute can be


attached to a conveyor or a bin.

Figure 3.4.3 Feeding from a vibrating feeder,


direct onto the spider cap.

The feeder's supports must be such that it is easy to adjust the position of the feeder to
obtain correct material distribution in the crusher. A feed box of the type shown in figs.
3.4.1 and 3.4.2 can also be used.
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3. Installation 2001-11-15

Figure 3.4.4 Feeding from a belt conveyor to a crusher


with a feed distributor.

A feed distributor can also be used when the material comes from a chute or a feeder.

3.5 Feed arrangements for fine crushing

Of the different types of crushing duty, fine crushing gives rise to the highest loads on the
crusher. To obtain correct feeding, a feed distributor should be used with feed sizes up to
80 mm. The distributor prevents segregation and also distributes the material evenly around
the crushing chamber.

For installation dimensions of the feed distributor and the feed hopper, see the installation
drawing. The topshell arms must be correctly oriented relative to the distributor - see Fig.
3.3.2.

The material must be led into the distributor through the chain-dotted area shown in Fig.
3.5.1. This can be arranged by using a cover plate over the feed hopper and cutting an
appropriate opening.

The function of the distributor is to split the material into several non-segregated streams
which provide an even distribution around the crushing chamber. It rests on the spider cap,
which forms the bottom of the middle "compartment". The width of this middle
compartment can be adjusted by slackening off the screws (not shown in Fig. 3.5.1)
between the distributor and the supporting angle profile across the feed hopper. After a
short period of operation, three "cushions" of stone (not shown in Fig. 3.5.1) will be
formed and these will reduce the wear on the plate components.
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3. Installation 2001-11-15

Feed

Adjustable

Figure 3.5.1 Feed distributor

3.6 Feed arrangements for S-type Hydrocone crushers


(and H-type Hydrocone crushers with EC or C crushing chamber)

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

"Stone box"

Figure 3.6.1 Feeding from a belt conveyor


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3. Installation 2001-11-15

Figure 3.6.2 Feeding from a chute. The chute can


be attached to a conveyor or a bin

The feeder's supports must be such that it is


easy to adjust the position of the feeder to
obtain correct material distribution in the
crusher. A feed box of the type shown in
figs. 3.6.1 and 3.6.2 can also be used.

Figure 3.6.3 Feeding from a vibrating feeder,


direct onto the spider cap

3.7 Discharge arrangements

The discharge arrangement must be designed so that there is no


Caution !! possibility of material building up beneath the crusher. If
material does build up, the crusher's dust seal ring can be
damaged, thus allowing contamination to enter the lubrication
oil. Protect the lubrication and Hydroset lines from falling
material.

To facilitate removal of components from the Hydroset cylinder there must be sufficient
height between the discharge conveyor and the crusher, or the conveyor must be easily
removable. See the installation drawing.
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3. Installation 2001-11-15

Figure 3.7.1 Crusher mounted on concrete foundation or steel


supporting structure with discharge hole in floor.
Openings in the foundation are blanked off with plate
or planks.

Figure 3.7.2 Crusher mounted on concrete foundation where the foundation


forms two sides of the discharge hopper. The two remaining sides
and the hopper bottom are attached to anchor plates cast into the
foundation.
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3. Installation 2001-11-15

Figure 3.7.3 Crusher mounted on sub-frame or steel supporting


structure with discharge hopper attached to the sub-frame
or structure.The conical part of the hopper is of wearing
rubber.

Figure 3.7.4 Crusher mounted on sub-frame or steel supporting


structure with discharge hopper attached to the sub-
frame or structure. The hopper has a flat bottom of
plate.
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3. Installation 2001-11-15

3.8 Drive arrangement

See Section 16.

3.9 Lubrication system

Oil products present environmental and fire risks and can cause
Warning !!! injury if inhaled or brought into contact with the skin. Follow
your lubricant supplier's instructions and safety directions when
handling oils and greases.

See the installation drawing in the spare parts list for the crusher.

The tank unit should be situated so that it is both easily accessible and protected against
falling objects, stones and water etc. Ensure that there is sufficient room to drain out oil.
Place the tank unit as close to the crusher as possible to give the shortest possible return
pipe and thus reduce the return pipe resistance to a minimum. The hoses supplied for inlet
and outlet connections must be fitted to the crusher to prevent the transmission of
vibrations to the tank unit. Pipes for connection between these hoses and the tank unit are
not supplied with the crusher, but normal water pipe can be used. Regarding pipe thread
sealing, see Section 2.8.7.

The return pipe must have an even slope of at least 1 in 12 (5°).


Caution !! If the pipe is longer than 3 m, increase the slope to 10° to
prevent the formation of air pockets. If the pipe is to include
changes of direction, avoid pipe elbows. Use large radius pipe
bends instead to reduce resistance in the pipe.

Oil is supplied to the crusher through one or two lines. Make


sure that the piping is free from burrs, metal shavings and dirt
before it is connected to the crusher and tank unit. The piping
should be run so that it is protected against falling stones and it
should be securely supported to avoid vibration.

If a water/oil heat exchanger is used, it can be mounted on the tank unit with the hoses
supplied. If the water/oil heat exchanger is mounted elsewhere, pipes can be used between
the hoses and the tank unit.

If an air/oil heat exchanger is mounted on the back of the tank unit, the hoses supplied with
the crusher will be sufficient. If the heat exchanger is installed in some other place, use
pipes to connect the tank unit to the hoses. Attach only hoses to the air/oil heat
exchanger.

To reduce as far as possible the amount of dust which settles in the radiator matrix, the
air/oil heat exchanger is best placed so that its fan blows towards the crusher.
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3. Installation 2001-11-15

If the ambient air contains a lot of dust, it is advisable to lead fresh air to the heat
exchanger through a duct from a dust-free place. The duct must not be so long that air flow
is restricted and it must not be rigidly connected to the heat exchanger.

3.10 Hydroset system

The Hydroset tank unit is combined with the lubrication tank unit. See figures 6.1.1 and
6.1.2.

The crusher is connected to the Hydroset control valve in the tank unit by a hose and
piping.

A hose is supplied with the crusher. This hose must be


Note ! connected to the crusher so that vibrations are not transmitted to
the tank. Carefully de-burr and clean out any rust, scale etc.
from the bore of the pipes before erection. Sharp pipe bends
should be avoided since they can lead to unnecessary pipe
resistance. Support the pipework properly. Regarding pipe
thread sealing, see Section 2.8.7.

The rest of the Hydroset line must be made of high-pressure pipe


Caution !! which can withstand a pressure of 20 MPa.

The Hydroset tank must be inspected and if necessary cleaned before it is filled with oil.
Before starting up the hydraulic system, it must be cleaned out with separate, suitable
cleaning equipment. Cleanliness is the best insurance against disturbances in operation.

Oil products present environmental and fire risks and can cause
Warning !!! injury if inhaled or brought into contact with the skin. Follow
your lubricant supplier's instructions and safety directions when
handling oils and greases.

3.11 Electrical system

See Section 4.

3.12 Over-pressure dust sealing

See Section 21.


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4. Electrical system 2001-11-15

4. Electrical system

Contents Page
4. Electrical system 2
1800-Series Hydrocone crushers S 223.392.00 en 2 (2)

4. Electrical system 2001-11-15

4. Electrical system

The crusher’s drive motor must be interlocked in such a way that


Caution !! it cannot be started unless the lubrication system is in operation,
i.e. the lubricating oil pump is running, the oil flows to and from
the crusher are correct and the oil is not too hot. On crushers
which have a circulatory system for pinionshaft lubrication
(H/S4800 and H/S6800) this pump must be interlocked in such a
way that it starts when the crusher’s drive motor starts.

If any of the safety interlocks listed above are activated, the


crusher motor will stop. To avoid stoppages when the crusher is
full of material, the interlocks can be arranged so that the feed
stops immediately and the crusher’s drive motor stops approx. 10
(max. 15) seconds later.

Important! The oil pump must not be stopped until after the
crusher has stopped.

If the crusher drive motor and the lubrication oil pump are started
and stopped with a common push button, interlocks must be
provided to ensure that the oil pump starts first. The crusher
drive motor must start only when the thermostat and return oil
flow switch are activated and indicate "crusher ready for start".
When the machine is to be shut down, the oil pump should not be
stopped until about one minute after the crusher drive motor has
stopped.

The feeding system must be connected in such a way that feeding


is impossible until both the crusher and the discharge system are
running and the crusher's pinionshaft speed is correct. The feed
must stop if the discharge system and/or the crusher stops.

The components inside the oil tank are wired to the connection box on the outside of the
tank.
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5. Starting up 2001-11-15

5. Starting up

Contents Page
5.1 General 2
5.2 Running in 4
5.3 Checking the setting 6
5.4 Maximum load 6
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5. Starting up 2001-11-15

5.1 General

Before a new or overhauled crusher is started, follow the sequence described below:

1. Check that the lubrication and Hydroset lines between the crusher and the tank unit are
correctly installed and that the oil return line has sufficient fall and is adequately
dimensioned.

2. Check that the voltage and frequency of the electrical supply match the data given on
the motors and heaters.

3. Check that the motor overload protection relays are set to the correct current values.

4. Fill the lubrication and Hydroset tanks with oil. For oil types and quantities, see
Section 9 – Lubricant recommendations.

NOTE! The same type of oil is used in both tanks, but with different viscosities.

5. Check the setting of the heater thermostat (TG3). For operating conditions which differ
from normal, thermostat TG 3 must be reset.
See Table 6.15.1 in Section 6.

6. Switch on the oil heaters.

7. Check that the shut-off valves are open on the suction lines to the lubrication and
Hydroset pumps.

8. Check that the pinionshaft housing of an H or S 2800 or 3800 crusher has been filled
with oil up to the top of the oil level tube. For oil type and quantity, see Section 9 –
Lubricant recommendations.

Before starting a new or overhauled crusher for the first time, fill the pinionshaft
housing with oil up to the correct level, even if the crusher has a circulatory lubrication
system. This is because the pinionshaft lubrication pump starts at the same time as the
crusher's drive motor and it takes a little time for oil to reach the pinionshaft housing.

9. Check that the spider bearing is filled with grease up to the top of the bushing when the
mainshaft is in its lowest position. For grease recommendations, see Section 9.5 –
Spider bearing lubrication.

10. Check the direction of rotation of the motor on the lubrication oil pump. See Section
6.6 – Oil Pump.

11. In the case of an H or S 4800 or 6800 crusher, check the direction of rotation of the
pinionshaft lubrication pump. See Section 6 – Lubrication system.
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5. Starting up 2001-11-15

12. If the crusher is fitted with an air/oil heat exchanger, check the direction of rotation of
the fan motor and the air flow direction. Air should be sucked through the cooler
matrix.

If a water/oil heat exchanger is fitted, check that cooling water is available and that the
water lines do not leak.

13. Start the lubrication oil pump and check that there is no leakage in the oil lines. Run the
pump for about 30 minutes and then clean off any contaminants (e.g. remnants of
sealing compound etc.) that have collected on the return oil strainer or in the dirt trap.
Start the pump again.

14. Raise and lower the mainshaft slightly several times and check that the electrical setting
control circuits are correctly connected.

15. Bleed all air out of the Hydroset system. See Section 8.3 – Starting up.

16. Lower the mainshaft to its lowest position and measure the distance between the head
nut and the underside of the spider and record this dimension (="A-dimension"). This
will later permit the determination of the wear on the step bearing without taking the
crusher apart.

17. Raise the mainshaft 10-15 mm from its lowest position.

18. Check that the crusher's drive is correctly aligned and that the V-belts are correctly
tensioned.

19. Start the crusher's drive motor and check that the direction of rotation is correct. See
Section 16 – Drive arrangement. Run the crusher without load until the return oil
temperature reaches about 40°C (104°F).

20. In the case of an H or S 4800 or 6800 crusher, check that the pinionshaft lubrication
pump starts when the crusher drive motor starts.

21. Check the operation of the return oil flow switch and, if necessary, adjust (See
Section 6 – Lubrication system).

22. Bleed the Hydroset system again.

The crusher's drive motor must stop when the following checks are made:

23. Depress the float on the return oil flow switch.

24. Adjust the protective thermostat TG1 to a temperature just below the return oil
temperature (on the temperature gauge). When the check has been carried out, reset the
thermostat to the correct setting, as given in section 6.14 – Thermostats.
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25. Stop the crusher's drive motor and the lubrication pump motor.

IMPORTANT! The lubrication pump must never be stopped until the crusher has stopped
completely.

26. Clean the return oil strainer and the dirt trap.

Check that material cannot be fed to the crusher unless both the
Note ! crusher and the discharge system are running.

Starting a crusher in extremely low temperatures

At extremely low temperatures it may be found that oil overflows over the dust collar when
the crusher is started (before normal operating temperature is reached).

Stop the oil pump and allow the oil to run back to the tank.

Start and stop the oil pump repeatedly at 10 second intervals until the "Crusher ready for
start" signal is obtained. Start the crusher and allow it to run idle. Check that the oil flow is
normal.

For more information, see Section 22 – Operating in low temperatures.

5.2 Running in

The appropriate parts of this section apply also after repair work and the fitting of new parts.

1. Start the lubrication oil pump.


2. When the "Crusher ready for start" lamp lights up, start the crusher's drive motor.
3. Check and adjust the setting. See Section 5.3 – Checking the setting. During the
running-in period the setting should be a little larger than the smallest recommended.
4. Operate the crusher carefully and gradually increase the load until it reaches 75% of the
maximum motor load and Hydroset pressure values given in Section 5.4.
The load is altered by changing the setting.

The crushing chamber should be full. The crusher will not be


Caution !! run-in by idling. The crusher is normally run-in after
approximately 16 hours operating at 75% load. Thereafter
increase the load gradually up to full load. Depending on the
availability of material, and for other process engineering reasons,
running-in can take longer. It is important that points 5, 6 and 7
are followed carefully during the entire running-in procedure.
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5. Starting up 2001-11-15

5. Check the return oil temperature regularly. This temperature should normally lie
between 40°C (104°F) and 45°C (113°F).

6. Check that the cooling system cuts in at 45°C (113°F) and cuts out at 40°C (104°F) oil
temp.

If operating conditions differ from normal and an oil with ISO VG 220 or ISO VG 100
viscosity is used, set the thermostats at the correct values, as given in Table 6.14.2 in
Section 6.14 – Thermostats.

7. Inspect and clean the oil strainer regularly. Quite often, a small quantity of fine steel
and bronze particles can be found on the oil strainer during the initial running period.

8. Bleed the Hydroset system again.

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

10. Check that there are no oil leaks from the lubrication and Hydroset lines.

11. Check that the indicating pointer of the Hydroset pressure gauge moves steadily. (See
Section 8.10 - Damping valve for pressure gauge).

12. Check the temperature of the pinionshaft housing with a thermometer. The normal
temperature is 50-60°C (122-140°F).

13. Check that the feed is correctly distributed around the crushing chamber. See Sections
3.3-3.6.

14. Check the power consumption and Hydroset pressure.

15. Check and record the lubricating oil pressure(s) (Main lubrication system, plus – on an
H or S 4800 or 6800 crusher – also the pinionshaft lubrication system).

16. Shut off the feed to the crusher and listen for abnormal noises. A ringing sound can
indicate a loose mantle or concave ring.

17. Check that there are no grease leaks from the spider bearing.

18. Check the oil level in the pinionshaft housing when the oil is hot and the crusher is
standing still (H or S 2800 or 3800 crusher).

19. After running-in is completed, retighten all bolts and re-tension the V-belt drive.

20. It is very important to clean the dirt trap on the suction side of the lubrication oil pump,
since it is quite common for sealing compound from the oil lines to settle here.
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5. Starting up 2001-11-15

5.3 Checking the setting

The C.S.S. (Closed Side Setting) is most easily checked by using a lump of lead fastened to a
steel wire and lowering it slowly into the discharge area of the crushing chamber. The lead
lump will be squeezed and its thickness will then correspond to the setting. The lead lump
must of course be so large that it really does get squeezed.

The setting should occasionally be checked at 4 points, evenlyspaced around the crushing
chamber. This will enable you to detect uneven wear, which indicates an unsatisfactory feed
arrangement.

The setting must never be so small that the crusher’s power draw
Caution !! exceeds the limit given in Table 5.4.3. In addition, the Hydroset
pressure must not exceed the limit given in Table 5.4.4.

5.4 Maximum Load

The power drawn by the crusher and the Hydroset pressure during operation are dependent
on the crushing chamber, the eccentric throw, the crusher's setting and the feed material's
crushability, size analysis, moisture content, etc.

Tables 5.4.1.1-4 and 5.4.2 show the average power which is normally required. However,
the power draw – if it is even and without peaks – can be higher as long as the Hydroset
pressure does not exceed the value given in Table 5.4.4. The average power draw must not
exceed the value given in Table 5.4.3.

Average power in kW (measured on the motor shaft).

Table 5.4.1.1

H2800 HYDROCONE
Throw EF F MF M C EC
13 45 51 54
16 47 50 54 61 65
18 52 55 59 67 71
20 56 60 65 74 78
22 61 61 65 70 80 85
25 68 68 73 78 90
28 75 75 80
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5. Starting up 2001-11-15

Tabell 5.4.1.2

H3800 HYDROCONE
Throw EF F MF M MC C EC
16 67 70 74
19 73 77 81 85
22 75 79 83 87 92 97
25 83 88 92 97 102 108
29 94 94 99 105 110 116 123
32 102 102 108 114 120 127 132
34 108 108 114 120 126
36 113 113 120 127 132

Table 5.4.1.3

H4800 HYDROCONE
Throw EF F MF M MC C EC
16 96 99 104
20 109 115 119 125
24 114 119 127 133 139 145
28 129 136 145 152 159 166
32 145 145 152 163 171 179 187
36 161 161 169 180 190 198 208
40 176 176 185 198 209 218
44 192 192 202 216
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5. Starting up 2001-11-15

Table 5.4.1.4
H6800 HYDROCONE
Throw EF F MF M MC C EC
18 139 145 152
20 151 158 165
24 167 176 184 193
28 180 190 200 211 221
32 190 202 213 225 237 248
36 197 211 224 237 250 263 276
40 216 231 245 260 275 289 304
44 235 251 267 283 299 315
48 254 272 289 307
50 264 282 300 315

Table 5.4.2
S-type HYDROCONE
Throw S2800 S3800 S4800 S6800
C EC C EC C EC C EC
16 54 61 76 86
20 65 74 92 105 111 124 136 153
25 78 90 111 127 134 150 164 184
30 131 150 156 175 191 215
35 218 247
36 184 207
40 245 278

Tabell 5.4.3
Crusher Max. average power in kW
H2800 90
H3800 132
H4800 220
H6800 315
S2800 90
S3800 150
S4800 220
S6800 315
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5. Starting up 2001-11-15

Max. average Hydroset pressure in MPa.

H- & S-type Hydrocones

Table 5.4.4

Crusher Crushing chamber (MPa /Psi)


EF, F 3.5/507
H2800 MF, M 3.2/464
C 3.0/435
EC 2.8/406
EF, F 4.0/580
H3800 MF, M 3.8/551
MC, C 3.6/522
EC 3.4/493
EF, F 4.2/609
MF, M 4.0/580
H4800 MC 3.8/551
C 3.6/522
EC 3.4/493
EF, F 3.6/522
MF, M 3.4/493
H6800 MC 3.2/464
C 3.0/435
EC 2.8/406
S2800 C, EC 2.1/304
S3800 C, EC 2.5/363
S4800 C, EC 2.5/363
S6800 C, EC 2.5/363
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6. Lubrication system 2001-11-15

6. Lubrication system

Contents Page
6.1 Introduction 2
6.2 Description 4
6.3 Flow diagrams 5
6.4 Cleaning 7
6.5 Dirt trap 7
6.6 Oil pump 8
6.7 Temperature gauge 13
6.8 Pressure gauge 14
6.9 Pressure drop indicator 14
6.10 Oil filter 14
6.11 Pressure relief valve 16
6.12 Return oil flow switch 17
6.13 Oil strainer 18
6.14 Thermostats 19
6.15 Oil heating 21
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6. Lubrication system 2001-11-15

6.1 Introduction

To ensure that it has sufficient and efficient lubrication and cooling, the crusher is equipped
with a lubrication tank with safety and monitoring devices and a heat exchanger.

Oil products present environmental and fire risks and can cause
Warning !!! injury if inhaled or brought into contact with the skin. Follow
your lubricant supplier's instructions and safety directions when
handling oils and greases.

The lubrication oil tank is combined with the Hydroset oil tank.

All tank units including instruments and valves are checked and adjusted at the factory to
the correct settings for normal operating conditions (max. 32°C, 90°F ambient air
temperature and oil viscosity ISO VG 150).

Even though the tank unit has been checked, all instruments and
Note ! gauges must be rechecked before the crusher is put into
operation.

Under normal conditions, all checks and adjustments must be made at a return oil
temperature of 40-45°C (104-113°F).

For operation under conditions which differ from normal, thermostats TG1, TG2 and TG3
must be adjusted to the values shown in Tables 6.14.2 and 6.15.1, and a different grade of
lubricating oil must be used. See Sections 9.1 and 9.2.

For operation at elevated temperatures, the adjustments must be made at a return oil
temperature of 47-51°C (117-124°F).

For operation in low temperatures, the adjustments must be made at a return oil
temperature of 33-37°C (91-99°F).

The lubricating oil is cooled by a heat exchanger, either air/oil or water/oil.


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6. Lubrication system 2001-11-15

Figure 6.1.1 Tank unit for H2800, H3800, S2800 and S3800

1. From crusher 3. Hydroset line


2. To crusher 4. To pinionshaft housing

Figure 6.1.2 Tank unit for H4800, H6800, S4800 and S6800
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6. Lubrication system 2001-11-15

6.2 Description

The free-standing tank unit (see Figs. 6.1.1 and 6.1.2) consists of a front component
cabinet and - at the rear - lubrication and Hydroset oil tanks. The component cabinet
contains the motor-driven lubrication oil pump(s), oil filter(s), and various protective
devices.

Lubrication oil is pumped from the tank, through the filter and heat exchanger to the
crusher's oil inlet. Oil entering the crusher is pressed through the step bearing and up
between the eccentric bushing and the mainshaft and between the bottomshell bushing and
the eccentric to lubricate these bearings. The oil lubricates the wearing plate and the bevel
gears before running back to the tank unit by gravity.

In the case of an H2800, H3800, S2800 or S3800 crusher, the pinionshaft has oil-bath
lubrication. The oil level is regulated by a level tube. The oil level must be checked by
regular inspection and topped up if necessary.

In the case of an H4800, H6800, S4800 or S6800 crusher, the pinionshaft bearings are
lubricated by a separate circulatory system. A small amount of oil is bled off from the main
lubrication system between the filter and the heat exchanger. This bleed oil is pumped
through a separate filter to the oil inlet in the top of the pinionshaft. The oil level in the
pinionshaft housing is regulated by a level tube and excess oil returns to the tank by
gravity.

See flow diagram 6.3.1 for an H2800, H3800, S2800 or S3800 crusher.
See flow diagram 6.3.2 for an H4800, H6800, S4800 or S6800 crusher.
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6. Lubrication system 2001-11-15

6.3 Flow diagrams

1. Shut-off valve 7. Return oil temperature gauge


2. Dirt trap 8. Oil strainer
3. Oil pump 9. Pressure relief valve
4. Pressure gauge 10. Tank
5. Oil filter with pressure drop OG1 Return oil flow switch
indicator and by-pass valve TG1 Protective thermostat
6. Heat exchanger TG2 Thermostat for heat exchanger

Figure 6.3.1 Lubrication oil flow diagram for an H2800, H3800, S2800
or S3800 Hydrocone crusher
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6. Lubrication system 2001-11-15

1. Shut-off valve 10. Pressure gauge


2. Dirt trap 11. Oil filter with pressure drop
3. Main oil pump indicator and by-pass valve
4. Pressure gauge 12. Non-return valve
5. Oil filter with pressure drop 13. Oil strainer
indicator and by-pass valve 14. Tank
6. Oil filter with by-pass valve 15. Return oil temperature gauge
7. Pressure relief valve TG1 Protective thermostat
8. Heat exchanger TG2 Thermostat for heat
9. Oil pump for pinionshaft exchanger
bearing lubrication OG1 Return oil flow switch

Figure 6.3.2 Lubrication oil flow diagram for an H4800, H6800, S4800
or S6800 Hydrocone crusher
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6.4 Cleaning

Contaminants such as stone dust, water etc., which enter the lubricating oil will to a certain
degree sink towards the bottom of the tank. This should therefore be cleaned out a couple
of times a year, if this proves to be necessary. This periodical cleaning prevents sludge
following with the oil which is withdrawn from the tank through the outlet just above the
tank bottom. Condensation water can be removed by taking out the screw in the drain plug.

When the tank is to be cleaned, remove the oil hose from the heat exchanger (or break the
circuit at another suitable point) and pump out the oil into a drum.

Stop the pump when the oil level has dropped to just above the
Caution !! suction outlet, as there will otherwise be a major risk of pump
damage.

Remove the drain plug in the tank. Drain out the remaining oil.

Clean out the tank with white spirit, or other suitable solvent.

6.5 Dirt trap

The dirt trap (Fig. 6.5.1) protects the oil pump and is mounted ahead of it. If it is not
cleaned but is allowed to clog, cavitation will occur in the pump. This can result in pump
breakdown.

The shut-off valve ahead of the dirt trap must be closed before the plug is unscrewed. Have
a bucket ready to catch the oil which runs out.

During the running-in period, and when the tank has been cleaned, check the dirt trap daily.

The gauze element must not, under any circumstances, be left out or replaced by another
with a different mesh.

1. Plug
2. Gauze element

Figure 6.5.1 Dirt trap


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6.6 Oil pump

A gear-type oil pump is used.

The pump requires very little attention. If clean oil is used, very little wear will occur.
Wear can, however, be considerable if the oil contains stone dust or similar contaminants.
The most usual sign of pump wear is a reduction in oil flow.

Pump capacity (main pump, RB5 and RB6)

The pump's total capacity at normal operating temperature and pressure, when the motor is
connected to a 50 Hz supply, is shown in Table 6.6.1. If the motor is connected to a 60 Hz
supply, the pump speed will be 20% higher and the delivery will increase.

The oil pump must be changed when the delivery has dropped below the minimum figure
given in the relevant column in Table 6.6.1.

Oil delivery can conveniently be checked by measuring the return oil flow. Position a
bucket with a known volume beneath the opening in the float chamber and measure the
time taken to fill the bucket.

Example. A 10 lit. bucket takes 7.3s to fill. The oil flow is thus: 10x60 = 82 lit/min.
7.3

Table 6.6.1 Lubrication oil flow

H2800 H3800 H4800 H6800


S2800 S3800 S4800 S6800
50 Hz Normal
supply capacity 33 38 82 120
lit/min
(US. gal./min) (8.72) (10.04) (21.66) (31.70)
Min.
capacity 27 32 70 100
lit/min
(US. Gal/min) (7.13) (8.45) (18.49) (26.42)
60 Hz Normal
supply capacity 40 46 98 144
lit/min
(US. gal./min) (10.57) (12.15) (25.89) (38.04)
Min.
capacity 27 32 70 100
lit/min
(US. gal./min) (7.13) (8.45) (18.49) (26.42)
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6. Lubrication system 2001-11-15

Pump capacity (pinionshaft pump) -


applies to H4800, H6800, S4800 and S6800 crushers only

The pinionshaft pump has a total capacity of 0.7 lit./min (0.18 US gal./min) at normal
operating temperature and pressure, when the motor is connected to a 50 Hz supply. If the
motor is connected to a 60 Hz supply, the pump speed will be 20 % higher and the delivery
will increase to 0.8 lit./min (0.21 US gal./min).

An HPI pump is used. It is always delivered set up for anti-clockwise rotation.

The pinionshaft oil pump should be changed when the delivery has dropped to 0.5 lit./min
(0.13 US gal./min).

Oil delivery can conveniently be checked by disconnecting the inlet line from the
pinionshaft housing and measuring the time taken to fill a bucket with a known volume.

Carry out this check above the opening in the oil tank unit - after removing the cover - to
avoid oil spillage.

RB5 and RB6 pumps

Starting the pump

When the pump is started, the oil tank must be full of oil so that the pump does not operate
dry. Note that the pump's direction of rotation must correspond to the arrow on the pump
body.

Before starting the pump, check that the shut-off valve ahead of the dirt trap is open.

Direction of rotation

When a new pump is fitted, check that its direction of rotation is correct.

The pump can be changed from anti-clockwise rotation to clockwise (and vice-versa) by
loosening the shaft-end cover plate and rotating it through 180°. The upper arrow indicates
the correct direction of rotation. See Fig. 6.6.2.
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6. Lubrication system 2001-11-15

Anti-clockwise rotation: H2800,


H3800, S2800 and S3800

Clockwise rotation: H4800, H6800,


S4800 and S6800

1. Pressure connection
2. Suction connection
3. Suction side

Figure 6.6.2 Pump rotation direction (seen from shaft end)


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6. Lubrication system 2001-11-15

Shaft seal

The pump is fitted with a mechanical rubbing packing system which is self-sealing. It
needs no adjustment or tightening. This seal is intended for liquids which are relatively free
from solid contaminants and with a maximum working temperature of 175°C (345°F).
Occasionally, slight leakage may occur when the pump is started, but this usually
disappears after a short time.

Leakage from the shaft seal can be due to a damaged packing, damaged sealing surfaces or
incorrect assembly.

Replacement of seal ( see Fig. 6.6.3)

1. Remove the coupling half and the key (24). Use an extractor.

2. Remove any burrs on the shaft (8) or in its keyway.

3. Unscrew the gland nut or the cover and remove all of the components from the shaft.

4. Remove the O-ring (16) and fit a new one.

5. Fit the retaining ring (19) and check that it sits properly in the groove on the shaft. Fit
the inner washer (20) with the chamfer towards the retaining ring.

6a. With some types of packing, the spring (21) and the outer washer (20) are then fitted.
Next, carefully pull a new rubber ring/O-ring (22) on to the shaft. Be careful to avoid
damage when sliding it over the keyway! Fit the rotor ring (23) so that the rubber
ring/O-ring (22) is pressed into the correct position in the rotor ring. Take care to
avoid damaging the sealing surface.

6b. On other types of packing, items 20, 21, 22 and 23 are integrated into a single
component which must be fitted in place carefully, without damaging the sealing
surfaces.

Before screwing on the gland nut/cover, fit a new O-ring (17) inside. Press the new
stator ring (18) into position inside the O-ring (17). Take care to avoid damaging the
sealing surface. Tighten the gland nut/cover.

7. Finally, fit the key (24) in position and press the coupling half onto the shaft with
light blows. Lock it in position with the stop screw. The play between the coupling
halves must be 2 mm.
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6. Lubrication system 2001-11-15

Figure 6.6.3 Mechanical rubbing seal

Extra spacer

Figure 6.6.3 Mechanical rubbing seal

Axial play

When a disassembled pump is reassembled, it is very important that the rotor's axial play is
correct. This can be measured by using a dial gauge against the end of the shaft. The axial
play must be 0.07 mm (0.0028") for the RB5 and RB6.

Measure the play when the pump is clean and dry.


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6. Lubrication system 2001-11-15

Faults and possible causes (RB5 and RB6 )

Low capacity or low pressure

1. The pump sucks air through a leak in the suction line.


2. The pump sucks air through the shaft seal.
3. The suction line is completely or partially blocked.
4. The pump rotates in the wrong direction.
5. Low capacity due to high pressure and wrong type of oil.

The pump does not suck

1. The pump is too dry - fill with oil.


2. The pump sucks air through the suction line or the shaft seal.
3. The pump rotates in the wrong direction.
4. The suction line is blocked or the shut-off valve is closed.

Abnormal noise from the pump

1. Cavitation in the pump.


2. There is air in the oil - there is a leak in the suction line or the shaft seal is worn.
3. The gear teeth in the pump are worn.
4. The dirt trap on the suction side is blocked, causing cavitation.
5. The pump is not correctly aligned.

6.7 Temperature gauge

An indicating temperature gauge is built into the tank unit to monitor the temperature of the
return oil. The return oil flow passes over the sensing head of the gauge.

The normal return oil temperature depends on the ambient air temperature and the viscosity
of the lubricating oil. See Section 6.14 – Thermostats.

The gauge should be checked once a year against a reference thermometer to ensure that it
reads correctly. The check should be carried out at an oil temperature of 40-50°C
(104-122°F).
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6.8 Pressure gauge

The pressure gauge is situated between the oil pump and the filter (two pressure gauges on
an H4800, H6800, S4800 or S6800 crusher).

Check the pressure(s) at regular intervals and keep a record of the readings. At operating
temperature, the pressure in the main system is normally 0.15-0.5 MPa (21.8-72.5 psi),
depending on tank installation. If the pressure ahead of the oil filter rises, this is a sign that
the filter should be changed. An abnormally low pressure can mean that the pump is worn,
or that the dirt trap is choked.

6.9 Pressure drop indicator (PG2, PG3)

The pressure drop indicator monitors the pressure drop across the filter and gives a signal
when the pressure drop exceeds 0.22 MPa (32 psi).

This signal indicates that the filter element(s) should be changed. The signal is given both
electrically - to a lamp on the outside of the tank unit - and in the form of a red button
which protrudes (about 4 mm) from the top of the indicator.

During a cold start, the indicator can give an incorrect signal. The electrical signal will
automatically be reset when working temperature has been reached, but the mechanical
signal (the red button) must be reset manually. If the red button jumps out again
immediately, or if the lamp does not go out when working temperature has been reached,
the filter element(s) must be changed.

6.10 Oil filter

The oil filters used in the lubrication system are of the full-flow type. This means that all
oil pumped to the crusher is filtered. The filter is of simple design and it is very easy to
remove and replace the filter elements, which are of the throw-away type.

An H2800, H3800, S2800 or S3800 crusher has a single filter for the circulatory oil system
(1 filter element).

An H4800, H6800, S4800 or S6800 crusher is fitted with two parallel filters (4 filter
elements).

In addition, an H4800, H6800, S4800 or S6800 crusher has a separate filter (one filter
element) in the pinionshaft lubrication line.

A by-pass valve is built into the filter and it opens when the pressure drop across the filter
element exceeds 0.35 MPa (51 psi). When the valve is open, part of the oil flow by-passes
the filter element and is thus not filtered.
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6. Lubrication system 2001-11-15

The filter element must be changed when the pressure drop is 0.22 MPa (32 psi) at normal
operating temperature.

The pressure drop indicator and the pressure gauge are of great help when planning filter
changes.

Before changing the filter, close the shut-off valves between the filter and the heat
exchanger and between the tank and the dirt trap to avoid oil spillage.
Regular checks should be made on the pressure drop across each filter so that new filter
elements can be ordered in good time for the next replacement.

Note! When the fan of the air/oil heat exchanger is running, the pressure in the oil system
generally rises. Avoid reading off the pressure at such times.

If filter elements have to be changed often, the crusher's dust sealing system must be
checked.

1. Filter element
2. Filter base
3. Differential pressure sensor
and electrical connector
4. Sensor body
5. By-pass valve
6. Seal
7. Piston
8. Spring
9. Magnet
10. Locking ring
11. Seal ring
12. Circlip
13. O-ring
14. O-ring
15. Red button

Figure 6.10.1 Oil filter


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6. Lubrication system 2001-11-15

6.11 Pressure relief valve

A pressure relief valve (see Fig. 6.11.1) is fitted between the main filter and the heat
exchanger. Note! Different types are used for H2800, H3800, S2800 and S3800 crushers
and for H4800, H6800, S4800 and S6800 crushers. Its duty is to decrease the pressure over
the pump and heat exchanger when starting the crusher at low temperature. The oil in the
pipes to the crusher – and particularly in the heat exchanger – becomes thicker and more
viscous due to the low temperature. Under extreme conditions it can be advisable to take
one or more of the measures described in Section 22.

The valve is set at 0.7 MPa (102 psi).

IMPORTANT! This valve setting must not be altered.

If a new pressure relief valve is fitted, its setting must be checked. To do this, close the
shut-off valve between the relief valve and the heat exchanger. Start the pump and slacken
or tighten the adjusting screw in the relief valve until the pressure gauge shows a reading of
0.7 MPa (102 psi). Don't forget to re-open the shut-off valve, after the relief valve setting
has been adjusted.

1. Adjusting screw

For H2800, H3800, For H4800, H6800,


S2800 and S3800 S4800 and S6800
crushers crushers

Figure 6.11.1 Pressure relief valve


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6. Lubrication system 2001-11-15

6.12 Return oil flow switch (OG1)

An automatic check on the return oil flow is provided by an oil flow switch which is built
into the return oil discharge in the oil tank.

The duty of the return oil flow switch is to ensure that the oil pumped to the crusher also
returns to the tank unit, i.e. there is no break in a hose or pipe or any blockages in a line.

The return oil flow switch consists of a level monitor placed in an oil chamber at the point
where the return line enters the tank unit. This return oil chamber has an adjustable lower
outlet and an overflow weir.

The level monitor consists of a float and a microswitch. When the float moves up and
down, the microswitch will be activated and a changeover contact function is obtained.

The level monitor is connected in such a way that the crusher's drive motor cannot be
started unless sufficient oil is pumped to the crusher and thus back to the tank via the return
oil flow switch.

In addition, the level monitor is connected to the starting circuit of the lubrication pump
motor so that the pump cannot be started unless the level monitor is functioning properly
from an electrical viewpoint.

When the correct amount of oil is returning to the tank, the oil level in the return chamber
should be 5 mm (0.2") above the weir. See Fig. 6.12.1.

The weir is adjusted at the factory before delivery and must not
Caution !! be adjusted later as the pump wears.

With this oil level in the return chamber, the float is completely immersed in the oil but the
lifting force from the oil means that the float is held up against its upper stop.

If the oil flow to the tank decreases, the oil level will drop in the return chamber. When the
oil level has dropped about 15 mm (5/8"), the float will be floating on the oil with its upper
surface about 5 mm (0.2") below the upper stop. In this position the contact inside the level
monitor will open and stop the crusher's drive motor.

The correct operation of the level monitor can be checked by pushing the float down about
5 mm (0.2") from its upper stop. The crusher's drive motor should then stop.
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6. Lubrication system 2001-11-15

Float

Weir

Adjustable lower outlet

Figure 6.12.1 Return oil flow switch

6.13 Oil strainer

The oil strainer's functions are to separate coarser contaminants from the oil and to deaerate
the oil. The strainer can be removed for cleaning through the opening in the top of the tank.

The oil strainer requires careful inspection, and especially during


Note ! the running-in period, it should be checked daily. An abnormal
amount of metal particles on the strainer can indicate trouble in
the crusher, and the cause should be investigated to forestall
possible damage.

In the tank for an H4800, H6800, S4800 or S6800 there is an additional de-aeration screen
beneath the oil strainer. The purpose of the de-aeration screen is to remove any air bubbles
which are present in the oil returning to the tank and to prevent them going back to the
crusher through the pump. The de-aeration screen normally requires no attention.

1. Oil strainer
2. De-aeration screen

2 Figure 6.13.1
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6. Lubrication system 2001-11-15

6.14 Thermostats

Two thermostats are mounted at the return oil discharge in the oil tank (see Fig. 6.14.1).
One of them controls the cooling of the oil pumped to the crusher, whilst the other stops
the crusher drive motor if the oil temperature is too high.

1.

2.

1. Protective thermostat TG 1
2. Thermostat for heat exchanger TG 2

Figure 6.14.1

It is extremely important that thermostats TG 1 and TG 2 are set according to the


recommendations given for different operating conditions in Table 6.14.2.

Table 6.14.2
Normal operating Operation at Operation in low
conditions elevated temperatures
temperature
Ambient air Max. 32°C Max. 40°C Below 0°C
temperature (90°F) (104°F) (32°F)
Oil viscosity ISO VG 150 ISO VG 220 ISO VG 100
Protective thermostat TG 1
Basic setting 60°C (140°F) 65°C (149°F) 52°C (126°F)
Closes at 60°C (140°F) 65°C (149°F) 52°C (126°F)
Opens at 63°C (145°F) 68°C (154°F) 55°C (131°F)
Differential setting 1 1 1
Electrical connections 1-2 1-2 1-2
Cooling control thermostat TG 2
Basic setting 40°C (104°F) 47°C (117°F) 33°C (91°F)
Closes at 45°C (113°F) 51°C (124°F) 37°C (99°F)
Opens at 40°C (104°F) 47°C (117°F) 33°C (91°F)
Differential setting 4 3 3
Electrical connections 1-4 1-4 1-4
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The protective thermostat (TG 1) described above operates when


Note ! a serious fault occurs in the lubrication system, for instance
when the oil temperature rises excessively or the cooling system
doesn't work correctly. It is therefore important that none of the
instruments should be bypassed if the protective system trips out
the crusher drive motor starter for some reason. Investigate the
cause of the stoppage and correct it before the crusher is re-
started.

The thermostats can be checked by immersing the sensing head in a slowly warmed oil
bath together with a thermometer. Make a note of the temperature at which the contacts
break and then allow the oil to cool and make a note of the temperature at which the
contacts close. The cooling control thermostat (TG 2) can be checked by holding a
thermometer near the sensing head and noting the temperatures at which the cooling fan or
water pump starts and stops or at which the water valve opens and closes.

If the thermostat does not make and break at the desired temperatures, remove the
protective cover and rotate the shaft clockwise or anti-clockwise until the required impulse
is obtained. When this has been done, loosen the screw which locks the temperature scale
and re-set it to the correct temperature.

When this adjustment is made, make sure that the differential setting is correct for the
thermostat in question.
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6. Lubrication system 2001-11-15

6.15 Oil heating

The oil should be heated to the temperature given in Table 6.15.1 before the crusher is
started. This is to prevent oil overflowing over the dust collar.

The standard oil tank unit is fitted with electrical immersion oil heaters. The heating
elements are installed in tubes so that the oil is heated indirectly. There is a separate control
thermostat, TG 3, mounted on the wall of the oil tank.

Table 6.15.1 Normal operating Operation at Operation in low


conditions elevated temperatures
temperature
Ambient air temperature Max. 32°C Max. 40°C Below 0°C
(90°F) (104°F) (32°F)
Oil viscosity ISO VG 150 ISO VG 220 ISO VG 100
Suitable oil temperature 30°C 37°C 25°C
before crusher is started (86°F) (99°F) (77°F)
Heating control thermostat TG3
Basic setting 30°C (86°F) 37°C (99°F) 20°C (68°F)
Closes at 30°C (86°F) 37°C (99°F) 20°C (68°F)
Opens at 35°C (95°F) 42°C (108°F) 25°C (77°F)
Differential setting 3 3 3
Electrical connections 1-2 1-2 1-2

The heating should be on all day. Shutdown occurs automatically by means of a thermostat.

Make sure that the heater element tubes and thermostat are
Note ! always covered by oil during operation.
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7. Heat exchanger 2001-11-15

7. Heat exchanger

Contents Page
7. Heat exchanger 2

Air/oil heat exchanger 2

Water/oil heat exchanger 3


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7. Heat exchanger 2001-11-15

7. Heat exchanger

To provide cooling for the oil, a heat exchanger is fitted, of either air/oil or water/oil type.
All of the oil passes through this heat exchanger.

Air/oil heat exchanger

To maximize the effect of the heat exchanger, it should be regularly cleaned on the outside.
Compressed air or water is normally sufficient. If the core is very dirty, it can be cleaned
with a high-pressure water jet.

If a high-pressure water jet is used, the water jet must be kept


Caution !! parallel to the fins in order to avoid damage.

Cleaning additives can be added to the water but it is important


Note ! that such additives have no corrosive effect on aluminium.

Oil and grease can be washed off with hot water. If the heat exchanger is cleaned with
water, cover up the motor and wait until the heat exchanger has cooled down before
starting.

If there is vibration in the fan wheel, clean it or fit a new one. If this is not done, the heat
exchanger will sooner or later be damaged.

When the oil is changed, the heat exchanger should be flushed out internally with diesel
oil. Clean out the tank and pour in diesel oil. Disconnect the return hose from the heat
exchanger and arrange it so that the diesel oil will return to the tank instead of being
pumped through the crusher. Pump the diesel oil through the heat exchanger. Finish off the
cleaning procedure by flushing out the tank, oil lines and heat exchanger with clean new oil
to remove all traces of diesel oil. Fill the tank with clean new oil. See Section 9.2.

To provide the maximum possible cooling effect, the air must be sucked through the
radiator matrix. This is determined by the direction of rotation of the fan. See Fig. 7.1.

Since there is a relatively large oil flow through the heat exchanger, the oil inlet to the
radiator matrix can be either at the top for the bottom. It is normally unnecessary to bleed
air from the heat exchanger.
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7. Heat exchanger 2001-11-15

Air

Figure 7.1 Air/oil heat exchanger

The fan motor is controlled by thermostat TG 2. Thermostat settings are given in Table
6.14.2.

Water/oil heat exchanger

Plate type water/oil heat exchanger

The plate-type heat exchanger consists of thin, profiled stainless steel plates. The plates are
profiled to give optimum heat transfer and to form channels for the oil and water flows. See
Fig. 7.2.

Plate-type heat exchangers normally need no maintenance. If the oil channels do get
blocked up, clean them out in the same way as described above for air/oil heat exchangers.
If the water channels are blocked by dirty water, flush them out by reversing the water flow
direction. If the water channels are blocked by lime, clean them out with a deliming agent,
e.g. a 15 % hydrochloric acid solution which is then neutralized with a 5 % soda solution
and finally flushed out with clean water.

The water connections must be open when a deliming agent is


Note ! used, to provide ventilation for any gas which may be produced.
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7. Heat exchanger 2001-11-15

1. Oil in
2. Water out
3. Water in
4. Oil out

Figure 7.2 Plate type water/oil heat exchanger

Temperature control is provided by thermostat TG 2.

If a water/oil heat exchanger is used, set the thermostats at the


Note ! values given for "normal operating conditions", whatever the
ambient air temperature. See Table 6.14.2.

If a separate water pump is used, it can be started and stopped by thermostat TG 2. If the
heat exchanger is connected to a water main, an electrically operated water valve can be
incorporated in the supply pipe. Again, thermostat TG 2 can be used to control the water
valve.

The amount of water required depends on the water temperature, etc.

Clean fresh water must be used. If only contaminated water is available, contact Sandvik
Rock Processing first!
Don't forget to drain all water out of the heat exchanger
Note ! when the crusher is shut down during the winter.
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8. Hydroset system 2001-11-15

8. Hydroset system

Contents Page
8.1 Description 2
8.2 Flow diagrams 4
8.3 Starting up 6
8.4 Hydroset pump 6
8.5 Control valve 7
8.6 Dirt trap (magnetic plug) 10
8.7 Oil filter 10
8.8 Safety valve 11
8.9 Pressure gauge 11
8.10 Damping valve for pressure gauge 11
8.11 Flow regulator (H2800, H3800, H4800 & H6800) 12
8.12 Accumulator (H2800, H3800, H4800 & H6800) 12
8.13 User's responsibility 15
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8. Hydroset system 2001-11-15

8.1 Description

The hydraulic system used in Hydrocone crushers - the Hydroset system - is shown
schematically in figure 8.1.1. The Hydroset system enables setting changes to be made
easily and quickly. In addition, setting control can be automated in a simple way.

To protect an H-type crusher against overloads - for example, when tramp iron enters the
crushing chamber - the Hydroset system incorporates an accumulator.

In addition, there is a relief valve in the Hydroset system of both H & S types to protect the
piping and other components.

The setting of the crusher is changed by raising (setting decrease) or lowering (setting
increase) the Hydroset piston and the mainshaft assembly (complete with mantle) which is
supported by this Hydroset piston. When the setting is to be reduced, oil is pumped into the
Hydroset cylinder by a motor-driven pump. When the setting is to be increased, oil is
pumped back to the Hydroset tank.

On the tank unit is a pressure gauge which indicates the pressure in the Hydroset system.

Oil products present environmental and fire risks and can cause
Warning !!! injury if inhaled or brought into contact with the skin. Follow
your lubricant supplier's instructions and safety directions when
handling oils and greases.

Flow diagrams
See figures 8.2.1 and 8.2.2.
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8. Hydroset system 2001-11-15

Setting decrease

Oil is pumped from the tank to the


Hydroset cylinder to raise the mantle
to the desired position.

Setting increase

Oil is pumped from the Hydroset cylinder


back to the Hydroset tank, allowing the
mantle to sink to the desired position.

Increase of setting due to overload

(applies only to an H-type crusher). Oil is


forced out of the Hydroset cylinder and
into the accumulator, allowing the mantle
to sink far enough to let the tramp iron
pass through the crushing chamber. The
gas pressure in the accumulator forces
the oil back into the Hydroset cylinder
as soon as the tramp iron has left the
crushing chamber.

Figure 8.1.1
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8. Hydroset system 2001-11-15

8.2 Flow diagrams

1. Shut-off valve 7. PG1 (for ASR)


2. Hydroset pump 8. Magnetic plug
3. Safety valve 9. Flow regulator
4. Control valve 10. Accumulator
5. Damping valve 11. Filter
6. Pressure gauge

Figure 8.2.1 Flow diagram for an H2800, H3800, H4800 or H6800 Hydrocone
1800-Series Hydrocone crushers S 223.364.00 en 5 (15)

8. Hydroset system 2001-11-15

1. Shut-off valve 6. Pressure gauge


2. Hydroset pump 7. PG1 (for ASR)
3. Safety valve 8. Magnetic plug
4. Control valve 9. Filter
5. Damping valve

Figure 8.2.2 Flow diagram for an S2800, S3800, S4800 or S6800 Hydrocone
1800-Series Hydrocone crushers S 223.364.00 en 6 (15)

8. Hydroset system 2001-11-15

8.3 Starting up

Filling the system with oil

When the Hydroset tank and piping have been connected up and thoroughly cleaned, fill
the tank with clean new oil. Information on oil type, viscosity and quantity can be found in
Section 9.3 – Oil for Hydroset system.

Bleeding air from the system

Open the shut-off valve between the tank and the Hydroset pump. Start the pump with the
"reduce setting" push button to pump oil to the crusher and raise the mainshaft a few mm.
Open the upper air bleed screw until bubble-free oil comes out. Raise the mainshaft a few
mm more.

On an H2800, H3800, H4800 or H6800 Hydrocone, the upper


Note ! air bleed screw is mounted on the throat of the accumulator. See
figure 8.12.1, item 2.

In the case of a S-type, which has no accumulator, the upper air


bleed screw is mounted in the connection block on the mounting
flange of the bottomshell.

Use a 5 mm hexagon key to open the air bleed screw in the Hydroset cylinder cover so that
any air can escape. Raise and lower the mainshaft a few mm, several times. Repeat the air
bleeding procedure at both points until completely bubble-free oil flows out.

8.4 Hydroset pump

The Hydroset pump is a reversible gear pump.

When the pump is started there must be oil in the tank and the valve on the suction line
between the tank and the control valve must be fully open.
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8. Hydroset system 2001-11-15

Figure 8.4.1 Hydroset pump

At the bottom of the pump (see arrow "A" in figure 8.4.1) there
Note ! is a drain port which is connected to the Hydroset tank. The
drain line valve "B" on the tank must always be fully open.

8.5 Control valve

Between the crusher and the Hydroset pump is a specially manufactured flow-actuated
non-return valve. It incorporates a relief valve to protect the pump.

Operating principle

The flow-actuated control valve assembly consists of a base plate where all the external
connections are made, and a valve block which is bolted to the base plate. See figure 8.5.1.

Setting decrease

1. The Hydroset pump is started and oil is sucked from the tank through ports T and A
in the valve.

2. The oil flow moves the sleeve 1 over towards the right so that the oil flow area is
increased.

3. Oil is pumped to port B and pushes the spindle 2 towards the right.

4. The pump pressure opens the main non-return valve 3 which allows the oil to pass
freely to the crusher.
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8. Hydroset system 2001-11-15

Setting increase

1. The pump is started in the other direction and oil is sucked from the tank through
port T, non-return valve 4 and port B.

2. The pump pressure at port A pushes the spindle 2 to the left and opens the main non-
return valve 3.

3. There is now a direct connection from the crusher.

4. Non-return valve 4 closes and the pump now sucks oil from the crusher through the
valve.

5. The excess oil pumped to port A opens the pressure limiting valve 6 and oil flows
through filter 11 back to the tank.
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8. Hydroset system 2001-11-15

Correct setting

1. The Hydroset pump is stationary and the pressure in the Hydroset system keeps the
main non-return valve 3 closed.

An adjustable pressure limiting valve 5 is provided to protect the pump from overloads
when the setting is being decreased. This valve is set at the correct pressure before
delivery.

Setting Setting
increase decrease

Figure 8.5.1 Control valve

Emergency manual valve actuation

The control valve has a manual actuation facility for emergency use if contamination in the
oil has blocked the valve so that normal motorized setting increase is impossible. This
manual actuation facility is provided by components 7-10, shown in Figure 8.5.1.

Manual operation is carried out as follows:


Unscrew cap 8.

Push in pin 7. If this cannot be done by hand, place a 10 mm dia. ball or other suitable
object in the cap and screw it back on so that the pin is pushed in.
1800-Series Hydrocone crushers S 223.364.00 en 10 (15)

8. Hydroset system 2001-11-15

Start the pump for setting increase and lower the mainshaft to the desired position.

Stop the pump.

If the valve still does not operate correctly, it must be removed and cleaned. If the valve
does operate correctly, replace the cap.

To reduce the risk that contamination interferes with the correct operation of the valve, the
Hydroset system must always be kept clean.

8.6 Dirt trap (magnetic plug)

Mounted in the Hydroset line to the crusher, next to the control valve, is a T-coupling with
a magnetic plug fitted in the third branch.

The purpose of the magnetic plug is to remove magnetic particles from the system.

The magnetic plug is easy to unscrew and clean when the pressure in the system has been
relieved, i.e. when the mainshaft and the Hydroset piston are at the bottom of their travel.
Watch out for escaping oil.

8.7 Oil filter

The oil filter mounted between the control valve and the Hydroset tank is of the full-flow
type. This means that all of the oil passing through is filtered.

The filter is of simple design and it is easy to remove and replace the filter element, which
is of the throw-away type.

When a filter change is carried out - which should be each time the Hydroset oil is changed
or every six months - relieve the pressure in the system by lowering the mainshaft and
Hydroset piston to their bottom positions. Unscrew the filter element and replace it with a
new one. At the same time, clean out the dirt trap (see Section 8.6).
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8. Hydroset system 2001-11-15

8.8 Safety valve

The safety valve is mounted on the base plate of the control valve. It is tested at a setting of
7.5 MPa (1088 psi) and sealed before delivery. See also Section 8.13 - User's
Responsibility.

8.9 Pressure gauge

A pressure gauge is fitted on the tank unit so that the operating pressure in the Hydroset
system can be observed. A special pressure transducer can be fitted to give remote
indication of the Hydroset pressure on the control cabinet of an ASR system.

8.10 Damping valve for pressure gauge

To prevent damage to the pressure gauge indicating pointer due to vibration when the
crusher is in operation, a damping valve is fitted between the Hydroset line and the
pressure gauge.

This damping valve must be mounted as shown in figure 8.10.1, with the arrow pointing
towards the pressure gauge.

Open the valve once each week to clean out the needle valve. When this has been done,
close the valve until the indicating pointer of the gauge moves smoothly during normal
operation.

Figure 8.10.1. Damping valve


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8. Hydroset system 2001-11-15

8.11 Flow regulator


(H2800, H3800, H4800 and H6800 Hydrocone crushers only)
To prevent the mainshaft rising too quickly after tramp iron has passed through the crusher,
a throttling check valve - the flow regulator - is fitted between the Hydroset cylinder and
the accumulator. See figure 8.12.1. When oil flows from the crusher to the accumulator, it
passes unhindered through the flow regulator. When the oil returns from the accumulator,
it is slowed down so that the mantle is slowly raised to its original position.

8.12 Accumulator
(H2800, H3800, H4800 and H6800 Hydrocone crushers only)
The accumulator (see figure 8.12.1) consists of a cylindrical steel pressure vessel which
contains a rubber bladder fixed at the top of the vessel by a valve. The rubber bladder is
filled with Nitrogen at the pressure shown in Table 8.12.2.

Use only Nitrogen (N2) in the accumulator. Do not subject the


Warning !!! accumulator to mechanical or thermal damage (impact, welding,
etc).

1. Accumulator
2. Upper air bleed screw
3. Flow regulator

Figure 8.12.1 Accumulator


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8. Hydroset system 2001-11-15

Table 8.12.2 Accumulator charging pressure

H2800 4.2 MPa (609 psi) ± 5%


H3800 5.0 MPa (725 psi) ± 5%
H4800 5.0 MPa (725 psi) ± 5%
H6800 4.2 MPa (609 psi) ± 5%

Pressure gauge/charging kit


A special pressure gauge/charging kit can be used to check the gas pressure in the
accumulator and to add nitrogen when necessary. This pressure gauge/charging kit is not
included in the crusher's normal toolkit but can be ordered as an extra-cost option.

The pressure gauge/charging kit consists of a connection assembly with a pressure gauge, a
hose and an adapter for connection to the accumulator. See Fig. 8.12.3.

Figure 8.12.3

Checking the gas pressure in the accumulator


Fitting the pressure gauge/charging kit

Unscrew the spindle (item 3 in Fig. 8.12.3) as far as it will go and close the bleed valve (4).
The connection assembly body incorporates a non-return valve so that it is unnecessary to
connect the kit to a nitrogen bottle when the accumulator's gas pressure is to be checked.

Unscrew the protective cap from the accumulator's charging valve. Attach the pressure
gauge/charging kit by screwing on the swivel adapter (2). Tighten by hand sufficiently to
prevent gas leakage.

Screw down the spindle (3) so that the valve in the accumulator opens and then read off the
charging pressure on the pressure gauge.
Removing the charging kit
1800-Series Hydrocone crushers S 223.364.00 en 14 (15)

8. Hydroset system 2001-11-15

Unscrew the spindle (3) and then open the bleed valve (4). The swivel adapter (2) can then
be unscrewed easily and the charging kit can be removed.

Refil the protective cap on he accumulator's charging valve.

Charging the accumulator

Use only nitrogen gas N2 to fill the accumulator bladder.


Warning !!!

Unscrew the spindle (item 3 in Fig. 8.12.3) as far as it will go and close the bleed valve (4)
before you attach the pressure gauge/charging kit to the nitrogen gas bottle.

Unscrew the protective cap from the accumulator's charging valve. Attach the pressure
gauge/ charging kit to the accumulator by screwing on the swivel adapter (2). Tighten by
hand sufficiently to prevent gas leakage.

Screw down the spindle (3) so that the gas can pass freely through the charging valve.

Carefully open the valve on the nitrogen gas bottle so that the bladder expands slowly
inside the accumulator and closes the oil valve. Check that this is the case before raising
the pressure to the full charging pressure.

Take into account that the pressure in the accumulator will drop
Note ! slightly when the compressed gas cools down. Charge the
accumulator bladder to 20% above the desired pressure.

Close the valve on the nitrogen gas bottle and wait for five minutes. Check the pressure. If
the pressure is too high, release a little gas through the bleed valve (4). Recheck the
charging pressure after 1, 2 and 3 weeks and thereafter at 6-month intervals.

Unscrew the spindle (3) and the swivel adapter (2). Check that there is no gas leakage from
the valve. Use soapy water or oil for this check.

Refit the protective cap on the accumulator's charging valve.

Remove the pressure gauge/charging kit from the nitrogen gas bottle.
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8. Hydroset system 2001-11-15

8.13 User's responsibility

It is the responsibility of the crusher's user to arrange for recertification of the accumulator
and the relief valve if there are grounds to suspect that the accumulator has been damaged
or if the seal on the relief valve has been broken. New components are best obtained from
Sandvik Rock Processing.
1800-Series Hydrocone crushers S 223.365.00 en 1 (12)

9. Lubricant recommendations 2001-11-15

9. Lubricant recommendations

Contents Page
9.1 General 2
9.2 Oil for lubrication system 2
9.3 Oil for Hydroset system 6
9.4 Pinionshaft lubrication 8
9.5 Spider bearing lubrication 10
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9. Lubricant recommendations 2001-11-15

9.1 General

If the crusher is to be utilized optimally, stringent demands must be made on the lubricants
that are used.

Lubricants which do not meet Sandvik Rock Processing’s requirements must not be used
during the warranty period.

Oil products present environmental and fire risks and can cause
Warning !!! injury if inhaled or brought into contact with the skin. Follow
your lubricant supplier's instructions and safety directions when
handling oils and greases.

Miscibility

Care should be exercised when changing the brand and/or the type of lubricant. Different
brands and types of lubricant cannot always be mixed. If non-miscible lubricants are
mixed, the result can be an expensive breakdown.

Normally the old lubricant must be flushed out very carefully before a change is made. The
lubricant manufacturer(s) can provide information on whether mixing can take place.

Storage

Store the lubricant in a clean room and in accordance with the instructions given by the
lubricant supplier. Clean the caps before opening cans and drums. Use only well-cleaned
containers.

If water finds its way into the oil system - through condensation, for example - or if a lot of
dust has got into the oil, change the oil. A change in oil colour may indicate the presence of
water or dirt.

9.2 Oil for lubrication system

The oil we recommend must have mild EP-additives and must comply with the following
demands and with the requirements specified in Table 9.2.1

Normally, an oil with ISO VG 150 viscosity is used.

If the ambient temperature is so high that the cooling system cannot keep the return oil
temperature below 50°C, it may be necessary to permit operation at an elevated
temperature. In such a case, contact Sandvik Rock Processing. At the same time, a change
must be made to a lubricating oil with higher viscosity. See "Operation at elevated
temperature" in Table 9.2.1.
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9. Lubricant recommendations 2001-11-15

In extremely low temperatures, it can sometimes be advisable to change to a less viscous


oil. See "Operation in low temperatures" in Table 9.2.1.

If such a change is made, thermostats TG1, TG2 and TG3 must be reset. See Tables 6.14.2
and 6.15.1. Important! When a change is made back to the normal oil, the thermostats
must be reset again.

Requirement specification

General:
The oil shall comply with the demands of DIN 51 517-CLP for the respective viscosity
values and shall contain additives to prevent oxidation and foaming and also contain anti-
wear additives. Copper alloys are used in the crusher’s bearings, which is why the oil must
be harmless for these materials.

Table 9.2.1 below specifies lubricating oil types for use under different operating
conditions.

Table 9.2.1. Lubricating oil specification.

OPERATING CONDITIONS
Normal Operation at Operation in low
elevated temperatures
temperature
Ambient air temperature Max. 32°C Max. 40°C Under 0°C
Oil viscosity ISO VG 150 ISO VG 220 ISO VG 100
Specification DIN 51 517-CLP DIN 51 517-CLP DIN 51 517-CLP
150 220 100
Properties Test method Requirement Requirement Requirement
Base oil viscosity at DIN 51 519 150 220 100
40°C in mm2/s (cSt)
Viscosity Index DIN ISO ≥ 100 ≥ 100 ≥ 100
2909
FZG DIN 51 354 ≥ 12 ≥ 12 ≥ 12
Lowest pour point DIN ISO ≤ -9°C ≤ -6°C ≤ -12°C
3016
EP-additives Sulphur/ Sulphur / Sulphur /
Phosphorus Phosphorus Phosphorus
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9. Lubricant recommendations 2001-11-15

Example of oils for lubrication system

The examples below are lubricants which – according to the respective manufacturer –
comply with Sandvik Rock Processing’s requirements.

We have received this information from the manufacturers. Local variations can occur in
different countries. For safety’s sake, check with your supplier that the selected lubricant
complies with the requirements in question.

In addition to the lubricants listed, a number of other brands and qualities meet Sandvik
Rock Processing’s requirements and are accordingly also usable.

Mineral oils

For operation under normal conditions:


BP Energol GR-XP 150 Molub-Alloy Tribol 1100/150
ESSO Spartan EP 150 Shell Omala 150
Klüber Klüberoil GEM 1-150 Statoil LoadWay EP 150
Mobil Mobilgear 629 Texaco Meropa 150

For operation at elevated temperatures:


BP Energol GR-XP 220 Molub-Alloy Tribol 1100/220
ESSO Spartan EP 220 Shell Omala 220
Klüber Klüberoil GEM 1-220 Statoil LoadWay EP 220
Mobil Mobilgear 630 Texaco Meropa 220

For operation in low temperatures:


BP Energol GR-XP 100 Molub-Alloy Tribol 1100/100
ESSO Spartan EP 100 Shell Omala 100
Klüber Klüberoil GEM 1-100 Statoil LoadWay EP 100
Mobil Mobilgear 627 Texaco Meropa 100

Biologically degradable oil

If an oil of this kind is to be used, we recommend that only a 100% synthetic oil of ester
type is selected. Due to the higher viscosity index of this type of oil, an ISO VG 150 grade
can normally be used all year round.

If the ambient air temperature is over 32°C (90°F), it may still be necessary to reset
thermostats TG1 and TG2 for "Operation at elevated temperatures" since TG1 could
otherwise trip because of excessively high oil temperature and thus stop the crusher.

Tribol Bio Top 1418/150


(VI > 170)
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9. Lubricant recommendations 2001-11-15

Oil quantity

The lubricating oil tank volume is given in Table 9.2.2.

When the crusher is running, the oil level must be above the minimum level mark. See the
oil level indicator in the tank unit.

Table 9.2.2. Oil quantity

H-type H2800 H3800 H4800 H6800


S-type S2800 S3800 S4800 S6800
Oil volume lit. 150 150 400 400
(US. gal.) (40) (40) (105) (105)

A certain amount of oil will remain in the crusher and the oil supply lines, and the tank
should therefore be topped up after test-running. To prevent oil flooding over the oil
strainer when oil drains back to the tank after the crusher has been stopped, you should be
very restrictive with topping-up if the oil lines between the tank and the crusher are long.

Make sure that the heating element tubes and their thermostat
Caution !! are always covered with oil during operation. This is to avoid
overheating in the heating elements.

Oil changes

To keep a check on the condition of the oil, it is advisable to send an oil sample to the oil
supplier each month so that suitable oil change intervals can be established in cooperation
with the supplier.

When oil is to be changed to a different brand or type, all of the oil must be changed. This
is especially important if the change is from an oil with a lead additive to an oil with
sulphur/phosphorus additives. The oil which is trapped in the crusher must be drained out
by breaking the supply line at a suitable point between the crusher and the tank unit. When
this is done, the mainshaft must be raised to its highest position so that the oil in the
Hydroset piston runs out.
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9. Lubricant recommendations 2001-11-15

9.3 Oil for Hydroset system

The oil used in the Hydroset system must be miscible with


Caution !! the lubricating oil and comply with the same requirements.
However, the viscosity must be according to ISO VG 68.

The oil must comply with DIN 51 517-CLP 68.

Table 9.3.1. Hydroset oil specification.

Properties Test method Requirement


Base oil viscosity at DIN 51 519 68
40°C in mm²/s (cSt)
Viscosity Index DIN ISO 2909 ≥100
FZG DIN 51 354 ≥12
Lowest pour point DIN ISO 3016 ≤-15°C
EP additives Sulphur/Phosphorus

Never use oil thicker than ISO VG 68, nor normal hydraulic
Note ! oils.

In the case of a crusher which operates outdoors in very low temperatures, there can be
problems with the normally recommended oil. If this is the case, contact Sandvik Rock
Processing for information on a change to an oil with lower viscosity.

Examples of oils for Hydroset system

The examples below are oils which – according to the respective manufacturer – comply
with Sandvik Rock Processing’s requirements.

We have received this information from the manufacturers. Local variations can occur in
different countries. For safety’s sake, check with your supplier that the selected oil
complies with the requirements in question.

In addition to the lubricants listed, a number of other brands and qualities meet Sandvik
Rock Processing’s requirements and are accordingly also usable.
1800-Series Hydrocone crushers S 223.365.00 en 7 (12)

9. Lubricant recommendations 2001-11-15

Mineral oils

BP Energol GR-XP 68 Molub-Alloy Tribol 1100/68


ESSO Spartan EP 68 Shell Omala 68
Klüber Klüberoil GEM 1-68 Statoil LoadWay EP 68
Mobil Mobilgear 626 Texaco Meropa 68

Biologically degradable oil

If an oil of this kind is to be used, we recommend that only a 100% synthetic oil of ester
type is selected.

Tribol Bio Top 1448/68

Oil quantity

When the Hydroset tank is filled, the mainshaft must be in its lowest position. If the tank is
filled when the mainshaft is in its highest position, there may not be sufficient room in the
tank for all of the oil when the mainshaft is lowered. Oil quantities are given in Table 9.3.2.

Table 9.3.2

H-type H2800 H3800 H4800 H6800


S-type S2800 S3800 S4800 S6800
Oil volume lit. 40 40 85 85
(US. gal.) (10.7) (10.7) (22.5) (22.5)

Oil changes

The oil in the Hydroset system should be changed when the lubricating oil is changed. See
Section 9.2 – Oil for lubrication system – Oil changes.
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9. Lubricant recommendations 2001-11-15

9.4 Pinionshaft lubrication

Two different principles are used for pinionshaft lubrication: an oil bath for the H2800,
H3800, S2800 and S3800 and a circulatory system for the H4800, H6800, S4800 and
S6800.

Oil bath lubrication for H2800, H3800, S2800 and S3800

Close to the pinionshaft there is a decal which shows the type of oil in the pinionshaft
housing when the crusher is delivered from the factory. Do not mix different types of oil.

The oil used for pinionshaft lubrication is the same as the oil in the main circulatory
lubrication system. See Section 9.2 - Oil for lubrication system.

The pinionshaft housing has an oil level tube to provide the correct oil level and is topped
up manually. Oil quantities are given in Table 9.4.1.

Table 9.4.1 Oil quantity for pinionshaft housing

H2800 0.8 liter


S2800 (0.21 US. gal.)
H3800 1.5 liter
S3800 (0.40 US. gal)

The drain plug and oil level tube are mounted in the bottom of the pinionshaft housing, as
shown in Figure 9.4.2.

When oil is added, the drain plug must be in place. Slightly more than the required quantity
should be added. When the oil level has stabilized in the pinionshaft housing, the excess oil
can be drained out through the level tube when the plug has been taken out. Top up and
drain off excess oil every time the oil level is to be checked since there is otherwise a risk
that a small amount of oil in the level tube will run out and give the impression that the oil
level is high, even though it is in fact low.
1800-Series Hydrocone crushers S 223.365.00 en 9 (12)

9. Lubricant recommendations 2001-11-15

1. TREDO-ring
2. Oil level
3. Level tube
4. Drain plug

Figure 9.4.2 (H & S 2800 and 3800)

Oil changes

Check the oil level regularly and change the oil after approx. 2000 operating hours or about
once a year. Drain out the oil by unscrewing the level tube and drain plug.

The filler plug on the top of the pinionshaft housing is fitted with an air vent nipple. This
nipple should be cleaned at intervals of about two months as there is otherwise a risk of
damage to the seals and leakage could then occur.

Circulatory lubrication system for H4800, H6800, S4800 and S6800

The pinionshaft housing receives an automatically controlled flow of oil. See Section
14 - Pinionshaft assembly and Section 6 - Lubrication system.

Oil quantity

The volume of oil in the pinionshaft housing is limited by the level tube. See Figure 9.4.4.
See also Section 5.1 – Paragraph 8.

Table 9.4.3 Oil quantity for pinionshaft housing

H4800 1.3 liter


S4800 (0.34 US. gal.)
H6800 3.0 liter
S6800 (0.79 US. gal.)
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9. Lubricant recommendations 2001-11-15

Remove the drain plug (magnetic plug) and clean it at least twice a year. This will also
drain out any sediment from the pinionshaft housing.

1. Oil level
2. Level plug
3. Discharge tube

Figure 9.4.4 (H & S 4800 and 6800)

9.5 Spider bearing lubrication

The motion of the mainshaft in the spider bearing is both gyratory and rotary. The speed is
relatively low and the pressure is high. It is important that the correct grade of lubricant is
used so that the grease can penetrate to the bearing surfaces.

Requirement specification

The grease must comply with the demands in the table below in order to guarantee
lubrication of the spider bearing for long periods, under conditions of vibration and
extremely high loads. In addition, the grease must provide good protection against
corrosion. The spider bearing contains components of alloyed steel, cast iron and nitrile
rubber. The grease must therefore be harmless to these materials.

Table 9.5.1 Spider bearing grease specification.

Properties Test method Requirements


Consistency NLGI 0 or 00
Base oil viscosity at ≥ 400
40°C in mm2/s (cSt)
Thickening agent Lithium or Sodium
Drop point DIN ISO 2176 ≥ 140°C
Corrosion protection DIN 51 802 SKF Approved
Emcor
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9. Lubricant recommendations 2001-11-15

Other properties:
- Must contain EP additives
- Must be pumpable

The recommended operating temperature range is -10°C to +100°C. For operation under
extreme ambient temperatures, contact the lubricant supplier.

Examples of greases

The examples below are greases which – according to the respective manufacturers –
comply with Sandvik Rock Processing’s requirements.

We have received this information from the manufacturers. Local variations can occur in
different countries. For safety’s sake, check with your supplier that the selected grease
complies with the requirements in question.

In addition to the greases listed, a number of other brands and qualities meet Sandvik Rock
Processing’s requirements and are accordingly also usable.

Mobil Mobilith SHC 007 (643569) Statoil GreaseWay LiCaX90


Molub-Alloy Tribol 3020/1000-00 Texaco Marfak 00 (01907)

Grease quantity

The grease must fill the spider bearing up to the top of the spider bushing. See Table 9.5.2.
When the spider bearing is being greased, the mainshaft must be in its lowest position.
Grease can be pumped in through a channel in one of the topshell spider arms.

Checking and changing the grease

During the first few weeks of operation, the grease level should be checked daily by
unscrewing the plug in the spider cap. If an unusually large quantity of grease is observed
on the mainshaft beneath the spider bearing, it is possible that the spider bearing seal has
been damaged. It is important to keep the mainshaft free of grease and stone dust
accumulations to prevent such contamination being pressed into the spider bearing through
the spider bearing seal each time the mainshaft is raised. The grease level should be
checked frequently and new grease should be added when necessary. Naturally, the spider
bearing seal must be replaced as quickly as possible. See Sections 11.1 and 11.2.

Alongside the grease nipple on one of the topshell arms there is a decal which shows the
type of grease pumped into the spider bearing before delivery. Do not mix greases of
different types.

When a new mantle and/or concave is fitted, the spider bearing and seal should be carefully
cleaned and then filled with new grease. To avoid unscheduled stoppages, we recommend
that the spider bearing seal should be changed each time the liners are changed.
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9. Lubricant recommendations 2001-11-15

Table 9.5.2 Grease quantity

Crusher Grease
quantity kg
(lbs)
H2800 3-4
S2800 (6.6-8.8)
H3800 4-6
S3800 (8.8-13.2)
H4800 6-8
S4800 (13.2-17.6)
H6800 7-9
S6800 (15.4-19.8)
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10. Topshell assembly & concave ring 2003-06-10

10. Topshell assembly & concave ring

Contents Page
10.1 Evaluation of liner wear 2
10.2 Checks prior to removal 4
10.3 Removal and reinstallation of topshell 4
10.4 Replacement of concave ring - H2800 Hydrocone 6
10.5 Replacement of concave ring - H3800 Hydrocone 10
10.6 Replacement of concave ring - H4800 Hydrocone 15
10.7 Replacement of concave ring - H6800 Hydrocone 19
10.8 Filler ring 24
10.9 Replacement of concaves and lower concave ring - 29
S2800 Hydrocone
10.10 Replacement of concaves and lower concave ring - 32
S3800 Hydrocone
10.11 Replacement of concaves and lower concave ring - 35
S4800 Hydrocone
10.12 Replacement of upper and lower concave rings - 39
S6800 Hydrocone
10.13 Replacement of lower concave ring only - 42
S-type Hydrocones
10.14 Crushing hard but less abrasive material 44
1800-Series Hydrocone crushers S 223.370.01 en 2 (44)

10. Topshell assembly & concave ring 2003-06-10

10.1 Evaluation of liner wear


Apart from the recommended annual removal for cleaning and inspection, the topshell is
usually removed for liner replacement.

Inspection of crushing chamber:

1. Inspection of the liners must be carried out at the correct intervals. See Section 17 –
Routine maintenance. A new machine must be inspected at frequent intervals. After
one or two liner changes, the intervals between inspections can be successively
increased.

2. These routine inspections will give an indication of when the liners must be changed.
It is difficult to give an exact limit at which the liners are worn out. They can be said
to be worn out when capacity drops off or when the thickness has been reduced so
much that indentations or cracks have occurred.

Extreme operating conditions can require liner replacement before the liners are "worn
out". One reason can be incorrect feeding so that increased wear occurs over a certain
section of the concave ring or concaves. This also means that the setting varies according
to where measurement is carried out around the crushing chamber. The feed arrangement
must be such that the feed material is evenly distributed around the crushing chamber,
segregation is prevented and the crushing chamber is kept full. Examples of different feed
arrangements are given in Section 3 – Installation. Incorrect feeding arrangements cause
very poor liner utilization, higher power consumption (= higher bearing loads), lower
capacity, lower reduction and poorer product shape.

Inspection of the liners is a preventive measure intended to avoid:

3. Expensive damage to the contact surfaces of the topshell and the headcentre. In
addition, the liners must be replaced if the maintenance of the desired setting entails
raising the mainshaft so high that the distance between the head nut and the
underside of the spider is less than 15 mm ("A-dim." in Fig. 10.1.1).

4. Loss of production due to reduced capacity or an incorrect final product or because


of an unscheduled shutdown.

Problems similar to those caused by an incorrect feeding arrangement can also be


experienced if the feed material is not an evenly graded mixture. The crushing chamber is
selected on the basis of the maximum feed size. If almost all of the feed is close to the
maximum size, crushing will be concentrated to the upper portion of the chamber. This can
give rise to an annular groove around the entire crushing chamber (see B in Fig. 10.1.1). A
preponderance of fine material in the feed concentrates crushing to the lower part of the
chamber, with the result shown by C in Fig. 10.1.1.
1800-Series Hydrocone crushers S 223.370.01 en 3 (44)

10. Topshell assembly & concave ring 2003-06-10

Figure 10.1.1 Liner wear

The crusher must not be put into full-scale operation until it has
Note ! been established that the feed arrangement functions correctly
and that the feed size is correct.

The benefits gained by continuing to crush with worn liners are small in comparison with
the disadvantages described in 3 and 4 above. Planned liner replacement at the right time
always gives optimum operating economics. These recommendations also apply to
crushers fitted with automatic setting regulation equipment.

Liner wear is compensated for by hydraulically raising the mainshaft so that the desired
setting can be maintained.
1800-Series Hydrocone crushers S 223.370.01 en 4 (44)

10. Topshell assembly & concave ring 2003-06-10

Dimension A is an indication of the position of the mainshaft inside the crusher.

The mainshaft must not be raised so far that the A-dimension, as


Caution !! shown in Fig. 10.1.1, is less than 15 mm for an H or S 2800,
3800 or 4800 crusher, or 20 mm for an H or S 6800 crusher. If
the mainshaft is raised further, expensive damage can be caused
to the spider bearing in the topshell.

Note! The liners are normally worn out before this limit is reached.

10.2 Checks prior to removal


Whenever a crusher is to be dismantled, the checks described
Note ! below must be carried out in good time before the topshell is
removed. This is so that an idea can be obtained about how far
the crusher needs to be stripped down, for instance when a liner
change is planned.

1. Check the play between the mainshaft sleeve and the spider bearing. (See
Section 11.1).

2. Check the play between the dust seal ring and the dust collar. (See Section 12.9 –
Dust seal ring).

3. Check the backlash in the gears. (See Section 15.3 – Gear backlash).

4. Inspect the return oil strainer for any contamination. If an unusual amount or type of
contamination is found - metal particles, for example - the cause must be investigated
at once.

10.3 Removal and reinstallation of topshell


Remove the bolts which clamp the topshell to the bottomshell. There are four press screws
in the topshell flange to facilitate splitting the joint.

Remove the spider cap to prevent a vacuum which can cause the mainshaft to rise a little
when the topshell is lifted. The air breather and air channel could be blocked.

Use amply dimensioned lifting gear (strops etc.). Take great care
Caution !! when lifting the topshell to avoid damaging the mainshaft, the
spider bushing and other machined surfaces.
1800-Series Hydrocone crushers S 223.370.01 en 5 (44)

10. Topshell assembly & concave ring 2003-06-10

Inspection

Check that the tapered mating surfaces are free from rust. Check to see if there has been
any motion between the topshell and the bottomshell which has resulted in damage to the
tapered mating surfaces. If this is the case, the surfaces must be built up by welding and re-
machined. Consult Sandvik Rock Processing.

Thoroughly clean and oil the tapered mating surfaces on the topshell and bottomshell.

Place the topshell on timber supports (planks or similar) so that the machined surfaces are
not damaged.

Reinstallation

Coat the tapered mating surfaces and the contact faces of the flanges with grease or thick
oil. The use of a grease or oil containing molybdenum disulphide will reduce the risk of
contact corrosion.

Grease the spider bushing, the spider bearing seal and the mainshaft sleeve. Use the normal
spider bearing grease - see Section 9.5 – Spider bearing lubrication.

Lower the topshell carefully and make sure that the spider
Caution !! bearing seal is not damaged by the mainshaft. When the topshell
is resting on the bottomshell there is a gap of about 3 mm
between the flanges.

Tighten the bolts in diagonal rotation until the flanges lie flush.
Note ! After the machine has been crushing for a few hours, retighten
these bolts. In the meantime, check occasionally that there is no
relative movement by placing a finger across the joint.

Fill the spider bearing up to the top with grease. This should be done with the mainshaft
lowered, i.e. with the Hydroset piston at the bottom of its travel. See Section 9.5 – Spider
bearing lubrication.

Grease the contact surfaces of the spider cap and its seating. Inspect the spider bearing
seal. Refit the spider cap. See Section 11.2 – Replacement of spider bushing and seal.
1800-Series Hydrocone crushers S 223.370.01 en 6 (44)

10. Topshell assembly & concave ring 2003-06-10

H2800

10.4 Replacement of concave ring - H2800 Hydrocone crusher


The design of the H2800 Hydrocone is such that all concave rings - from EF to EC - can be
fitted into a single topshell. This is made possible - despite the great difference in shape of
the various concave rings - by using a filler ring. See Section 10.8 - Filler ring. The filler
ring is installed with a metal-to-metal taper fit in the topshell and the concave ring is in
turn a metal-to-metal fit inside the filler ring.

The EC concave ring is an exception: it fits directly inside the topshell without a filler
ring.

The concave ring is clamped with four bolts through the attachment lugs at the bottom. See
Fig. 10.4.1.

If lifting lugs are to be welded to the concave ring, make sure they are amply dimensioned
and use a welding electrode suitable for manganese. See Section 2.9.4.

1. Concave ring
2. Filler ring
3. Sealing compound
4. Locking ring
5. O-ring
6. Sleeve
7. Disc spring
8. Clamping ring
9. Plank
10. Gap between Figure 10.4.1 H2800
clamping ring and
topshell
1800-Series Hydrocone crushers S 223.370.01 en 7 (44)

10. Topshell assembly & concave ring 2003-06-10

H2800

Removal

When the topshell has been lifted off the crusher, position it on planks so that the concave
ring is unobstructed. Remove the bolts which clamp the concave ring in the topshell. Make
a note of the way the disc springs are arranged. See Fig. 10.4.3.

The screws in the top of the topshell hold the filler ring and
Note ! should not be removed during a normal liner change.

It should be possible to remove the concave ring from the topshell with a few heavy blows
on the top rim.

If the concave ring does not come loose, two jacks can be positioned between the top rim
of the concave ring and the topshell arms. See Fig. 10.4.2.

Hit the concave ring around its top rim at the same time as the jacks are operated.

Figure 10.4.2
1800-Series Hydrocone crushers S 223.370.01 en 8 (44)

10. Topshell assembly & concave ring 2003-06-10

H2800

Inspection

Lift up the topshell and inspect the contact surface in the topshell or filler ring.

If any ridges or depressions have been formed in the topshell or filler ring by the machined
contact surfaces of the concave ring, they must be ground off before reassembly is started.
If there is serious wear or if the concave ring has worn deep grooves in the topshell or filler
ring, contact Sandvik Rock Processing for advice about the appropriate course of action.

Check that the filler ring is securely installed in the topshell.

If the filler ring has come loose it must be taken out for inspection of the contact surfaces
and the retaining ring screws. See Section 10.8 - Filler ring.

Reassembly

In principle, the concave ring is installed in the following way:

Place the clamping ring on planks with the four clamping bolts positioned in their holes.
See Fig. 10.4.1.

Position the concave ring with its locating bosses in the appropriate recesses in the
clamping ring.

Check that the locating dowels are properly screwed into the lower edge of the topshell.

To increase the life of the clamping ring (wear on the inside diameter), it can be rotated
relative to the topshell.

Lower the topshell onto the clamping ring, using the locating dowels to ensure correct
positioning. Check that the gap between the clamping ring and the topshell is even all
round. See Fig. 10.4.1.

Fit the washers, disc springs, sleeves and nuts. See Fig. 10.4.1. Measure dimension "T"
before tightening the nuts. See Fig. 10.4.3.

When installing the concave ring, ensure that there is an even fit
Note ! all around the topshell by tightening the bolts in diagonal
rotation until the dimension T-3.2 mm is reached. This
corresponds to 460° rotation of the nut.

When you have tightened the bolts, check with a feeler gauge that there is no play between
the topshell or filler ring and the lower part of the concave ring.

When the concave ring clamping bolts have been tightened, fill the space between the
concave ring and the topshell or filler ring with a sealing foam (sealing compound) to
prevent penetration by dust or moisture.
1800-Series Hydrocone crushers S 223.370.01 en 9 (44)

10. Topshell assembly & concave ring 2003-06-10

H2800

Check the tightness of the clamping bolts after a short period of operation.

Figure 10.4.3 Concave ring clamping bolts and nuts


1800-Series Hydrocone crushers S 223.370.01 en 10 (44)

10. Topshell assembly & concave ring 2003-06-10

H3800
800800
10.5 Replacement of concave ring - H3800 Hydrocone crusher
The design of the H3800 Hydrocone is such that all concave rings - from EF to EC - can be
fitted into a single topshell. This is made possible - despite the great difference in shape of
the various concave rings - by using filler rings. See Section 10.8 - Filler ring.

The filler ring is installed with a metal-to-metal taper fit in the topshell and the concave
ring is in turn a metal-to-metal fit inside the filler ring.

The EC concave ring is an exception: it fits directly inside the topshell without a filler
ring.

When the EF concave ring is used, a 2-piece wearing ring is welded to the locking ring
with the help of the four 10 x 10 x 75mm bars supplied. Use an A-dimension of 3 - 4mm.

See Fig. 10.5.1.

The concave ring is clamped with four bolts through the attachment lugs at the bottom. See
Fig. 10.5.1.

If lifting lugs are to be welded to the concave ring, make sure they are amply dimensioned
and use a welding electrode suitable for manganese. See Section 2.9.4.
1800-Series Hydrocone crushers S 223.370.01 en 11 (44)

10. Topshell assembly & concave ring 2003-06-10

H3800

1. Concave ring
2. Filler ring
3. Sealing compound
4. Locking ring
5. O-ring
6. Sleeve
7. Disc spring
8. Spherical washer and
conical seat
9. Plank
10. Wearing plate (Only with
EF crushing chamber)

EF crushing chamber

Figure 10.5.1 H3800


1800-Series Hydrocone crushers S 223.370.01 en 12 (44)

10. Topshell assembly & concave ring 2003-06-10

H3800

Removal

When the topshell has been lifted off the crusher, position it on planks so that the concave
ring is unobstructed. Remove the bolts which clamp the concave ring in the topshell. Make
a note of the way the disc springs are arranged. See Fig. 10.5.3.

The screws in the top of the topshell hold the filler ring and
Note ! should not be removed during a normal liner change.

The locating blocks for the concave ring need not be removed. They are adjusted when the
new concave ring is being installed.

It should be possible to remove the concave ring from the topshell with a few heavy blows
on the top rim.

If the concave ring does not come loose, two jacks can be positioned between the top rim
of the concave ring and the topshell arms. See Fig. 10.5.2.
Hit the concave ring around its top rim at the same time as the jacks are operated.

Figure 10.5.2
1800-Series Hydrocone crushers S 223.370.01 en 13 (44)

10. Topshell assembly & concave ring 2003-06-10

H3800

Inspection

Lift up the topshell and inspect the contact surface in the topshell or filler ring.

If any ridges or depressions have been formed in the topshell or filler ring by the machined
contact surfaces of the concave ring, they must be ground off before reassembly is started.
If there is serious wear or if the concave ring has worn deep grooves in the topshell or filler
ring, contact Sandvik Rock Processing for advice about the appropriate course of action.

Check that the filler ring is securely installed in the topshell.

If the filler ring has come loose it must be taken out for inspection of the contact surfaces
and the retaining ring screws. See Section 10.8 - Filler ring.

Reassembly

In principle, the concave ring is installed in the following way:

Place the concave ring on planks and position the four clamping bolts - complete with the
spherical washers and conical seats - in the attachment lug slots. Lower the topshell down
onto the concave ring and screws and fit the washers, disc springs, sleeves and nuts. See
Fig. 10.5.1. Measure dimension "T" before tightening the nuts. See Fig. 10.5.3.

When installing the concave ring, ensure that there is an even fit
Note ! all around the topshell by tightening the bolts in diagonal
rotation until the dimension T-3.5 mm is reached. This
corresponds to 420° rotation of the nut.

When you have tightened the bolts, check with a feeler gauge that there is no play between
the topshell or filler ring and the lower part of the concave ring.

Check and adjust the locating blocks so that they butt against the lugs on the concave ring.
These locating blocks have an eccentrically placed hole so that good alignment against the
concave ring lugs can easily be obtained.

When the concave ring clamping bolts have been tightened, fill the space between the
concave ring and the topshell or filler ring with a sealing foam (sealing compound) to
prevent penetration by dust or moisture.

Check the tightness of the clamping bolts after a short period of operation.
1800-Series Hydrocone crushers S 223.370.01 en 14 (44)

10. Topshell assembly & concave ring 2003-06-10

H3800

Figure 10.5.3 Concave ring clamping bolts and nuts


1800-Series Hydrocone crushers S 223.370.01 en 15 (44)

10. Topshell assembly & concave ring 2003-06-10

H4800

10.6 Replacement of concave ring - H4800 Hydrocone crusher


The design of the H4800 Hydrocone is such that all concave rings - from EF to EC - can be
fitted into a single topshell. This is made possible - despite the great differences in shape of
the various concave rings - by using filler rings. See Section 10.8 - Filler ring.

No filler ring is used with C and EC concave rings. These are mounted direct in the
topshell with plastic backing.

The concave ring is pulled into the topshell by a clamping ring with six clamping bolts.
The concave ring has locating bosses which fit into recesses in the clamping ring, whilst
the ring itself is positioned against the topshell by locating dowels. See Fig. 10.6.1.

If lifting lugs are to be welded to the concave ring, make sure they are amply dimensioned
and use a welding electrode suitable for manganese. See Section 2.9.4.

1. Concave ring
2. Filler ring
3. Locking ring
4. Shim
5. Gap between clamping
ring and topshell
6. Clamping ring
7. Plank
8. Lifting hole/plastic
backing level hole

Figure 10.6.1 H4800


1800-Series Hydrocone crushers S 223.370.01 en 16 (44)

10. Topshell assembly & concave ring 2003-06-10

H4800

Removal

When the topshell has been removed from the crusher, position it on planks so that the
concave ring is unobstructed. See Fig. 10.6.2.

Remove the bolts which hold the concave ring in the topshell. Make a note of the way the
disc springs are arranged. See Fig. 10.6.3.

The screws in the top of the topshell hold the filler ring and
Note ! should not be removed during a normal liner change.

Since the concave ring of an H4800 Hydrocone is backed with plastic composition, it may
remain in the topshell and must then be driven out. Hit the top rim of the concave ring with
a sledge hammer.

If the concave ring does not come loose, two jacks can be positioned between the top rim
of the concave ring and the topshell arms. See Fig. 10.6.2.

Hit the concave ring around its top rim at the same time as the jacks are operated.

Figure 10.6.2
1800-Series Hydrocone crushers S 223.370.01 en 17 (44)

10. Topshell assembly & concave ring 2003-06-10

H4800

If the concave ring does not come loose when these methods are used, it must be split with
a cutting torch.

Take great care to avoid damage to the topshell and filler ring.

Use a breathing mask when cutting liners and plastic backing.


Warning !!! Make sure the work-place is well ventilated. We advise against
using explosives to loosen the concave ring. This would entail
risks of injury for personnel and damage to equipment. The
cost of resultant damage can far outweigh any time-saving
during liner replacement.
Inspection

Lift up the topshell and inspect the contact surface in the topshell.

If any ridges or depressions have been formed in the topshell by the machined contact
surfaces of the concave ring, they must be ground off so that they do not prevent good
contact between the new concave ring and the topshell.

If there is serious wear or if the concave ring has worn deep grooves in the topshell,
contact Sandvik Rock Processing for advice about the appropriate course of action.

Check that the filler ring is securely installed in the topshell. If the filler ring has come
loose it must be taken out for inspection of the contact surfaces and the retaining screws.
See Section 10.8 - Filler ring.

Reassembly

In principle, the H4800 concave ring is installed in the following way:

Place the clamping ring on planks with the six clamping bolts positioned in their holes. See
Fig. 10.6.1.

Position the concave ring with its six locating bosses in the appropriate recesses in the
clamping ring.

Check that the locating dowels are properly screwed into the lower edge of the topshell.

Coat the topshell/filler ring surfaces which will be in contact with plastic backing with a
thin layer of grease or silicon spray to facilitate removal and cleaning next time the liners
are changed.

To increase the life of the clamping ring (wear on the inside diameter), it can be rotated
relative to the topshell (6x60°).

Lower the topshell onto the clamping ring, using the locating dowels to ensure correct
positioning. Check that the gap between the clamping ring and the topshell is even all
round. See Fig. 10.6.1.
1800-Series Hydrocone crushers S 223.370.01 en 18 (44)

10. Topshell assembly & concave ring 2003-06-10

H4800

Fit the washers, disc springs, sleeves and nuts. Measure dimension "T" before tightening
the nuts. See Fig. 10.6.3.

When installing the concave ring, ensure that there is an even fit
Note ! all around the topshell by tightening the bolts in diagonal
rotation until the dimension T-4.5 mm is reached. This
corresponds to 460° rotation of the nut.

When you have tightened the bolts, check with a feeler gauge that there is no play between
the topshell or filler ring and the lower part of the concave ring. There are holes in the
clamping ring to facilitate this check.

When the concave ring has been properly installed, fill the space between the concave ring
and the topshell or filler ring with plastic backing composition up to the level of the lifting
holes in the mantle. See Section 19 – Backing with plastic composition.

Check the tightness of clamping bolts after a short period of operation.

Figure 10.6.3 Concave ring clamping bolts and nuts


1800-Series Hydrocone crushers S 223.370.01 en 19 (44)

10. Topshell assembly & concave ring 2003-06-10

H6800

10.7 Replacemant of concave ring - H6800 Hydrocone crusher


The design of the H6800 Hydrocone is such that all concave rings - from EF to EC - can be
fitted into a single topshell. This is made possible - despite the great difference in shape of
the various concave rings - by using filler rings. See Section 10.8 - Filler ring.

No filler ring is used with C, CX, EC and EF concave rings. These are mounted direct in
the topshell with plastic backing.

When the EF concave ring is used, a 4-piece wearing ring is installed. Its lugs are welded
to the topshell. Use an A-dimension of 4 - 5mm. See Fig. 10.7.1.

The concave ring is pulled into the topshell by a clamping ring with six clamping bolts.
The concave ring has locating bosses which fit into recesses in the clamping ring, whilst
the ring itself is positioned against the topshell by locating dowels. See Fig. 10.7.1.

If lifting lugs are to be welded to the concave ring, make sure they are amply dimensioned
and use a welding electrode suitable for manganese. See Section 2.9.4.
1800-Series Hydrocone crushers S 223.370.01 en 20 (44)

10. Topshell assembly & concave ring 2003-06-10

H6800

1. Locking ring
2. Shims
3. Concave ring
4. Filler ring
5. Clamping ring
6. Plank
7. Gap between clamping ring
and topshell
8. Lifting hole/plastic backing
level hole
9. Wearing plate (only
with EF crushing
chamber).

H6800

EF crushing chamber

Figure 10.7.1 H6800


1800-Series Hydrocone crushers S 223.370.01 en 21 (44)

10. Topshell assembly & concave ring 2003-06-10

H6800

Removal

When the topshell has been removed from the crusher, position it on planks so that the
concave ring is unobstructed. See Fig. 10.7.2.

Remove the bolts which hold the concave ring in the topshell. Make a note of the way the
disc springs are arranged. See Fig. 10.7.3.

The screws in the top of the topshell hold the filler ring and
Note ! should not be removed during a normal liner change.

Since the concave ring of an H6800 Hydrocone is backed with plastic composition, it may
remain in the topshell and must then be driven out. Hit the top rim of the concave ring with
a sledge hammer.

If the concave ring does not come loose, two jacks can be positioned between the top rim
of the concave ring and the topshell arms. See Fig. 10.7.2.

Hit the concave ring around its top rim at the same time as the jacks are operated.

Figure 10.7.2
1800-Series Hydrocone crushers S 223.370.01 en 22 (44)

10. Topshell assembly & concave ring 2003-06-10

H6800

If the concave ring does not come loose when these methods are used, it must be split with
a cutting torch.

Take great care to avoid damage to the topshell and filler ring.

Use a breathing mask when cutting liners and plastic backing.


Warning !!! Make sure that the work-place is well ventilated. We advise
against using explosives to loosen the concave ring. This
would entail risks of injury for personnel and damage to
equipment. The cost of resultant damage can far outweigh any
time-saving during liner replacement.

Inspection

Lift up the topshell and inspect the contact surface in the topshell.

If any ridges or depressions have been formed in the topshell by the machined contact
surfaces of the concave ring, they must be ground off so that they do not prevent good
contact between the new concave ring and the topshell.

If there is serious wear or if the concave ring has worn deep grooves in the topshell,
contact Sandvik Rock Processing for advice about the appropriate course of action.

Check that the filler ring is securely installed in the topshell.

If the filler ring has come loose it must be taken out for inspection of the contact surfaces
and the retaining screws. See Section 10.8 - Filler ring.

Reassembly

In principle, the H6800 concave ring is installed in the following way:

Place the clamping ring on planks with the six clamping bolts positioned in their holes. See
Fig. 10.7.1.

Position the concave ring with its six locating bosses in the appropriate recesses in the
clamping ring.

Check that the locating dowels are properly screwed into the lower edge of the topshell.

Coat the topshell and filler ring surfaces which will be in contact with plastic backing with
a thin layer of grease or silicon spray to facilitate removal and cleaning next time the liners
are changed.

To increase the life of the clamping ring (wear on the inside diameter), it can be rotated
relative to the topshell (6x60°).
1800-Series Hydrocone crushers S 223.370.01 en 23 (44)

10. Topshell assembly & concave ring 2003-06-10

H6800

Lower the topshell onto the clamping ring, using the locating dowels to ensure correct
positioning. Check that the gap between the clamping ring and the topshell is even all
round. See Fig. 10.7.1.

Fit the washers, disc springs, sleeves and nuts. Measure dimension "T" before tightening
the nuts. See Fig. 10.7.3.

When installing the concave ring, ensure that there is an even fit
Note ! all around the topshell by tightening the bolts in diagonal
rotation until the dimension T-4.5 mm is reached. This
corresponds to 460° rotation of the nut.

When you have tightened the bolts, check with a feeler gauge that there is no play between
the topshell or filler ring and the lower part of the concave ring. There are holes in the
clamping ring to facilitate this check.

When the concave ring has been properly installed, fill the space between the concave ring
and the topshell or filler ring with plastic backing composition up to the level of the lifting
holes in the mantle. See Section 19 - Backing with plastic composition.

Check the tightness of clamping bolts after a short period of operation.

Figure 10.7.3 Concave ring clamping bolts and nuts


1800-Series Hydrocone crushers S 223.370.01 en 24 (44)

10. Topshell assembly & concave ring 2003-06-10

10.8 Filler ring

H2800 Hydrocone

As explained previously, all concave rings can be fitted into the single topshell.

The filler ring in the H2800 Hydrocone acts as a spacer with metal-to-metal contact against
both the topshell and the concave ring. See Fig. 10.4.1.

The filler ring of the H2800 is intended for EF, F, MF, M and C concave rings. The EC
concave ring is mounted directly in the topshell without a filler ring.

Removal

If the intention is to change to an EC crushing chamber, the filler ring must be removed.

Remove the screws which hold the locking ring and the filler ring in the topshell.

The filler ring has a tapered seating in the topshell and jacks must be used to press it out.

Position the jacks between the top edge of the filler ring and the topshell arms. Press out
the filler ring. Use two jacks, each with a capacity of approx. 40 tons. If the filler ring still
does not come free, it may be necessary to heat the topshell while the jacks are operated.

Inspection

Clean the filler ring. Inspect the contact surfaces of the filler ring and the topshell. If there
are any ridges or depressions, they must be ground off before reassembly is started.

Reassembly

Lubricate the O-ring and position it in its groove in the outer surface of the filler ring. See
Fig. 10.4.1.

Raise the filler ring into position in the topshell. Install the locking ring (which pulls the
filler ring up into position), coat the screws with grease and fit them.
Tighten the bolts in diagonal rotation until they are tight. Check the tightness of the screws
after a few days of operation. In some cases this will mean removing the cone plates in the
feed hopper.
1800-Series Hydrocone crushers S 223.370.01 en 25 (44)

10. Topshell assembly & concave ring 2003-06-10

H3800 Hydrocone

As explained previously, all concave rings can be fitted into the single topshell.

The filler ring in the H3800 Hydrocone acts as a spacer with metal-to-metal contact against
both the topshell and the concave ring. See Fig. 10.5.1.
Two types of filler ring are used. One (M) is intended for F, MF and M concave rings. The
other (C) is intended for MC, C and EF concave rings. The EC concave ring is mounted
directly in the topshell without a filler ring.

Removal

If the intention is to change to a coarser crushing chamber, the filler ring may need to be
removed. Check in the spare parts list which filler ring is used with which concave ring.

Remove the screws which hold the locking ring and the filler ring in the topshell.

The filler ring has a tapered seating in the topshell and jacks must be used to press it out.

Position the jacks between the top edge of the filler ring and the topshell arms. Press out
the filler ring. Use two jacks, each with a capacity of approx. 40 tons. If the filler ring still
does not come free, it may be necessary to heat the topshell while the jacks are operated.

Inspection

Clean the filler ring. Inspect the contact surfaces of the filler ring and the topshell. If there
are any ridges or depressions, they must be ground off before reassembly is started.

Reassembly

Lubricate the O-ring and position it in its groove in the outer surface of the filler ring. See
Fig. 10.5.1

Raise the filler ring into position in the topshell. Install the locking ring (which pulls the
filler ring up into position), coat the screws with grease and fit them.
Tighten the bolts in diagonal rotation until they are tight. Check the tightness of the screws
after a few days of operation. In some cases this will mean removing the cone plates in the
feed hopper.
1800-Series Hydrocone crushers S 223.370.01 en 26 (44)

10. Topshell assembly & concave ring 2003-06-10

H4800 Hydrocone

The filler ring in the H4800 reduces the volume of the space between the topshell and the
concave ring.
Two types of filler ring are used, the MF and the MC. The MF filler ring is backed with
plastic composition in its upper part and has metallic contact with the topshell in the lower
part. The MC filler ring has full-height metallic contact and is not backed against the
topshell. The filler ring provides an even gap to the concave ring, intended for filling with
plastic backing composition. See Fig. 10.6.1.

The MF filler ring is intended for F and MF concave rings whilst the MC filler ring is
intended for M, MC and EF concave rings. The C and EC concave rings are installed
directly in the topshell - without a filler ring - and are backed with plastic composition.

Removal

If the intention is to change to a coarser crushing chamber, the filler ring may need to be
removed. Check in the spare parts list which filler ring is used with which concave ring.

If a filler ring which is backed with plastic composition comes


Note ! loose during operation, it must be removed, inspected,
reinstalled and backed with plastic composition again. If a solid
filler ring comes loose during crushing, it should be removed
and its contact surfaces inspected before it is refitted.

Remove the screws which hold the filler ring in the topshell. The filler ring has a tapered
seating in the topshell and jacks must be used to press it out.

Position the jacks between the top edge of the filler ring and the topshell arms. Press out
the filler ring and at the same time use a sledge hammer to hit around the top edge and the
inside of the filler ring. Use two jacks, each with a capacity of approx. 40 tons. If the filler
ring still does not come free, it may be necessary to heat the topshell while the jacks are
operated.

Inspection

Clean the filler ring. Inspect the contact surfaces of the filler ring and the topshell. If there
are any ridges or depressions, they must be ground off before reassembly is started.
1800-Series Hydrocone crushers S 223.370.01 en 27 (44)

10. Topshell assembly & concave ring 2003-06-10

Reassembly

Press a little grease into each threaded hole in the filler ring.
When the bolts have been threaded all the way into the filler ring, the holes must be
completely filled with grease to prevent corrosion and the accumulation of dirt. This will
make it easier to remove the filler ring next time.

Never grease those surfaces on the topshell and filler ring which
Note ! are affected by plastic backing.

Pull the filler ring up into position in the topshell by tightening the six screws in diagonal
rotation – with the washers and shims in position - until they are tight. See Fig. 10.6.1.

When an MF filler ring has been properly seated, back it with plastic composition. See
Section 19 – Backing with plastic composition.

Check the tightness of the screws after a few days of operation. In some cases this will
mean removing the cone plates in the feed hopper.

H6800 Hydrocone

The filler ring in the H6800 reduces the volume of the space between the topshell and the
concave ring.

Two types of filler ring are used, the (MF) and the (MC). The lower part of the filler ring
has metallic contact with the topshell, whilst the upper part is backed with plastic
composition. The filler ring provides an even gap to the concave ring, intended for filling
with plastic backing composition. See Fig. 10.7.1.

The (MF) filler ring is intended for F and MF concave rings, whilst the (MC) filler ring is
intended for M and MC concave rings. The C, CX, EC and EF concave rings are installed
directly in the topshell - without a filler ring - and are backed with plastic composition.
1800-Series Hydrocone crushers S 223.370.01 en 28 (44)

10. Topshell assembly & concave ring 2003-06-10

Removal

If the intention is to change to a coarser crushing chamber, the filler ring may need to be
removed. Check in the spare parts list which filler ring is used with which concave ring.

If the filler ring comes loose during operation, it must be


Note ! removed, inspected, reinstalled and backed with plastic
composition.

Remove the screws which hold the filler ring in the topshell.

The filler ring has a tapered seating in the topshell and jacks must be used to press it out.
Position the jacks between the top edge of the filler ring and the topshell arms. Press out
the filler ring and at the same time use a sledgehammer to hit around the top edge and
inside surface of the filler ring. Use two jacks, each with a capacity of approx. 40 tons. If
the filler ring still does not come free, it may be necessary to heat the topshell while the
jacks are operated.

Inspection

Clean the filler ring. Inspect the contact surfaces of the filler ring and the topshell. If there
are any ridges or depressions, they must be ground off before reassembly is started.

Reassembly

Press a little grease into each threaded hole in the filler ring.

Never grease those surfaces on the topshell and filler ring which
Note ! are affected by plastic backing.

Pull the filler ring up into position in the topshell by tightening the six screws in diagonal
rotation until they are tight. See Fig. 10.7.1.

When the filler ring has been properly seated, back it with plastic composition. See Section
19 – Backing with plastic composition.

Check the tightness of the screws after a few days of operation. In some cases this will
mean removing the cone plates in the feed hopper.
1800-Series Hydrocone crushers S 223.370.01 en 29 (44)

10. Topshell assembly & concave ring 2003-06-10

S2800

10.9 Replacement of concaves and lower concave ring -


S2800 Hydrocone crusher
The S2800 Hydrocone crusher has a crushing chamber which is formed on the outside by
an upper row of concaves and a lower concave ring. If only the lower concave ring is to be
changed, see Section 10.13.

If lifting lugs are to be welded to the concaves or lower concave ring, make sure they are
amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.

Removal

All of the concaves are chamfered on the rear edges to make removal easier. See Fig.
10.9.1. Remove the concaves with wedges. It may be necessary to resort to a cutting torch
to remove the concaves, depending on how worn they are.

Do not stand inside the crusher when removing the


Warning !!! concaves! Do not use explosives to loosen concaves.

When cutting plastic-backed concaves with a torch, ensure that the work-place is well
ventilated and use a breathing mask.

If the topshell is upside down when the concaves are being removed, protect the spider
bushing so that it will not be damaged by falling concaves.

Protect the machined surfaces of the topshell. Block up the feed


Caution !! hopper attachment flange. See Fig.10.13.1.

1. Area which may need to be burnt off.


2. Chamfer

Figure 10.9.1 Concaves


1800-Series Hydrocone crushers S 223.370.01 en 30 (44)

10. Topshell assembly & concave ring 2003-06-10

S2800

To make removal of the first concave easier, the edges of the adjacent concaves can be
burnt off, as shown Fig. 10.9.1.

The lower concave ring has recesses on the back to make removal with wedges easier.

Split the lower concave ring at the three marking notches and use wedges in the recesses to
press out the smallest segment first. See Fig. 10.9.2.

When cutting with a torch, ensure that the work-place is well


Warning !!! ventilated and use a breathing mask.

1. Recesses for wedges


2. Marking notch

Figure 10.9.2 Concave ring

Inspection

Carefully clean out all plastic backing from the inside of the topshell. If there are deep
depressions, they must be filled in by welding and the topshell must be remachined.
Ledges, recesses and grooves in the topshell must be completely free from remnants of
plastic backing to ensure satisfactory bonding when the new lower concave ring is backed.
1800-Series Hydrocone crushers S 223.370.01 en 31 (44)

10. Topshell assembly & concave ring 2003-06-10

S2800

Reassembly

1. Lower concave ring


2. Topshell
3. Sealing compound
4. Plate

Figure 10.9.3

Place the topshell and lower concave ring on a smooth surface (e.g. a piece of plate), well
sealed with unbroken strings of sealing compound. See Fig. 10.9.3.

Never grease the surfaces of the topshell and lower concave ring
Note ! which will come into contact with plastic backing.

Adjust the position of the lower concave ring so that there is an even gap to the topshell all
around. See Fig. 10.9.3.

Position the concaves in the topshell with even gaps (6-8 mm) between each one. Lock the
concaves in place by driving wooden wedges between the concaves and a support ring. See
Fig. 10.11.4.

Seal the gaps between adjacent concaves to a depth of 10-15 mm from the crushing
surface. Use a cement mortar which does not shrink, for example with an additive such as
Sika-3 or similar. Oakum can also be used but in this case the gaps should be given
additional sealing with plastic composition or hot asphalt.

Pour the thoroughly mixed plastic composition through the cut-outs in the top edges of the
concaves so that the space behind the concaves is filled to the top. See Section 19 –
Backing with plastic composition.
1800-Series Hydrocone crushers S 223.370.01 en 32 (44)

10. Topshell assembly & concave ring 2003-06-10

S3800

10.10 Replacement of concaves and lower concave ring -


S3800 Hydrocone crusher
The S3800 Hydrocone crusher has a crushing chamber which is formed on the outside by
an upper row of concaves and a lower concave ring.

If only the lower concave ring is to be changed, see Section 10.13.

If lifting lugs are to be welded to the concaves or lower concave ring, make sure they are
amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.

Removal

All of the concaves are chamfered on the rear edges to make removal easier. See Fig.
10.10.1. Remove the concaves with wedges. It may be necessary to resort to a cutting torch
to remove the concaves, depending on how worn they are.

Do not stand inside the crusher when removing the


Warning !!! concaves! Do not use explosives to loosen concaves.

When cutting plastic-backed concaves, ensure that the workplace is well ventilated and use
a breathing mask.

If the topshell is upside down when the concaves are being removed, protect the spider
bushing so that it will not be damaged by falling concaves.

Protect the machined surfaces of the topshell. Block up the feed


Caution !! hopper attachment flange. See Fig. 10.13.1.

1. Area which may need to be burnt off


2. Chamfer

Figure 10.10.1 Concaves


1800-Series Hydrocone crushers S 223.370.01 en 33 (44)

10. Topshell assembly & concave ring 2003-06-10

S3800

To make removal of the first concave easier, the edges of the adjacent concaves can be
burnt off, as shown in Fig. 10.10.1.

The lower concave ring has recesses on the outside to make removal with wedges easier.

Split the lower concave ring at the three grooves (directly beneath the marking notches)
and use wedges in the recesses to press out the smallest segment first. See Fig. 10.10.2.

When cutting with a torch, ensure that the work-place is well


Warning !!! ventilated and use a breathing mask.

1. Recesses for wedges


2. Marking notch

Figure 10.10.2 Concave ring

Inspection

Carefully clean out all plastic backing from the inside of the topshell. If there are deep
depressions, they must be filled in by welding and the topshell must be remachined.
Ledges, recesses and grooves in the topshell must be completely free from remnants of
plastic backing to ensure satisfactory bonding when the new lower concave ring is backed.
1800-Series Hydrocone crushers S 223.370.01 en 34 (44)

10. Topshell assembly & concave ring 2003-06-10

S3800

Reassembly

1. Lower concave ring


2. Topshell
3. Sealing compound
4. Plate

Figure 10.10.3

Place the topshell and lower concave ring on a smooth surface (e.g. a piece of plate), well
sealed with unbroken strings of sealing compound. See Fig. 10.10.3.

Never grease the surfaces of the topshell, lower concave ring


Note ! and concaves which will come into contact with plastic backing.

Adjust the position of the lower concave ring so that there is an even gap to the topshell all
around. See Fig. 10.10.3.

Position the concaves in the topshell with even gaps between each one. There must also be
6-8 mm gaps between the concaves and the top of the lower concave ring. Lock the
concaves in place by driving wooden wedges between the concaves and a support ring. See
Fig. 10.11.4.

Seal the gaps between adjacent concaves to a depth of 10-15 mm from the crushing
surface. Use a cement mortar which does not shrink, for example with an additive such as
Sika-3 or similar. Oakum can also be used but in this case the gaps should be given
additional sealing with plastic composition or hot asphalt.

Pour the thoroughly mixed plastic composition through the cut-outs in the top edges of the
concaves so that the space behind the concaves is filled to the top. See Section 19 –
Backing with plastic composition.
1800-Series Hydrocone crushers S 223.370.01 en 35 (44)

10. Topshell assembly & concave ring 2003-06-10

S4800

10.11 Replacement of concaves and lower concave ring -


S4800 Hydrocone crusher
The S4800 Hydrocone crusher has a crushing chamber which is formed on the outside by
an upper row of concaves and a lower concave ring.

If only the lower concave ring is to be changed, see Section 10.13.

If lifting lugs are to be welded to the concaves or lower concave ring, make sure they are
amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.

Removal

All of the concaves are chamfered on the rear edges to make removal easier. See Fig.
10.11.1. Remove the concaves with wedges. It may be necessary to resort to a cutting torch
to remove the concaves, depending on how worn they are.

Do not stand inside the crusher when removing the


Warning !!! concaves! Do not use explosives to loosen concaves.

When cutting plastic-backed concaves, ensure that the work


place is well ventilated and use a breathing mask.

If the topshell is upside down when the concaves are being removed, protect the spider
bushing so that it will not be damaged by falling concaves.

Protect the machined surfaces of the topshell. Block up the feed


Caution !! hopper attachment flange. See Fig. 10.13.1.

1. Area which may need to be burnt off


2. Chamfer

Figure 10.11.1
1800-Series Hydrocone crushers S 223.370.01 en 36 (44)

10. Topshell assembly & concave ring 2003-06-10

S4800

To make removal of the first concave easier, the edges of the adjacent concaves can be
burnt off, as shown in Fig. 10.11.1.

The lower ring has recesses on the outside to make removal with wedges easier.

Split the lower ring at the grooves (directly beneath the marking notches) and use wedges
in the recesses to press out the segment. See Fig. 10.11.2.

When cutting with a torch, ensure that the work-place is well


Warning !!! ventilated and use a breathing mask.

1. Recesses for wedges


2. Marking notch and groove for cutting
3. Groove

Figure 10.11.2 Concave ring

Inspection

Carefully clean out all plastic backing from the inside of the topshell. If there are ridges or
deep depressions, they must be filled in by welding and the topshell must be remachined.
Ledges, recesses and grooves in the topshell must be completely free from remnants of
plastic backing to ensure satisfactory bonding when the new lower ring is backed.
1800-Series Hydrocone crushers S 223.370.01 en 37 (44)

10. Topshell assembly & concave ring 2003-06-10

S4800

Reassembly

1. Lower concave ring


2. Topshell
3. Sealing compound
4. Plate

Figure 10.11.3

Place the topshell and lower concave ring on a smooth surface (e.g. a piece of plate), well
sealed with unbroken strings of sealing compound. See Fig. 10.11.3.

Never grease the surfaces of the topshell, lower concave ring


Note ! and concaves which will come into contact with plastic backing.

Position the lower concave ring so that the grooves on the outside come beneath the spider
arms - as shown in Fig. 10.11.2 - in order to prevent undesirable wearing through into the
grooves.

Adjust the position of the lower concave ring so that there is an even gap to the topshell all
around. See Fig. 10.11.3.

Position the concaves in the topshell with even gaps between each one. There must also be
6-8 mm gaps between the concaves and the top of the lower concave ring. Lock the
concaves in place by driving wooden wedges between the concaves and a support ring. See
Fig. 10.11.4.
1800-Series Hydrocone crushers S 223.370.01 en 38 (44)

10. Topshell assembly & concave ring 2003-06-10

S4800

Seal the gaps between adjacent concaves to a depth of 10-15 mm from the crushing
surface. Use a cement mortar which does not shrink, for example with an additive such as
Sika-3 or similar. Oakum can also be used but in this case the gaps should be given
additional sealing with plastic composition or hot asphalt.

Pour the thoroughly mixed plastic composition through the cut-outs in the top edges of the
concaves so that the space behind the concaves is filled to the top. See Section 19 –
Backing with plastic composition.

1. Support ring
2. Wooden wedge

Figure 10.11.4 Reassembly of concaves


1800-Series Hydrocone crushers S 223.370.01 en 39 (44)

10. Topshell assembly & concave ring 2003-06-10

S6800

10.12 Replacement of upper and lower concave rings -


S6800 Hydrocone crusher
The S6800 Hydrocone crusher has a crushing chamber which is formed on the outside by
an upper concave ring and a lower concave ring.

In contrast to other 1800-Series S-type crushers, the S6800 has a 2-piece upper shell. See
Fig. 10.12.1.

If only the lower concave ring is to be changed, see Section 10.13.

If lifting lugs are to be welded to the upper and lower concave rings, make sure they are
amply dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.

1. Spider
2. Topshell

Figure 10.12.1 S6800


Removal

Remove the complete upper shell (i.e. topshell and spider) from the crusher.

Before removing the upper and lower concave rings, take off the spider from the topshell.

Remove the nuts from the bolts which clamp the spider to the topshell.

There are four press screws in the topshell flange to facilitate splitting the joint.
1800-Series Hydrocone crushers S 223.370.01 en 40 (44)

10. Topshell assembly & concave ring 2003-06-10

S6800

The spider can then be lifted off the topshell with the spider arm liners and rim liners still
in place.

Protect the machined surfaces of the spider and the topshell.


Caution !! Support them with planks.

The topshell can now be turned upside down so that the lower concave ring can be
removed and then, if necessary, the upper concave ring as well.

Both upper and lower concave rings have grooves on the outside to make removal easier.

Split the lower concave ring at the grooves and press out the smaller segment first, with
wedges. See Fig. 10.12.2.

When the lower concave ring has been removed you can determine the positions of the
grooves in the upper concave ring. Split the upper ring at the grooves and press out the
segment with wedges.

When cutting with a torch, ensure that the work-place is well


Warning !!! ventilated and use a breathing mask. Do not stand inside the
crusher when removing the segments! Do not use explosives to
loosen the segments.

1. Recesses for wedges


2. Marking notch and groove for cutting
3. Groove

Figure 10.12.2 Concave ring


1800-Series Hydrocone crushers S 223.370.01 en 41 (44)

10. Topshell assembly & concave ring 2003-06-10

S6800

Inspection

Carefully clean out all plastic backing from the inside of the topshell. If there are ridges or
deep depressions, they must be filled in by welding and the topshell must be remachined.
Ledges, recesses and grooves in the topshell must be completely free from remnants of
plastic backing to ensure satisfactory bonding when the new concave rings are backed.

Reassembly

1. Lower concave ring


2. Topshell
3. Sealing compound
4. Plate

Figure 10.12.3

Place the topshell and lower concave ring on a smooth surface (e.g. a piece of plate), well
sealed with unbroken strings of sealing compound. See Fig. 10.12.3.

The lower concave ring can be lowered into the topshell from above.

Never grease the surfaces of the topshell and crushing rings


Note ! which will come into contact with plastic backing.

Position the upper and lower concave rings so that the grooves on the outside come
beneath the spider arms - as shown in Fig. 10.12.2 - in order to prevent undesirable
wearing through into the grooves.

Adjust the position of the upper and lower concave rings so that there is an even gap to the
topshell all around. See Fig. 10.13.1.

There must be a gap of 6-8 mm between the upper concave ring and the lower concave
ring.
1800-Series Hydrocone crushers S 223.370.01 en 42 (44)

10. Topshell assembly & concave ring 2003-06-10

Seal the gap between the upper and lower concave rings to a depth of 10-15 mm from the
crushing surface. Use a cement mortar which does not shrink, for example with an additive
such as Sika-3 or similar. Oakum can also be used but in this case the gap should be given
additional sealing with plastic composition or hot asphalt.

Pour the thoroughly mixed plastic composition through the cut-outs in the top edge of the
upper concave ring so that the space behind the concave rings is filled to the top of the
upper ring. See Section 19 – Backing with plastic composition.

10.13 Replacement of lower concave ring only – S-type


Hydrocones
If only the lower concave ring is to be replaced, this is most conveniently done with the
topshell turned upside down.

Protect the machined surfaces of the topshell.

Block up beneath the feed hopper attachment flange, see Fig. 10.13.1.

If lifting lugs are to be welded to the lower concave ring, make sure they are amply
dimensioned and use a welding electrode suitable for manganese. See Section 2.9.4.

Never grease the surfaces of the topshell and concave ring


Note ! which will come into contact with plastic backing.

Lift the lower concave ring into the topshell and make sure that there is an even gap all
around inside the topshell and between the lower concave ring and the upper concave ring
or the upper row of concaves.

Seal the gaps between the lower concave ring and the upper concave ring or the concaves.

Pour in the plastic backing between the lower concave ring and the topshell. See Section
19 – Backing with plastic composition.

If the topshell must be turned right way up and installed before the plastic backing has set,
follow the sequence described below:

Fit four plate segments with screws in the bottom edge of the topshell to lock the lower
concave ring in place. See Fig. 10.13.1. Carefully seal the gap.

Carefully turn the topshell upright and place it on the bottomshell.

Final installation of the bolts which clamp the topshell to the bottomshell should be
delayed until the plastic backing has set.
1800-Series Hydrocone crushers S 223.370.01 en 43 (44)

10. Topshell assembly & concave ring 2003-06-10

If a new lower concave ring is installed together with a worn


Note ! upper concave ring or worn concaves, the transition area must
be inspected to ensure that there is no "shelf" in the crushing
chamber. If there is such a "shelf", and it protudes more than
8-10 mm (S2800, S3800) or 10-12 mm (S4800, S6800), chamfer
it or remove it with a cutting torch.

1. Plate segment
2. Chamfer or remove this shelf

Figure 10.13.1 Replacement of lower concave ring only


1800-Series Hydrocone crushers S 223.370.01 en 44 (44)

10. Topshell assembly & concave ring 2003-06-10

10.14 Crushing hard but less abrasive material


Special precautions must be taken when replacing concaves on a crusher which crushes
hard but less abrasive material. A hard material which is not abrasive will peen the
concaves faster than they wear. See Fig. 10.14.1.

A. If special precautions are not taken, the gaps between concaves can disappear
completely and this can lead to cracks in the topshell.

B. Check the gaps between concaves every day. When they decrease below 3 mm, burn
off the edges of the concaves. This also applies for the gap between the lower
concave ring and the upper concaves (concave ring). Use a carbon arc cutter if
possible.

Figure 10.14.1
1800-Series Hydrocone crushers S 223.394.00 en 1 (5)

11. Spider bearing 2001-11-15

11. Spider bearing

Contents Page
11.1 Spider bearing - checking play 2
11.2 Replacement of spider bushing and seal 3
1800-Series Hydrocone crushers S 223.394.00 en 2 (5)

11. Spider bearing 2001-11-15

11.1 Spider bearing – checking play

The spider bearing has an important function in the crusher since it is the pivot point for
the gyratory movement of the mainshaft.

1800-Series crushers have an hourglass-shaped bushing with a tapered outer surface. See
Fig. 11.1.1.

1. Circulation hole
2. O-ring
3. Air vent
4. Lubricant pipe
5. Spider bearing seal
6. Pivot point

Figure 11.1.1 Spider bearing – checking play

Table 11.1.2 Permitted max. play and distance to pivot point

Crusher S (mm) S (ins.) L (mm) L (ins.)


H2800 1.6 0.063 75 3.0
S2800 2.1 0.083 75 3.0
H3800 1.9 0.075 103 4.0
S3800 2.5 0.100 103 4.0
H4800 2.1 0.083 165 6.5
S4800 2.9 0.115 165 6.5
H6800 2.4 0.095 165 6.5
S6800 3.2 0.126 165 6.5
1800-Series Hydrocone crushers S 223.394.00 en 3 (5)

11. Spider bearing 2001-11-15

The maximum permissible play in the spider bearing ("S" in Fig. 11.1.1) must be checked
each time the liners are changed or at least twice per year. See Table 11.1.2.

If the play "S" is found to be near the maximum permissible, and it is decided to keep
running with the old bushing, the lubricant must be checked and topped up more frequently
than normal. Check the grease level through the plug in the spider cap and keep an eye
open for leakage down over the mainshaft sleeve. See also Sections 9.5 and 12.6.

When the play "S" is being measured, the mainshaft must be pushed in the direction in
which it is inclined and the measurement should then be made on the opposite side with a
feeler gauge. Measure on a level with the pivot point – see Dimension L in Fig. 11.1.1.
Feeler gauges are included in the tool kit supplied with the crusher.

If the maximum play has been exceeded, the spider bushing and/or the mainshaft sleeve
must be replaced. When the bearing is dismantled, the old components can be measured
and compared with the measurements obtained from new components so that it can be
determined which item is most worn and whether acceptable play can be obtained if just
one item is replaced.

For information on inspecting the surface finish of the mainshaft sleeve, see Section
12.6 – Mainshaft sleeve. If the play considerably exceeds the maximum allowable value,
the mainshaft has been given an abnormal inclination during crushing and has thus worn
the eccentric bushing at an incorrect angle.

If a new spider bushing and a new mainshaft sleeve are fitted,


Caution !! the shaft will be returned to its correct inclination. This will
result in line contact between the eccentric bushing and the
mainshaft. The excessive pressure will be too great for the
eccentric bushing and the result can be a seizure. The eccentric
bushing must therefore be changed as well when an extremely
worn spider bushing is replaced.

11.2 Replacement of spider bushing and seal

The spider bushing and seal can be changed without removing the topshell.

However, it is recommended that a change is carried out in connection with liner


replacement since accessibility is better and it is easier to clean the components when the
topshell has been removed. It can in some cases also be a good idea to change the spider
bearing seal each time the liners are changed.
1800-Series Hydrocone crushers S 223.394.00 en 4 (5)

11. Spider bearing 2001-11-15

Removal

Remove the screws which hold the spider cap and lift it off the topshell.

Remove the screws which retain the spider bushing and press it up out of the spider by
running the same screws into the threaded holes in the top flange of the bushing. Tighten
the screws all around with gradually increasing torque. See Fig. 11.2.2.

The spider bearing seal comes out with the bushing and can then be changed.

Inspection

Clean and inspect the seating for the O-ring between the spider cap and the topshell.

Clean and inspect the seatings in the topshell for the spider bushing and the seal.

Check that the lubrication and air vent passages in the topshell are unobstructed and that
grease can reach the bushing. Check also that the air vent is clean.

Clean out the circulation holes in the spider bushing and make sure that they are not
blocked.

Reassembly

When refitting the seal ring, snap it onto the locating groove at the bottom of the spider
bushing and make sure that the sealing lip points upwards. See Fig. 11.2.1.

When the bushing has been placed in the topshell, the gap between the flange of the
bushing and the topshell is approx. 3 mm.

Tighten the screws all round, gradually increasing the torque. See Fig. 11.2.2. The flange
on the spider bushing should be flush against the topshell. Tighten the screws to the torque
given in Table 2.8.1. Fill the spider bearing with grease up to the top edge of the bushing.
See Section 9.5 – Spider bearing lubrication.

Position the O-ring on its seat on the spider cap, as shown in Fig. 11.1.1. Grease the O-ring
thoroughly first.

Fit the spider cap and tighten the screws.

If the spider bushing and spider bearing seal are changed without the topshell being
removed from the crusher, it is important to properly oil the outer diameter and sealing lip
of the seal. This is in order to reduce the risk of the seal not seating properly. It is also
important that the space between the spider and the mainshaft sleeve has been properly
cleaned out.

Make sure that the inner surface of the spider bushing is liberally
Caution !! coated with grease before the bushing is lowered down over the
mainshaft sleeve.
1800-Series Hydrocone crushers S 223.394.00 en 5 (5)

11. Spider bearing 2001-11-15

1 Spider bushing
2. Spider bearing seal

Figure 11.2.1 Reassembly of spider bearing seal

Figure 11.2.2 Tightening of spider bushing screws


1800-Series Hydrocone crushers S 223.371.00 en 1 (13)

12. Mainshaft assembly & mantle 2002-12-15

12. Mainshaft assembly & mantle

Contents Page
12.1 Mainshaft - Nomenclature 2
12.2 General 3
12.3 Head nut 3
12.4 Inner head nut 5
12.5 Mantle 6
12.6 Mainshaft sleeve 8
12.7 Mainshaft 9
12.8 Headcentre 11
12.9 Dust seal ring 12
12.10 Scraper 13
1800-Series Hydrocone crushers S 223.371.00 en 2 (13)

12. Mainshaft assembly & mantle 2002-12-15

12.1 Mainshaft - Nomenclature

1. Head nut 6. Headcentre


2. Inner head nut 7. Dust seal ring
3. Mantle 8. Scraper
4. Mainshaft sleeve 9. Mainshaft step
5. Mainshaft 10. Circlip

H-type S-type
Hydrocone Hydrocone

Figure 12.1.1
1800-Series Hydrocone crushers S 223.371.00 en 3 (13)

12. Mainshaft assembly & mantle 2002-12-15

12.2 General

When the topshell assembly is removed, the mainshaft assembly remains in the bottomshell.

At this stage it is wise to carry out various inspection and maintenance procedures - for
example, change the mantle and check the play between dust collar and dust seal ring.

Even if the mantle is changed with the mainshaft in position in the


Note ! crusher, the shaft must always be lifted so that the step bearing can be
inspected. See Section 13 - Bottomshell assembly.

Inspect - and if necessary, clean out - the recess for the dust seal ring between the headcentre
and the retaining ring.

12.3 Head nut

Removal

Burn off the ring between the mantle and head nut and then
Caution !! unscrew the nut. NOTE! The H6800 and S6800 have a left-hand
thread on the head nut whilst the other crushers have a right-hand
thread. When burning off the ring, take care to keep the flame
away from the mainshaft.

The weld between the mantle and the burning ring is made with a
stainless electrode. Since it is difficult to cut stainless material
with a cutting torch, it is advisable to grind off the weld first. This
procedure also minimizes the heat input to the head nut and thus
reduces the risk that heat is transferred to the inner head nut,
destroying the adhesion of the locking fluid to the mainshaft.

When using a cutting torch, make sure that there is good


Warning !!! ventilation and use a breathing mask.

Inspection

Carefully clean the threads on the inner head nut and the head nut with a wire brush and
lubricate the threads with molybdenum disulphide paste or an equivalent.

Inspect the surface of the mainshaft below the threads. Polish any damaged areas until a
smooth surface is obtained.

To check the fit of the headcentre, measure the distance from the top of the headcentre to the
top of the shaft. Compare this measured value with the larger of the two dimensions stamped
on the top of the shaft. See Section 12.8.
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12. Mainshaft assembly & mantle 2002-12-15

Refitting

Screw on the nut and tighten it hard by hitting the lugs with a sledge hammer. Weld the ring
to the nut and the mantle. See Fig. 12.3.1 and the adjacent table. Begin welding between the
ring and the nut. Use 80 mm (3 ins.) long welds with 130 mm (5 ins.) gaps. Align the welds
to the mantle with the gaps between welds to the nut.

To prevent fine material from entering the opening between the burning ring ends, these can
be welded up using an OK 48.00 electrode.

Avoid welding immediately below the lugs on the head nut. A weld in this area makes it
more difficult to remove the head hut.

In some cases it may be necessary to weld all the way around the ring, for example when
moist material is crushed.

The electrode used to weld between the burning ring and the mantle must meet the
requirements of DIN 8556: E 18 8 Mn B 20+110, with the following approximate analysis in
the weld.

C Mn Cr Ni
% 0.1 6 18 8.5

An example of a suitable electrode is ESAB's OK Selectrode 67.45.

For the weld between the ring and the head nut, use an ESAB OK 48.00 electrode, or an
equivalent.

Always earth close to the welding area. Always connect the earth
Caution !! to the mainshaft nut/mantle.
1800-Series Hydrocone crushers S 223.371.00 en 5 (13)

12. Mainshaft assembly & mantle 2002-12-15

1. Mainshaft sleeve
2. Inner head nut
3. Head nut
4. Burning ring
5. Mantle

Crusher Weld size


(a-dimension)
H2800 5-6 mm
S2800 (0.20-0.25 ins.)
H3800
S3800
H4800 6-7 mm
S4800 (0.25-0.30 ins.)
H6800
S6800

Figure 12.3.1 Head nut

12.4 Inner head nut

The inner head nut need only be removed if its outer threads are damaged. The H6800 and
S6800 have a lefthand thread.

Removal

Chisel or grind a groove in the inner head nut and split it with a wedge.

Do not chisel or grind so deep that the mainshaft threads are


Caution !! damaged.

Refitting

Clean the threads of the mainshaft and inner head nut with a degreasing fluid. Check that the
inner head nut can be run down to the end of the thread. Remove the inner head nut again and
apply Loctite 270 or an equivalent to the mainshaft threads. Screw on the inner head nut until
it tightens against the radius on the mainshaft. See Fig. 12.3.1.
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12. Mainshaft assembly & mantle 2002-12-15

12.5 Mantle

Removal

When the head nut has been removed, lift the mantle off the headcentre with the help of
hooks under the bottom edge or by welding on two lifting lugs.

If lifting lugs are welded to the mantle, they must be amply dimensioned and must be welded
with an electrode suitable for manganese. See Sections 12.3 and 2.9.4.

Always earth close to the welded area. Always connect the earth
Caution !! to the mainshaft nut/mantle.

If the mantle is backed with plastic composition, removal may be difficult (applies to H4800,
H6800, S3800, S4800 and S6800). If the mantle cannot be lifted off, hit it around its bottom
edge with a sledge hammer whilst it is being lifted and - if necessary - heat the mantle.

The plastic composition decomposes at a temperature of approx.


Caution !! 160°C (320°F). Make sure that the working area is well ventilated.
Take care to avoid damaging the mainshaft's bearing surfaces and
threads with the mantle.
Inspection

Manganese flow in the mantle can give rise to a gap between the headcentre and the mantle,
allowing these components to move relative to each other. This causes wear on the lower part
of the contact surface on the headcentre. If this occurs, the fit must be restored by grinding
and polishing. If wear is severe, contact Sandvik Rock Processing for advice about what
measures to take.

Refitting a mantle which is a metal-to-metal fit


(H2800, S2800 and H3800)

Thoroughly clean the headcentre and mantle before reassembling.

Position the mantle on the headcentre and fit the head nut, as described in Section 12.3.
Before welding, check with a feeler gauge that the bottom of the mantle is in contact with the
headcentre all around its periphery.

NOTE! Plastic backing is not required on these crushers.

Refitting a plastic-backed mantle


(H4800, H6800, S3800, S4800 and S6800)

Thoroughly clean the headcentre and mantle before reassembling.

To simplify future mantle removal, cover the outer surface of the headcentre with a thin coat
of grease or silicon spray.
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12. Mainshaft assembly & mantle 2002-12-15

Position the mantle on the headcentre and tighten the head nut so that the bottom edge of the
mantle lies against the headcentre. Check with a feeler gauge around the bottom of the
mantle. Remove the head nut. Coat the outer threads of the inner head nut with some kind of
lubricating paste to protect against splashing when the plastic is poured in. Pour in well-
mixed plastic composition until the level shown in Fig. 12.5.1 and Table 12.5.2 is reached.
See Section 19 - Backing with plastic composition.

Do not allow the level of plastic composition to rise above the


Note ! shoulder on the headcentre. Refit the head nut and tighten it as
soon as the plastic composition has been poured in.

H-type Hydrocone H-type Hydrocone S-type Hydrocone


with EF-mantle

Figure 12.5.1 Backing the mantle with plastic composition

For dimension ”P”, see Table 12.5.2.


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12. Mainshaft assembly & mantle 2002-12-15

Table 12.5.2

Crusher "P" mm "P" ins.


S3800 300 11.8
H4800 130 5.1
H4800-EF 270 10.6
S4800 295 11.6
H6800 180 7.1
H6800-EF 280 11.0
S6800 360 14.2

12.6 Mainshaft sleeve

The top end of the mainshaft is fitted with a protective sleeve, which can be replaced if the
bearing surface becomes worn or damaged.

Wear on the bearing surface of the mainshaft sleeve can take the form of a regular pattern.
The lip of the spider bearing seal can also cause similar wear. This does not usually
necessitate replacement of the sleeve, as long as the maximum play does not exceed the
figure given in Section 11.1 - Spider bearing – checking play. The lower part of the mainshaft
sleeve is exposed to wear from the feed material. Each time the topshell is removed (e.g. for
manganese replacement), remove any burrs or ridges with emery paper. See also Section 9.5.

Removal

When the mainshaft sleeve is to be removed, grind a longitudinal


Caution !! groove in it so that it can be split with a wedge. Be very careful
when grinding to avoid damaging the mainshaft. Another method
is to shock heat the sleeve and pull it off at the same time.
Inspection

Inspect the machined surfaces on the mainshaft. Polish away any irregularities or rust, and
clean thoroughly.

Fitting

The mainshaft sleeve has a shrink fit on the mainshaft.

Before assembly, check that all surfaces are clean and smooth.

Heat the mainshaft sleeve to about 150°C (302°F). NOTE! Do not overheat the sleeve.
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12. Mainshaft assembly & mantle 2002-12-15

This can be done in an oil bath or if that is not available, by heating with an L.P.G. torch on
the inside of the sleeve.
If a torch is used, heat the sleeve in two stages. Heat the sleeve to 150°C (302°F) and allow
the heat to distribute itself evenly throughout the sleeve for about 5 minutes. Check the
temperature and - if necessary - reheat the sleeve to the correct temperature. Drop the sleeve
onto the mainshaft until it comes down against the shoulder.

12.7 Mainshaft
Removal
For further examination of the mainshaft, it must be lifted out of the bottomshell. Before this
is done, carefully clean the mainshaft, the flange and arms of the bottomshell and also around
the dust seal ring retainer, to prevent dirt entering the bearings when the shaft is lifted out.
When the shaft has been lifted out it is important to cover over the dust collar to prevent dirt
entering the oil and the bearings.
It is possible that when the mainshaft is lifted out, the step washer
Caution !! sticks to the mainshaft step and comes up with the shaft. Check
that it is in the correct position in the crusher and is not upside
down.
When the mainshaft is lifted out, the inner seal ring normally remains inside the dust collar.
See Section 13.3 - Inner seal ring.

When the mainshaft is lifted out of the eccentric bushing, the play between the mainshaft and
the eccentric bushing can be measured. Use micrometers to measure the mainshaft and
eccentric bushing. See Table 12.7.1.

Table 12.7.1 Shaft diameter


Crusher H2800 H3800 H4800 H6800
S2800 S3800 S4800 S6800
Nominal shaft 240 280 340 400
dia. (mm)
Nominal shaft 9.45 11.02 13.39 15.75
dia. (ins.)

After fitting a remachined mainshaft, the play must not exceed the value given in Table
12.7.2. If the bearing surfaces are evenly worn, a larger play is permissible, as long as neither
part is going to be repaired. In other words, a larger play is permissible between components
which have worn against each other. If the eccentric bushing is changed, the spider bearing
must also be checked. See Section 11.1.
As soon as the mainshaft has been raised, place a piece of clean paper over the dust collar to
prevent dirt entering the inside of the crusher and thus causing damage.

If there is an abnormal amount of dirt on the inside of the dust collar, see Section 18.9.
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12. Mainshaft assembly & mantle 2002-12-15

Table 12.7.2. Play between mainshaft and eccentric bushing

Hydrocone H2800 H3800 H4800 H6800


S2800 S3800 S4800 S6800
Play in mm 1.5 1.7 1.8 1.9
Play in inches 0.060 0.067 0.071 0.075

Inspection

Inspect the lower bearing surface of the mainshaft. If it has a dull appearance, this is a sign of
contaminated oil. A bright surface usually indicates clean oil.

Inspect also the step bearing components. See Section 13.5 - Step bearing.

Inspect the dust seal ring. See Section 12.9 - Dust seal ring.

Refitting

Before refitting the mainshaft, align the step washer so that its
Note ! centre is midway between the centreline of the Hydroset cylinder
and the extended centreline of the eccentric bushing bore. In
addition, make sure that the spherical surface is facing upwards.

Fix the inner seal ring on the mainshaft by placing it askew. When the shaft has entered the
eccentric bushing, the ring can be released from the shaft by a light blow and will fall down
onto the dust collar.

Re-install the mainshaft in the bottomshell and take great care


Note ! when lowering it into the eccentric bushing. The bearing surfaces
on the mainshaft and the mainshaft step must not be damaged by
impact or by falling against the bottomshell. The dust seal ring
may otherwise be damaged when the shaft is lowered.

To reduce the risk of injury to personnel and of damage to


Caution !! components, use the inspection holes in the bottomshell to
check that the dust seal ring is properly centred and slides
correctly down over the dust collar.

It will be easier to move the dust seal ring to the correct position if
the shaft is rotated when the ring is to go over the dust collar.
When the dust seal ring nears the dust collar, great care must be
taken to ensure that the seal ring glides correctly over the dust
collar. When the dust seal ring has come onto the dust collar the
rotation of the mainshaft should be stopped to prevent dislocation
of the step washer.
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12. Mainshaft assembly & mantle 2002-12-15

12.8 Headcentre

Before making repairs on the headcentre, contact Sandvik Rock


Note ! Processing.

The headcentre is shrunk onto the mainshaft at the factory.

To establish that the shrink fit is still sound, check the displacement of the headcentre by
measuring dimension "B" from the top of the headcentre to the top of the shaft. See Fig.
12.8.1.

The measured dimension "B" must correspond to the larger of the dimensions stamped into
the top end of the shaft (the smaller dimension indicates the position of the headcentre before
shrinking).

In addition, check the fit at the larger end of the headcentre and mainshaft. There must be no
play.

If dimension "B" does not correspond to the stamped dimension, or if there are other signs
that the headcentre has come loose, contact Sandvik Rock Processing.

Figure 12.8.1 Headcentre displacement


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12. Mainshaft assembly & mantle 2002-12-15

12.9 Dust seal ring

The dust seal ring, which is supported beneath the headcentre, is free to move and is an easy
sliding fit on the dust collar. It is the most important seal for the crusher's oil system.

The dust seal consists of the dust seal ring and a retaining ring. The retaining ring is secured
in the headcentre by screws. See Fig. 12.9.2.

Removal

To remove the dust seal ring, lift the mainshaft out of the crusher and lay it on wooden
blocks. Remove the screws and then put four screws back into the threaded holes in the
retaining ring. Tighten these four screws to press out the retaining ring from the headcentre.
Support the retaining ring so that it cannot fall down and damage the mainshaft.

Inspection

Inspect the machined surfaces on the retaining ring and polish away any scratches and rust
which could otherwise damage the dust seal ring. The fit between the retaining ring and the
headcentre must be very tight. There must be no movement between these two components.

Check that the dust seal ring slides easily on the dust collar under
Note ! its own weight. If this is not the case, the hole in the dust seal ring
may have been deformed during transport or storage. Adjust the
ring so that it can easily be moved up and down on the dust collar.

The play between the dust seal ring and the dust collar must not exceed the value given in
Table 12.9.1.

Refitting

Tighten the retaining ring screws.

When reassembling, check that the dust seal ring can move freely between the headcentre and
the retaining ring.

Table 12.9.1. Maximum permissible play between dust seal ring and dust collar.

Crusher H/S Play (mm) Play (ins.)


2800 1.3 0.051
3800 1.3 0.051
4800 1.5 0.060
6800 1.8 0.071
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12. Mainshaft assembly & mantle 2002-12-15

1. Dust seal ring


2. Retaining ring
3. Retaining plate
4. Rubber scraper
5. Dust collar

Figure 12.9.2. Dust seal ring

12.10 Scraper

To prevent the accumulation of dust and material etc. on the outside of the dust collar, the
crusher has a scraper mounted on the underside of the retaining ring. See Fig. 12.9.2.

The scraper consists of a rupper flap and a retaining plate which is bolted to the bottom of the
dust seal ring retaining ring.

The purpose of the scraper is to ensure that there is always room for the downward movement
of the mainshaft assembly, e.g. if tramp iron enters the crusher.

Check the condition of the scraper at regular intervals through the inspection openings in the
bottomshell.

Never open the inspection covers when the machine is crushing.


Warning !!! Never put a hand inside when the crusher is running.
1800-Series Hydrocone crushers S 223.372.00 en 1 (23)

13. Bottomshell assembly 2001-11-15

13. Bottomshell assembly

Contents Page
13.1 Bottomshell assembly - nomenclature 2
13.2 General 3
13.3 Inner seal ring 3
13.4 Locating bar 4
13.5 Step bearing 5
13.6 Eccentric bushing 7
13.7 Dust collar 10
13.8 Eccentric assembly 11
13.9 Gear carrier and counterweight 13
13.10 Eccentric gear 14
13.11 Wearing plate 14
13.12 Bottomshell bushing 15
13.13 Hydroset piston 17
13.14 Hydroset cylinder 18
13.15 Chevron packing 19
13.16 Hydroset cylinder bushing 22
13.17 Preparation for automatic setting regulation 23
1800-Series Hydrocone crushers S 223.372.00 en 2 (23)

13. Bottomshell assembly 2001-11-15

13.1 Bottomshell assembly - nomenclature

1. Inner seal ring 10. Bottomshell bushing


2. Locating bar 11. Hydroset piston
3. Step bearing (mainshaft step/step washer/ 12. Hydroset cylinder
piston wearing plate 13. Chevron packing
4. Eccentric bushing 14. Hydroset cylinder bushing
5. Dust collar 15. Seating ring
6. Eccentric assembly 16. Lubrication oil outlet
7. Gear carrier and counterweight 17. Lubrication oil inlet
8. Eccentric gear 18. Hydroset connection
9. Wearing plate 19. Key
20. Retaining ring

Figure 13.1.1
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13. Bottomshell assembly 2001-11-15

13.2 General

The bottomshell and the Hydroset cylinder can be regarded as a single unit since the Hydroset
cylinder need not normally be removed. Almost all service work can be carried out from
above when the topshell and mainshaft have been removed.

On the outside of the bottomshell are two inspection holes through


Warning !!! which the dust seal ring and dust collar can be inspected and
checks can be made on liner condition and oil leakage. Do not
open the covers while the machine is crushing. Do not put a hand
inside while the crusher is running.
Use amply dimensioned lifting equipment, strops etc. Take great
care to avoid damaging bearing surfaces and components.
Before any work is carried out inside the crusher, drain out the oil by breaking the oil inlet
line at a suitable point.

13.3 Inner seal ring

The inner seal ring is intended to prevent dust entering the bearings and to prevent oil from
the eccentric bushing splashing over the dust collar. See Fig. 13.1.1.

Removal

When the mainshaft has been lifted out, the inner seal ring remains in the dust collar.

Inspection

Clean the inner seal ring and make sure that the drain holes in the dust collar are free from
obstructions.

Check that the ring rests horizontally on the seating ring which, in turn, should lie flat in the
dust collar. See Fig. 13.4.1

H2800 and S2800 crushers have no seating ring - the inner seal ring rests on the dust collar
itself.

The play between the inner seal ring and the shaft must not exceed 2.5 mm (0.10 ins.).

Refitting

Place the inner seal ring on the mainshaft and keep it in place by hanging it askew.

When the lower part of the shaft has entered the eccentric bushing, free the inner seal ring
with a light blow so that it drops down into position in the dust collar.
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13. Bottomshell assembly 2001-11-15

13.4 Locating bar

The locating bar, which is attached by screws to the underside of the dust collar, acts as a stop
for the gear carrier to prevent upward movement caused by forces in the bevel gears.

Inspection

Measure the clearance "S" between the locating bar and the gear carrier with a feeler gauge
when the inner seal ring and the bushing retaining ring have been removed. This clearance is
the same for all ”1800-series” crushers. Normally it is 0.2 mm (0.008 ins.), whilst the
maximum permissible clearance is 0.4 mm (0.016 ins.). See Fig. 13.4.1.

The clearance is adjusted by removing or adding shims (T) between the locating bar and the
dust collar.

When the gear backlash is adjusted, the locating bar clearance should be checked.

Refitting

When refitting the locating bar, tighten the screws to the value given in Section 2.8.5.

1. Inner seal ring


2. Seating ring
3. Bushing retaining ring
4. Dust collar
5. Shim
6. Locating bar
7. Gear carrier

Figure 13.4.1 Locating bar


1800-Series Hydrocone crushers S 223.372.00 en 5 (23)

13. Bottomshell assembly 2001-11-15

13.5 Step bearing

We recommend that you inspect the step bearing components in conjunction with liner
changes and renew the bearing components at intervals which are based on experience.

If wear on the step bearing components is severe, see Section 18 -


Note ! Fault tracing.

Removal

The step bearing components can be lifted up through the eccentric bushing with the help of
the special lifting hook included in the toolkit supplied with the crusher. See Fig. 13.5.1. Take
care to avoid damaging or scratching the eccentric bushing. The mainshaft step is retained on
the bottom of the mainshaft by a circlip.

Since the step bearing components are normally covered in oil


Note ! they may stick together and to the top of the Hydroset piston. For
this reason, lift carefully and check that no sticking occurs.

1. Mainshaft step
2. Lifting hook
3. Step washer
4. Piston wearing plate

Figure 13.5.1 H&S 2800/3800/4800/6800 Hydrocones


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13. Bottomshell assembly 2001-11-15

The piston wearing plate rests on the Hydroset piston and is located by a recess in the middle
of the piston. An offset dowel prevents rotation on the piston. The step washer lies loose on
the piston wearing plate and comes out with the latter when it is removed.

Inspection

The mainshaft step and the piston wearing plate are made of a bronze with a high lead
content, and this can sometimes lead to a temporary blackening of the rubbing surfaces. The
step washer is made of steel and thus does not normally need replacement each time the
mainshaft step and piston wearing plate are changed. If the step washer is to be used again it
must be checked against the mainshaft step and the piston wearing plate. The maximum play
between the step bearing components is 0.05 mm (0.002 ins.). Continual trouble with the step
bearing indicates that the crusher is overloaded or that the oil is contaminated.

The step bearing components should be removed from the crusher at regular intervals for
inspection of the oil grooves. The mainshaft step and the piston wearing plate have oil
grooves in the rubbing surfaces which lie against the step washer. If the grooves have sharp
edges against the bearing surfaces, chamfer them off 1-2 mm (0.04-0.08 ins.) with a belt
grinder, for example. See Fig. 13.5.4.

When the total thickness of the step bearing (dimension H) is reduced to below the value
given in Table 13.5.2, the mainshaft step and the piston wearing plate must be replaced. This
corresponds approximately to the depth of the oil grooves.

Table 13.5.2. Thickness of step bearing

Crusher Dim. "H" (mm) Dim. "H" (ins.)


New Worn New Worn
H2800 73 63 2.87 2.48
S2800
H3800 85 73 3.35 2.87
S3800
H4800 110 95 4.33 3.74
S4800
H6800 125 108 4.92 4.25
S6800

Figure 13.5.3
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13. Bottomshell assembly 2001-11-15

1. Chamfers
2. Oil groove

Figure 13.5.4 Oil grooves

Assembly

Clean and degrease the rubbing surfaces. Coat the bearing surfaces with a thin layer of
molybdenum disulphide grease. Do not use too thick a coat and keep the grease out of the oil
grooves to avoid obstructing oil circulation.

Make sure that the dowels in the Hydroset piston and the mainshaft enter the corresponding
holes in the piston wearing plate and the mainshaft step but do not "bottom" in the holes.

The step washer must be turned so that its flat surface lies against the piston wearing plate.

Place the mainshaft step and the retaining circlip on the bottom end of the mainshaft. Check
that the mainshaft step can move slightly on the end of the mainshaft.

The step bearing components can also be changed from below if the Hydroset cylinder cover
and the Hydroset piston are removed. See Fig. 13.15.3 and read the adjacent text.

13.6 Eccentric bushing

The eccentric bushing is part of the eccentric assembly and it is held in place by a retaining
ring and a key. See Fig. 13.1.1.

The eccentric throw of the crusher is altered by rotating the bushing in the bore of the
eccentric or by changing the eccentric bushing.

The throw (in mm) is stamped into the top edge of the bushing
Note ! near the relevant keyway together with the letter H for an H-type
or letter S for a S-type. (e.g. H-32 or S-32). An arrow stamped
into the top of the eccentric bushing key way indicates which
eccentric throw has been set.

An eccentric bushing intended for a S-type cannot be used in an


H-type crusher, or vice-versa.

For details of the play between the mainshaft and the eccentric bushing, see Section 12.7 -
Mainshaft.
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13. Bottomshell assembly 2001-11-15

Removal

Lift out the mainshaft.

Lift out the inner seal ring and the seating ring, (if fitted).

Remove the eccentric bushing retaining ring from the top of the eccentric. See Fig. 13.4.1. In
the case of an H4800, H6800, S4800 or S6800, this ring is in two parts, of which only the
part locking the eccentric bushing need be removed. The bushing can then be withdrawn
from the eccentric with the help of the special lifting tool in the toolkit supplied with the
crusher (in principle as when lifting the bottomshell bushing - see Fig. 13.12.1).

If the bushing is a tight fit, the whole eccentric assembly must be removed. See Section 13.8.
The bushing can then be driven out from the eccentric with a wooden block and a hammer.
Protect the bearing surface on the upper side of the gear carrier from damage.

If the bushing cannot be driven out in this way, it must be pressed out with a hydraulic jack,
as shown in Fig. 13.6.1.

1. Eccentric 2. Wooden blocks 3. Reaction beam


4. Plate 5. Eccentric bushing

Figure 13.6.1 Eccentric bushing


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13. Bottomshell assembly 2001-11-15

If the mainshaft and mantle have rotated at the same speed as the eccentric during operation.
it is probable that the eccentric bushing has seized on the mainshaft. In this case the mainshaft
cannot be lifted out in the normal way.

The dust collar must be freed so that the mainshaft and eccentric assembly can be lifted out.

Try to take out the screws which clamp the eccentric bushing retaining ring to the top of the
eccentric.

If this proves to be impossible, try to push the eccentric downwards. If this cannot be done,
the dust collar must be destroyed. The eccentric can then be removed from the shaft and
bushing.

Inspection

Before fitting a new bushing, inspect the bore of the eccentric. It must be smooth and must
not be oval or conical. Any ovality or conicity must be corrected by scraping or grinding the
bore of the eccentric with a belt grinder.

The maximum permissible play between the eccentric bushing and the eccentric is
0.22 mm (0.009 ins.) for H & S 2800, 3800 and 4800 crushers and 0.25 mm (0.010 ins.) for
H & S 6800 crushers.

If a serious seizure occurs between the mainshaft and the eccentric bushing, the resultant high
temperature can lead to so-called heat cracks (reminiscent of fish scales) on the bearing
surface of the mainshaft. These heat cracks are narrow vertical lines – 3-5 mm
(0.125-0.2 ins.) long – which can be difficult to discover. If they are not dealt with, there is a
major risk of a new failure. Contact Sandvik Rock Processing for information on suitable
corrective measures.

Refitting

Make sure that the key is in place in the correct keyway in the bushing before it is installed in
the eccentric.

Coat the outer surface of the eccentric bushing with oil.

Under certain circumstances the bushing can become distorted. In such a case it may be
necessary to press the bushing into place. Never hit the bronze bushing.

The top edge of the eccentric bushing must not lie above the top of the eccentric. Measure the
bore of the bushing to check that it is round and straight.

Fit the eccentric bushing retaining ring which locks the eccentric bushing in the eccentric.
Tighten the screws to the correct torque, (see Section 2.8) and lock them with a locking fluid
(see Section 2.8.7)
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13. Bottomshell assembly 2001-11-15

13.7 Dust collar

It is not normally necessary to remove the dust collar unless the eccentric assembly is to be
taken out.

Removal

If the dust collar is to be removed, great care must be taken to avoid damage to the underlying
gasket. Use the full-length threaded screws to press the dust collar off the bottomshell.

To avoid upsetting the dust collar, use a four-part lifting sling in


Caution !! eyebolts, (Item 3 in Fig. 13.7.1).

Inspection

If the dust collar has worked loose and turned so that the fit against the bottomshell has been
destroyed, contact Sandvik Rock Processing. Check that the outer surface of the dust collar
has not been worn or damaged in such a way that dust can penetrate between the dust collar
and the dust seal ring.

Refitting

When the dust collar is to be refitted, make sure that the holes in the gasket line up with the
corresponding holes in the bottomshell. Make sure that the locating dowel in the bottomshell
lines up with the corresponding hole in the dust collar so that the locating block is positioned
above the pinion.

1. Dust collar
2. Gasket
3. Lifting eyes (4x)

Figure 13.7.1 Dust collar


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13. Bottomshell assembly 2001-11-15

13.8 Eccentric assembly

The eccentric assembly consists of the eccentric, the gear carrier and counterweight, the
eccentric bushing and the eccentric gear. The assembly is supported by the wearing plate
which is mounted on the bottomshell. See Fig. 13.1.1.

Removal

Remove the dust collar and then screw three lifting eyes into the
Note ! threaded holes in the top of the gear carrier. Lift the eccentric
assembly about 10 mm. Check with a screwdriver through the
hole in the gear carrier that the wearing plate remains in place in
the bottomshell. See Fig. 13.8.1

The eccentric assembly can then be lifted out. Take great care to
avoid damaging the bottomshell bushing.

Older crushers have no threaded holes in the top of the gear


carrier. In such a case, first remove the eccentric bushing retaining
ring and then raise the eccentric unit with the help of four lifting
holes in the top of the eccentric.

1. Checking hole in gear carrier

Figure 13.8.1 Eccentric assembly


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13. Bottomshell assembly 2001-11-15

If the eccentric has seized in the bottomshell bushing, it will be impossible to rotate the
crusher pulley. The bottomshell bushing and the wearing plate will then follow with the
eccentric assembly when it is lifted out. The bottomshell bushing - which has already been
seriously damaged on its bearing surface - must in some cases be split in order to remove it.

Inspection

Examine the eccentric to see if the wearing surfaces are scratched or have been subjected to
heavy wear or excessive temperature. Examine also the wearing plate, see Section 13.11
below. Inspect the inner surface of the eccentric bushing as well. Look especially for wear,
scratches or dark spots which can indicate that the bushing has been subjected to high
temperatures.

If a serious seizure occurs between the eccentric and the bottomshell bushing, the resultant
high temperature can lead to so-called heat cracks (reminiscent of fish scales) on the bearing
surface of the eccentric. These heat cracks are narrow vertical lines – 3-5 mm
(0.0125-0.2 ins.) long – which can be difficult to discover. If they are not dealt with, there is a
major risk of a new failure. Contact Sandvik Rock Processing for information on suitable
corrective measures.

Refitting

Coat the outer surface of the eccentric with oil. Take great care
Note ! when the eccentric is being lowered into the bottomshell bushing
to avoid damage to the latter. Just before the eccentric reaches its
final position, rotate the crusher pulley slightly in both directions
while lowering the eccentric carefully. This will ensure that the
eccentric gear and the pinion mesh correctly.
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13. Bottomshell assembly 2001-11-15

13.9 Gear carrier and counterweight

Removal

The gear carrier is an interference fit on the eccentric and must therefore be pressed off. See
Fig. 13.9.1.

1. Gear carrier 2. Eccentric 3. Key


4. Wooden blocks 5. Reaction beam 6. Plate

Figure 13.9.1

Inspection

Examine the bearing surfaces for signs of damage.

Refitting

Heat the gear carrier to a temperature about 50°C (90°F) above the temperature of the
eccentric and mount it on the eccentric. Make sure that the key is correctly installed and that
the gear carrier butts correctly against the shoulder on the eccentric when the components
have cooled down.
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13. Bottomshell assembly 2001-11-15

13.10 Eccentric gear

Removal

Three threaded holes are provided in the gear carrier. Use press screws in these holes to
remove the gear.

Inspection

Examine the tooth "footprint" and look for signs of wear. See Section 15 - Bevel gears.

Refitting

Pull the gear onto the carrier with the attachment screws until it lies flush against the seating
on the carrier. It is important that these screws are correctly tightened since there is no key in
the assembly. Tighten the screws to the correct torque. See Section 2.8 (2.8.6).

13.11 Wearing plate

The wearing plate upon which the eccentric assembly is supported is designed so that it
absorbs the rotating moment from the bottomshell bushing. The wearing plate is locked to the
bottomshell by dowels. See Fig. 13.12.1.

Inspection

Examine the protrusions which lock the bottomshell bushing and grind off any minor
deformation so that good contact is obtained in the cut-outs at the top of the bushing.

The wearing plate must be replaced if the correct play cannot be maintained when the gear
backlash is adjusted. It must however be replaced when it has been worn to the minimum
thickness shown in Table 13.11.1.

Table 13.11.1 Wearing plate

Crusher Min. wearing plate Min. wearing plate


thickness (mm) thickness (ins.)
H2800 18 0.71
S2800
H3800 23 0.91
S3800
H4800 25 0.98
S4800
H6800 23 0.91
S6800
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13. Bottomshell assembly 2001-11-15

13.12 Bottomshell bushing

Removal

The fit between the bushing and the bottomshell is such that the bushing can normally be
lifted out easily.

The bushing expands due to friction heat and there must therefore be enough room for this.

The bushing must be pulled from its seating with the help of a special lifting tool which is
positioned beneath the bottom edge of the bushing. This lifting tool is included in the toolkit
supplied with the crusher. This tool is not intended for lifting the bushing out from the
crusher. Use the lifting eyes supplied. Note! The lifting eyes are not designed to pull the
bushing from its seating. See Fig. 13.12.1.

1. Wearing plate 3. Bottomshell bushing 5. Lifting eye


2. Dowel 4. Lifting tool

Figure 13.12.1 Bottomshell assembly


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13. Bottomshell assembly 2001-11-15

Inspection

The play between the eccentric and the bottomshell bushing is found by measuring the
diameters with suitable micrometers. See Table 13.12.2.

Table 13.12.2

Crusher Bottomshell bushing Bottomshell bushing


Nominal bore dia.(mm) Nominal bore dia.(ins.)
H2800 350 13.78
S2800
H3800 420 16.54
S3800
H4800 510 20.08
S4800
H6800 600 23.62
S6800

If the eccentric is remachined, the maximum play must not exceed the value given in Table
13.12.3.
Table 13.12.3 Max. permissible play between eccentric and bottomshell bushing

Crusher Max. play (mm) Max. play (ins.)


H2800 1.3 0.051
S2800
H3800 1.5 0.060
S3800
H4800 1.7 0.067
S4800
H6800 1.9 0.075
S6800

If the bearing surfaces have worn evenly, a larger play is permissible as long as neither
component is to be replaced.
Before fitting a new bushing, inspect the hole in the bottomshell. It must be smooth and must
not be oval or conical. If the new bushing cannot be installed with a light push fit, it must not
be forced into place. Any ovality or conicity caused by hot running must be corrected by
scraping or grinding with a belt grinder in the bore of the bottomshell. The maximum
permissible play between the bottomshell and the bottomshell bushing is 0.22 mm (0.009
ins.) for the H & S 2800, 3800 and 4800, 0.25 mm (0.010 ins.) for the H & S 6800. If the
bore of the bottomshell is round, a slightly oval bushing can be carefully pressed down into
place.
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13. Bottomshell assembly 2001-11-15

Refitting

Since the lugs on the wearing plate are fixed in relation to the bottomshell, the bottomshell
bushing must be rotated to a position where its cut-outs match the wearing plate protrusions.
The flange around the top of the bushing must butt against the top of the bottomshell hub.

13.13 Hydroset piston

At the bottom of the piston is the chevron packing, held in place by a clamping ring.

In the upper part of the piston there is an oil groove fed with oil by narrow oil channels on the
outside of the piston. This provides lubrication for the upper part of the piston and prevents
dirt falling down between the piston and the Hydroset bushing.

The lubrication oil enters the crusher through the wall of the Hydroset cylinder and flows
through the Hydroset piston and up through the step bearing.

Removal

The Hydroset piston can be removed from above or below.

Before taking out the piston, disconnect the lubricating oil supply
Note ! line and raise the piston far enough to allow all of the oil inside
the piston to drain out. When this has been done, lower the piston
to its lowest position and disconnect the Hydroset line.

The piston can be lifted out with the help of the two lifting eyes included in the toolkit
supplied with the crusher.

If the piston is to be removed downwards, follow the directions given in Section


13.15 - Chevron packing.

Inspection

Clean the piston and, if necessary, change the chevron packing. Inspect the outer surface of
the piston. Inspect also the bore of the Hydroset cylinder bushing, as described below in
Section 13.16 - Hydroset cylinder bushing.
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13. Bottomshell assembly 2001-11-15

Refitting

Coat the rubbing surfaces of the piston and Hydroset cylinder bushing with molybdenum
disulphide before refitting the piston.

Carefully lubricate the sealing lips of the chevron packing. Take care to avoid damaging the
sealing lips of the chevron packing when the piston is lowered into the Hydroset cylinder and
into the Hydroset cylinder bushing.

If a new chevron packing has been fitted it may be difficult to push the piston down into the
bushing. If this is the case, install the step bearing components and use the mainshaft as a
weight to press the piston carefully down into the bushing.

The position sensor must be removed before the piston is fitted


Note ! from above as the position sensor can otherwise be damaged.

13.14 Hydroset cylinder

The bottomshell and Hydroset cylinder are separate units.

There is normally no reason to remove the Hydroset cylinder from the bottomshell.

The joint between the Hydroset cylinder and the bottomshell is sealed with an O-ring and
unless severe leakage occurs it very seldom needs changing. See Fig. 13.1.1. Regarding the
tightening of the screws, see Section 2.8 (2.8.3).

If the Hydroset cylinder is to be taken off, use the lowering rods in the toolkit supplied with
the crusher.
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13. Bottomshell assembly 2001-11-15

13.15 Chevron packing

If only the chevron packing is to be changed, the job can most conveniently be done from
below. See Fig. 13.15.1.

Removal

Disconnect the lubricating oil supply line and raise the Hydroset piston far enough to allow
the oil inside the piston to drain out.

If the mainshaft has not been removed, lower it to the bottom of


Caution !! its travel and then raise it slightly. Block up with timber beneath
the headcentre, on top of the arms in the bottomshell, and lower
the mainshaft onto the blocks. Make sure that the shaft rests
securely on the blocks. The mainshaft must not rest on the dust
collar inside the headcentre or on the dust seal ring. This is
prevented by the blocking-up, which also eliminates the risk of oil
remaining under pressure when the Hydroset line is disconnected.

Disconnect the Hydroset line and drain out the oil.

Use the lowering rods and piston retainer which are included in the toolkit supplied with the
crusher to lower the Hydroset cylinder cover. When the groove - about 90 mm (3.5 ins.) from
the bottom of the piston - becomes visible, fit the piston retainer, as shown in Fig. 13.15.1.
Use one of the screws which clamps the Hydroset cylinder cover to the Hydroset cylinder.
Make sure that the piston retainer is correctly aligned and is securely engaged in the
circumferential groove on the piston.

When the piston retainer is in position, lower the Hydroset cylinder cover so far that there is
room to take out the screws which hold the chevron packing clamp plate.

Place two of the lowering rods so that there is room between them
Note ! for removal of the piston if this proves necessary. The piston has a
boss which enters a recess in the Hydroset cylinder cover when
the piston is in its lowest position. See Fig. 13.1.1. For this reason
it is necessary - if the piston is to be taken out - to lower in stages
and use timber blocks.

Inspection

Examine the chevron packing for damage. Remember that it must withstand a pressure of up
to 20 MPa (2900 psi). If damage is found on the surface which seals against the cylinder
bushing, the piston must be removed so that the bushing can be examined.
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13. Bottomshell assembly 2001-11-15

Refitting

Oil each ring of the packing and oil also the piston and the cylinder bushing.

Fit the packing on the piston as shown in Fig. 13.15.2. The sealing lips must point
downwards. Make sure that the clamp plate is pulled up tight against the piston so that the
packing is compressed slightly. Since the chevron packing is designed for the dimensions of
its seating, it will be correctly clamped first when it (and the piston) have been installed in the
Hydroset cylinder bushing.

A. Removal upwards
B. Removal downwards, using the piston retainer (3).

1. Lifting eye 2. O-ring 3. Piston retainer


4. Chevron packing 5. Packing clamping plate 6. O-ring
7. Hydroset cylinder cover 8. Lowering rod

Figure 13.15.1 Removal of Hydroset piston


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13. Bottomshell assembly 2001-11-15

Assemble the various components in the crusher in the reverse of the order of removal. Take
great care to avoid damaging the sealing lips when inserting the packing into the Hydroset
cylinder bushing.

Always renew the O-ring between the Hydroset


Note ! cylinder and the cylinder cover.

Tighten the cover plate screws to the correct torque. See Section 2.8 (2.8.4).

1. Chevron packing

Figure 13.15.2 Chevron packing

If the piston is removed completely, inspect the step bearing components and if necessary
replace them. See Fig. 13.5.4. The bore of the Hydroset cylinder bushing can also be
inspected.
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13. Bottomshell assembly 2001-11-15

1. Mainshaft step 2. Hydroset cylinder bushing


3. Locking screw 4. Lowering rod
5. Washer 6. O-ring

Figure 13.15.3 Removal of mainshaft step

13.16 Hydroset cylinder bushing

The Hydroset cylinder bushing is a short bushing in the lower section of the Hydroset
cylinder, where the chevron packing seals.

The Hydroset cylinder bushing is locked in position by a small screw and washer beneath the
bottom edge of the Hydroset cylinder. This screw also locates the Hydroset cylinder cover so
that the Hydroset line always lies beneath one of the bottomshell arms.

The Hydroset cylinder bushing provides a sealing surface in the lower part of the Hydroset
cylinder. Together with the Hydroset piston, the chevron packing and the Hydroset cylinder
cover it functions as a hydraulic cylinder.

In the upper part of the Hydroset cylinder there is no bushing. The top of the Hydroset piston
is located by the inner surface of the cylinder. See Fig. 13.1.1.
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13. Bottomshell assembly 2001-11-15

Removal

When the Hydroset piston has been removed - as shown in Fig. 13.15.1 - the bushing can also
be removed with the help of the lowering rods and the Hydroset cylinder cover.

Inspection

Inspect the inner surface for scratches or unevenness. There must be no damage on the
bushing. Scratches or unevenness can easily allow oil to leak past the chevron packing and
thus allow the setting (CSS) to increase.

Inspect also the upper part of the Hydroset cylinder - above the bushing - which acts as a
locating surface for the piston. Polish away any scratches or unevenness in this area.

Assembly

Fit the O-ring and prepare the contact faces of the Hydroset cylinder and the bushing with
molybdenum disulphide. Press the bushing into the cylinder and lock it in position with the
screw at the bottom of the bushing. Fit the step bearing components, the piston, the O-rings
and the Hydroset cylinder cover, as described in Section 13.15 above.

Always renew the O-rings on the Hydroset cylinder cover and


Note ! between the Hydroset cylinder bushing and the Hydroset cylinder.

13.17 Preparation for Automatic Setting Regulation

If no automatic setting regulation system is fitted to the crusher, the holes required for the
installation of ASR components are plugged. No extra measures need be taken during normal
removal or refitting of the Hydroset cylinder assembly components.

If the crusher is fitted with ASR, information about the installation and maintenance of the
regulation components fitted to the crusher is given in a separate instruction manual.

Regarding tightening torques for the mainshaft position sensor and the adapter, see Section
2.8.
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14. Pinionshaft assembly 2001-11-15

14. Pinionshaft assembly

Contents Page
14.1 Lubrication 2
14.2 Removal of complete pinionshaft assembly 2
14.3 Removal of pinionshaft 4
14.4 Refitting pinionshaft 8
14.5 Refitting complete pinionshaft assembly 9
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14. Pinionshaft assembly 2001-11-15

14.1 Lubrication

The pinionshaft assembly forms a complete unit with separate lubrication.

The H2800, H3800, S2800 and S3800 have oil-bath lubrication. The oil level is checked
and topped up with the help of a level tube and a filler plug. The H4800, H6800, S4800
and S6800 have a circulatory lubrication system.

The circulatory system is designed so that a constant flow of oil is pumped from the tank
unit to the pinionshaft housing.

A level tube maintains a constant level in the pinionshaft housing whilst excess oil runs
back to the tank through the main return hose.

For more information, see Section 6 - Lubrication system and Section 9.4 - Pinionshaft
lubrication.

14.2 Removal of complete pinionshaft assembly

Check the gear backlash. See Section 15.

Measure the distance between the flange of the pinionshaft housing and the bottomshell
with a feeler gauge. There is a recess in the edge of the gasket to facilitate this
measurement. Write down the resulting dimension as this information will be useful if the
gasket is damaged when the pinionshaft assembly is withdrawn from the crusher.

Check the axial play in the bearings by pulling the crusher pulley outwards. Abnormally
large play can be an indication that a bearing replacement is necessary. Use a dial gauge for
this check.

Remove the magnetic plug or level tube in the bottom of the pinionshaft housing and drain
out the oil. Check to see if there is metal swarf or similar on the magnetic plug. If this is the
case, the pinionshaft bearings have probably been damaged.

Remove one of the mesh adjustment screws and the screws which retain the pinionshaft
assembly in the bottomshell. See Fig. 15.3.3.

Place a sling around the end of the pinionshaft housing and lift until the sling is tight.

Pull the pinionshaft housing out from the bottomshell.

Place the pinionshaft assembly on a pair of trestles.


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14. Pinionshaft assembly 2001-11-15

01.
Fille
r tube: H2800, H3800, S2800, S3800
Oil inlet: H4800, H6800, S4800, S6800

02. Level tube/oil outlet: H4800, H6800, S4800, S6800

03. Magnetic plug: H4800, H6800, S4800, S6800

04. Level tube: H2800, H3800, S2800, S3800

Figure 14.2.1 Pinionshaft lubrication connections


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14. Pinionshaft assembly 2001-11-15

14.3 Removal of pinionshaft

4800 crushers have seal rings made of fluorinated rubber. If they


Warning !!! have been exposed to extreme heat (burnt), they must be treated
in the same way as corrosive acid.

Remove the screws between the crusher pulley and the tapered bushing.

Put screws in the threaded holes in the crusher pulley and tighten them so that the pulley
comes loose.

Remove the pulley, the retaining washer, the tapered bushing and the key.

Remove the pinion in the following way:

Take off the locking ring.

Mount a robust extractor as shown in Figs. 14.3.2 and 14.3.3. If the pinion cannot be
removed with just the extractor, heat the pinion while the extractor is tightened.

Take great care when the pinion heats up and comes loose.
Caution !!

An H3800, H4800, H6800, S3800, S4800 or S6800 has a special bearing cover with a lip
for an extractor. See Fig. 14.3.3. In the case of an H2800 or S2800, pull off the pinion in
the manner shown in Fig. 14.3.2. Protect the teeth with a plate beneath the larger end of the
pinion.

Before the pinionshaft, bearings and spacers can be taken out from the pinionshaft housing,
the level tube (Fig. 14.2.1) must be removed, as described on page 7.

When this has been done, the pinionshaft - with bearings and spacers - can be removed.
See Fig. 14.3.1.

Carefully heat the spacers and remove them - and the bearings - from the shaft.

Great care must be taken and cleanliness is vital when work is


Caution !! carried out on the bearings. Never let bearing components lie
unprotected.
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14. Pinionshaft assembly 2001-11-15

H2800, H3800, H4800, H6800,


S2800, S3800, S4800 and S6800

1. Spacer
2. O-ring
3. Inner bearing
4. Pinionshaft
5. Outer bearing
6. Key
7. Key
8. Locking ring
9. Pinion
10. Bearing cover
11. Level tube
(H2800, H3800,
S2800, S3800)
12. Pinionshaft housing
13. Bearing cover
14. Tapered bushing
15. Retaining washer
16. Crusher pulley
17. Seal ring

Figure 14.3.1
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14. Pinionshaft assembly 2001-11-15

Figure 14.3.2 Removal of pinion (H2800 and S2800)

Figure 14.3.3 Removal of pinion (H/S3800, H/S4800 and H/S6800)

Remove the key. Make sure there are no burrs on the end of the pinionshaft.

Take out the screws and remove the two bearing covers.
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14. Pinionshaft assembly 2001-11-15

Removal of level tube

H2800, H3800, S2800 and S3800

The level tube is screwed into the bottom of the pinionshaft housing near the outer bearing.
See Fig. 14.2.1 - item 04. Unscrew the filler tube with the level plug and TREDO seal ring.

H4800, H6800, S4800 and S6800

The level tube is located near the inner bearing and is removed as described below:

Pull out the short discharge tube and take out the level tube. The level tube has a threaded
hole at the bottom for an M8 extractor screw. The level tube must be taken out before the
shaft can be pulled out in the direction of the arrow. See Fig. 14.3.4.

01. O-ring 04. Discharge tube


02. Steel wire 05. O-rings
03. Hole for removal 06. Extractor screw

Figure 14.3.4 Level tube


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14. Pinionshaft assembly 2001-11-15

14.4 Refitting pinionshaft

The work must be carried out indoors, in a clean environment.


Caution !! When heating bearings and components which are to be shrunk
into place, use an oil bath or an oven. Open flame must be
treated with great care since there is an obvious risk of
overheating or localized heating.

Heat the bearings and spacers to max. 100°C (212°F).

When heating bearing components, check the temperature with a


Caution !! thermometer, or other equipment recommended by the bearing
manufacturer.

Fit the components in the reverse of the removal sequence. Remember to fit new O-rings
between the spacers and the shaft (and also on the inner level tube of an H4800, H6800,
S4800 or S6800).

To avoid damage to the O-rings when they are being fitted onto the pinionshaft, remove all
sharp edges from keyways and locking ring grooves. Oil the surfaces over which the
O-ring is to be fitted. Place the O-ring in the recess in the spacer. Make sure that it is not
squashed or damaged.

The spring-loaded lips of the inner and outer seals must point towards the pinion.

Lock the bearing cover screws with a locking fluid. See Section 2.8 (2.8.7).

Heat the pinion to 130°C (266°F) and mount it, with the key, on the pinionshaft.

Mount the crusher pulley on the shaft. Tighten the central washer's retaining screw hard
before pulling the pulley up onto the tapered bushing.
1800-Series Hydrocone crushers S 223.373.00 en 9 (9)

14. Pinionshaft assembly 2001-11-15

14.5 Refitting complete pinionshaft assembly

If a new pinionshaft housing is to be fitted, or if the pinionshaft, gears or inner spacer have
been changed, you must check the gear backlash and the tooth bearing footprint, as
described in Section 15.

Refitting is the reverse of the removal sequence.

Fit a gasket of the correct thickness between the pinionshaft flange and the bottomshell (as
measured previously during removal, see Sections 14.2 and 15.2, Table 15.2.2).

Push the pinionshaft assembly into the bottomshell. When it nears its correct position,
slowly turn the shaft backwards and forwards so that the pinion meshes correctly with the
eccentric gear.

Put the retaining screws back into position in the bottomshell.

Install the mesh adjustment screw(s).

Tighten the screws which retain the pinionshaft assembly in the bottomshell.

Check the backlash in the gears. See Section 15.

Fit the oil inlet line and the other components of the circulatory lubrication system (if
applicable).

Fill the pinionshaft housing with oil up to the correct level. See Section 5.1 - Paragraph 8.
1800-Series Hydrocone crushers S 223.374.00 en 1 (9)

15. Bevel gears 2001-11-15

15. Bevel gears

Contents Page
15.1 General 2
15.2 Installing a complete pinionshaft assembly 2
15.3 Gear backlash 3
15.4 Tooth bearing "Footprint" 7
1800-Series Hydrocone crushers S 223.374.00 en 2 (9)

15. Bevel gears 2001-11-15

15.1 General

1800-Series Hydrocone crushers have spiral bevel gears. Under normal conditions, this
type of gear transmission is reliable and requires very little maintenance. The gear and
pinion are manufactured and marked as a matched set. For this reason, do not use a gear
from one set with a pinion from another set.

15.2 Installing a complete pinionshaft assembly

If the gear and pinion, pinionshaft housing etc. are to be replaced, or when a check was not
made on the thickness of the gasket between the pinionshaft housing flange and the
bottomshell during removal, the tooth bearing "footprint" and the backlash must be
adjusted. The thickness of the gasket can be calculated in accordance with the principle
shown in Fig. 15.2.1.

1. Wedge

Figure 15.2.1. Installing a complete pinionshaft assembly

Use a rod-type micrometer to measure dimension "A". Position the pinionshaft assembly
upright, resting on the crusher pulley. To compensate for the axial play in the bearings, drive
in a wooden wedge between the crusher pulley and the outer bearing cover. Then measure the
distance between the contact face of the pinionshaft flange (which seats against the
bottomshell) and the machined surface on the small end of the pinion. See Fig. 15.2.1.

Dimension "B" is stamped into the small end of the pinion.


Dimension "C" is stamped into the machined outer surface of the bottomshell.
1800-Series Hydrocone crushers S 223.374.00 en 3 (9)

15. Bevel gears 2001-11-15

The gasket thickness can then be calculated with the formula:


A + B - C = Gasket thickness.

Note that the calculated gasket thickness applies for compressed gaskets. See Table 15.2.2.

Table 15.2.2
Gasket thickness Gasket thickness Gasket thickness Gasket thickness
uncompressed (mm) compressed (mm) uncompressed (ins.) compressed (ins.)
0.5 approx. 0.3 0.020 approx. 0.012
0.8 approx. 0.5 0.030 approx. 0.020
1.5 approx. 0.9 0.059 approx. 0.035

Fit gaskets of the correct thickness, as determined by the calculation.

Slide in the pinionshaft assembly and rotate the shaft slowly backwards and forwards as the
pinion comes into mesh with the eccentric gear. Tighten the screws which clamp the
pinionshaft housing to the bottomshell. Check and - if necessary - adjust the backlash and the
tooth bearing "footprint".

When a new eccentric gear and pinion set is installed, the correct "toothprint" will be obtained
with the gasket thickness calculation described above.

15.3 Gear backlash

Table 15.3.2 gives the correct backlash for the bevel gears. These values are theoretically
calculated for reference during manufacture and installation of the gears.

Practical experience has shown that the nominal gear backlash can be exceeded - due to the
geometry of the installation - but the values given should be considered as a guide when
judging the condition of the gear and pinion. If problems are encountered, contact Sandvik
Rock Processing for advice. Correct backlash and tooth bearing "footprint" are essential if the
gears are to operate properly.

Inspection

Since there is a certain amount of play between the eccentric and the bottomshell bushing, the
backlash in the gears will vary in accordance with the position of the eccentric.

To correctly determine the backlash it is therefore necessary to make four measurements,


turning the pinion and rotating the eccentric gear through 90° between each measurement. The
average of these measurements is then taken as the actual backlash.

90° rotation of the eccentric corresponds to slightly less than one revolution of the crusher
pulley.
1800-Series Hydrocone crushers S 223.374.00 en 4 (9)

15. Bevel gears 2001-11-15

Due to the play in the pinionshaft bearings it is important that


Note ! the pulley and shaft are pulled outwards when the gear backlash
is measured. In addition, the screws that hold the pinionshaft
housing flange must be tight.

Since the backlash cannot be measured directly between the pinion and the eccentric gear, the
movement of the crusher pulley is measured and the backlash is calculated from this
measurement.

A dial gauge should be used for these measurements. If a dial gauge is not available, a set
square can be used. In this case, scribe marks are made on the pulley and the distance between
the marks is measured. See Fig. 15.3.1.

1. Set square
2. Dial gauge

Figure 15.3.1. Measuring backlash.

The following formula is used to check the backlash:

Crusher pulley Play in gears Crusher pulley


movement on = on pitch line x outer dia.
outer dia. Pinion pitch circle dia.

Example:
The H2800 Hydrocone has a crusher pulley with 385 mm o.d. What movement should be
measurable on the outer dia. of the crusher pulley?

See Table 15.3.2 for the correct backlash and then use the formula as shown below.

Maximum movement = 0.51 x 385 = Max. = 1.16 mm


on crusher pulley 170
outer dia.

Minimum movement = 0.41 x 385 = Min. = 0.93 mm


on crusher pulley 170
outer dia.

The standard crusher pulley diameters and the corresponding movements with correct gear
backlash are shown in Table 15.3.2.
1800-Series Hydrocone crushers S 223.374.00 en 5 (9)

15. Bevel gears 2001-11-15

Table 15.3.2 Hydrocone crushers

Crusher Pinion pitch Backlash on Crusher pulley Movement on outer


circle dia. pitch circle dia. outer dia. dia. of pulley with
mm (ins.) mm (ins.) mm (ins.) correct play
mm (ins.)
H2800 170 0.41 - 0.51 385 0.93 - 1.16
S2800 (6.7) (0.016 - 0.020) (15) (0.037 - 0.046)
H3800 180 0.60 - 0.80 385 1.28 - 1.71
S3800 (7.1) (0.024 - 0.031) (15) (0.050 - 0.067)
H4800 192 0.80 - 1.00 385 1.60 - 2.00
S4800 (7.6) (0.031 - 0.039) (15) (0.063 - 0.079)
H6800 255 0.89 - 1.14 510 1.78 - 2.28
(10.0) (0.035 - 0.045) (20) (0.070 - 0.090)
S6800 255 0.089 - 1.14 640 2.23 - 2.86
(10.0) (0.035 - 0.045) (25) (0.088 - 0.113)

Adjustment

Since the pinionshaft housing is eccentrically mounted, the backlash in the gears can be
adjusted by rotating the pinionshaft housing. See Fig. 15.3.3.

First slacken off the screws which retain the pinionshaft assembly. Release the gasket from the
flange on the pinionshaft housing. The gear backlash can then be adjusted as follows:

- Increase gear backlash by moving the adjusting lug downwards (=clockwise).


- Reduce gear backlash by moving the adjusting lug upwards (= anti-clockwise).
1800-Series Hydrocone crushers S 223.374.00 en 6 (9)

15. Bevel gears 2001-11-15

Decrease

Increase

Figure 15.3.3 Adjustment of backlash

When the correct backlash has been obtained, tighten the retaining screws and lock the
adjusting screws. Check the backlash one more time.

If the pinionshaft assembly is to be removed and the backlash is correct, take out only one of
the adjusting screws.

Use a feeler gauge to measure the thickness of the gasket


Note ! between the pinionshaft housing's flange and the bottomshell
before the attachment screws are loosened. There is a cut-out in
the edge of the gasket to facilitate measurement. New gaskets
may be needed. See Table 15.2.2.
1800-Series Hydrocone crushers S 223.374.00 en 7 (9)

15. Bevel gears 2001-11-15

15.4 Tooth bearing "Footprint"

The gear installation is correct only when the correct "footprint" and the correct backlash have
been obtained.

Checking the "footprint"

Spiral bevel gears are manufactured for operation with a certain tooth bearing "footprint". To
check the "footprint", apply Molykote Spray Rapid or marking blue to the teeth of the pinion.

Rotate/drive the crusher pulley in the correct direction so that the "footprints" show up clearly.
Ideal "footprints" are shown in Fig. 15.4.1 (H2800, H3800, H4800, S2800, S3800, S4800)
and Fig. 15.4.4 (H6800, S6800).

The ideal "footprint" is obtained when the contact mark is slightly high on the pinion and
slightly low on the eccentric gear.

Under light load, the length of the "footprint" is usually half the length of the teeth.

Normally, the "footprint" moves towards the "heel" (larger end) of the tooth under heavy load.
For this reason, the gears are adjusted so that the "footprint" lies nearer the "toe" (small end).

Adjustment

If the tooth bearing "footprint" differs from the ideal picture (shown in Fig. 15.4.1 and 15.4.4),
the gear tooth meshing can be adjusted by using gaskets of different thicknesses between the
flange of the pinionshaft housing and the bottomshell.

- If the "footprint" is at the larger end of the pinion (near the outside of the gear), move
the pinion outwards from the centre of the eccentric gear. To accomplish this, increase
the thickness of the gasket between the pinionshaft housing and the bottomshell. See
Fig. 15.4.2 (H2800, H3800, H4800, S2800, S3800 and S4800) and Fig. 15.4.5 (H6800
and S6800).

- If the "footprint" is at the smaller end of the pinion, (towards the inside of the gear)
move the pinion inwards towards the centre of the eccentric gear. This is accomplished
by reducing the gasket thickness. See Fig. 15.4.3 (H2800, H3800, H4800, S2800,
S3800 and S4800) and Fig. 15.4.6 (H6800 and S6800).
1800-Series Hydrocone crushers S 223.374.00 en 8 (9)

15. Bevel gears 2001-11-15

H2800, H3800, H4800, S2800, S3800 and S4800 Hydrocones

1. Pinion
2. "Footprint"
3. "Heel"
4. Eccentric gear
5. "Toe"

Figure 15.4.1

Figure 15.4.2

Figure 15.4.3
1800-Series Hydrocone crushers S 223.374.00 en 9 (9)

15. Bevel gears 2001-11-15

H6800 and S6800 Hydrocones


1. Pinion
2. "Footprint"
3. "Heel"
4. Eccentric gear
5. "Toe"

Figure 15.4.4

Figure 15.4.5

Figure 15.4.6
1800-Series Hydrocone crushers S 223.389.00 en 1 (4)

16. Drive arrangement 2001-11-15

16. Drive arrangement

Contents Page
16. Drive arrangement 2
Direction of rotation 2
Speed monitor 3
Belt tensioning 3
1800-Series Hydrocone crushers S 223.389.00 en 2 (4)

16. Drive arrangement 2001-11-15

16. Drive arrangement

Fixed guarding must be installed around the moving parts of the


Warning !!! crusher's drive system. Since the crusher has a V-belt drive, it
must be possible to check the tension in the belts. The guarding
must be designed so that it complies with the applicable safety
guarding regulations.

A V-belt drive is used as standard on H/S2800, 3800, 4800 and 6800 Hydrocone crushers
and a crusher pulley is fitted as standard.

Before the V-belts are fitted, the motor must be aligned so that the motor shaft and the
crusher's pinionshaft are parallel and the V-belts run at right-angles to the shafts.

The angle between the crusher's vertical centreline and the line joining the pulley centres
must not exceed 30° (preferably not more than 20-25°). See Fig. This applies for a crusher
supported on rubber compression mountings.

If the crusher is mounted rigidly, or if the motor and crusher are mounted on the same
frame, the motor can be placed where desired.

Direction of rotation

The crusher's V-belt pulley must rotate in the direction indicated


Caution !! by the arrow on the bottomshell. See Fig. 16.1. This is necessary
for the self-tightening action of the head nut.

H2800, S2800 H6800, S6800


H3800, S3800
H4800, S4800

Figure 16.1
1800-Series Hydrocone crushers S 223.389.00 en 3 (4)

16. Drive arrangement 2001-11-15

Speed monitor

To partially overcome the problems caused by slipping or broken V-belts, a speed monitor
should be fitted. It should be connected in such a way that the feed to the crusher is stopped
if the pinionshaft speed drops.

Belt tensioning

During the first few days of operation, the belt tension must be checked frequently since
new belts stretch. If the belts are not tensioned sufficiently, slipping can occur and belt life
will be reduced considerably.

The belt tension can be checked with a spring balance or a special instrument, a
Tensiometer or its equivalent. See Fig. 16.2. The belt tension can be determined with the
help of the deflection load. See Table 16.3.

l = deflection
W = belt span
F = deflecting load

Figure 16.2 Belt tension


1800-Series Hydrocone crushers S 223.389.00 en 4 (4)

16. Drive arrangement 2001-11-15

Table 16.3 Recommended deflection load (F)

F kp/belt (lbf/belt)
Belt profile Normal Max.
(newly fitted belts)
SPC 7 (15.4) 12.0 (26.5)
8V 9 (19.8) 14.0 (30.9)

1. Measure the belt span (W) in meters, as shown in Fig. 16.2.

2. Multiply the span by 1.5, to give the belt deflection (1) in cm.

3. Set the top side of the lower O-ring to the correct deflection in cm on the meter's
lower scale.

4. Push the upper O-ring up against the lower edge of the outer sleeve.

5. Press the meter against the belt in the middle of the span and press sufficiently hard
to bring the top side of the lower O-ring level with the belt alongside.

6. Remove the meter and read off the load (F) in kp (lbf) at the top side of the upper O-
ring. The correct load is obtained from Table 16.3, which is also reproduced on the
meter.

7. If the load is too low or too high on all of the belts, tighten or slacken them.
1800-Series Hydrocone crushers S 223.368.00 en 1 (5)

17. Routine maintenance 2001-11-15

17. Routine maintenance

Contents Page
17.1 General 2
17.2 Daily inspection 2
17.3 Weekly inspection 4
17.4 Yearly inspection 5
17.5 Checking manganese wear 5
17.6 Checks to be made before the topshell is removed 5
1800-Series Hydrocone crushers S 223.368.00 en 2 (5)

17. Routine maintenance 2001-11-15

17.1 General

Every crusher - and its extra equipment (such as an over-pressure dust sealing system) -
must be subjected to regular, systematic checks. This will result in fewer and smaller
repairs, less downtime and thus lower overall running costs.

Since crushers operate under widely differing conditions, it is impossible to recommend an


inspection and maintenance schedule applicable to all crushers. However, some kind of
regular inspection is necessary, for example in accordance with the schedule given below.

A new machine should first be inspected after a fairly short time


Note ! of operation. The intervals between inspections can then be
increased until a suitable frequency is found.

A written record must be kept. The crusher's operating conditions and loads, important
instrument readings, adjustments carried out and any repairs made should be noted down.
An example of such a record sheet is attached (S 223.405 en).

For tightening torques for threaded fasteners, see Section 2.8 - Tightening threaded
fasteners.

17.2 Daily inspection

1. Before starting the crusher

Check the oil level in the lubrication tank.

Check the oil level in the Hydroset tank.

Check that the shut-off valves between the tanks and pumps are fully open.

Check that no material has built up on the bottomshell arms.

2. After starting the lubrication pump

Check that lubricating oil returns to the tank and that the oil is clean.

Check that the oil lines do not leak.


1800-Series Hydrocone crushers S 223.368.00 en 3 (5)

17. Routine maintenance 2001-11-15

3. After starting the crusher

Check that the pinionshaft lubrication circuit is operating correctly (applies to H4800,
H6800, S4800 and S6800 crushers).

Check the setting.

Check that material has not jammed in the feed hopper or distributor and blocked the feed
opening.

4. While crushing

Listen for abnormal noises in the crusher.

Listen for abnormal noises in the lubrication pump(s).

Check the return oil temperature.

Check the drive motor current or power consumption.

Check the Hydroset pressure.

Check the temperature of the pinionshaft housing.

Check that the Hydroset pressure gauge damping is correct.


See Section 8.10 - Damping valve for pressure gauge.

Check the lubricating oil pressure at normal working temperature.

Check that no oil leakage has occurred.

Check that no bolts have come loose.

5. After stopping the crusher

Check that the oil heaters are connected.

Check the distance between the head nut and the underside of the spider (i.e. the
A-dimension).

Check that there is no increase or change in the contamination on the return oil strainer,
e.g. an abnormal amount of metal particles.
1800-Series Hydrocone crushers S 223.368.00 en 4 (5)

17. Routine maintenance 2001-11-15

17.3 Weekly inspection

Check all the items listed under "Daily inspection".

In addition:

Inspect the oil filter (check to see if the red button in the differential pressure sensor
assembly protrudes – see Fig. 6.10.1 – Item 15), the dirt trap and the oil tank. Change or
clean if necessary.

Inspect the manganese for wear and damage.

Measure the setting at 4 points around the crushing chamber to check for uneven wear.

Check the dust seal ring for wear.

Check the oil pump(s) for abnormal noise and wear.

Check the tightness of all bolts. Retighten if necessary. See Section 2.8.

Check the V-belts for wear and tension.

Check the play between the mainshaft sleeve and the spider bushing.

Check the backlash in the pinion and eccentric gear.

Check the grease level in the spider bearing.

Check the oil level in the pinionshaft housing or check that the pinionshaft lubrication
system operates correctly.

Check the cooler matrix of the air/oil heat exchanger. Blow clear if necessary.

Check the condition of the scraper which rotates above the dust collar. This can be done
through the inspection holes in the bottomshell.

Check - using feeler gauges - between the headcentre and the mantle and between the
topshell and the concave ring.
1800-Series Hydrocone crushers S 223.368.00 en 5 (5)

17. Routine maintenance 2001-11-15

17.4 Yearly inspection

Check all the items listed under "Daily inspection" and "Weekly inspection".

In addition:

Dismantle the crusher and inspect the following:

The topshell and bottomshell for wear.

The spider bearing for wear.

The spider bearing grease seal for wear.

The tapered contact faces of the topshell and bottomshell.

The mainshaft sleeve for wear and pitting.

The lower bearing surface on the mainshaft.

The inner seal ring for wear.

The play between the locating bar and the gear carrier.

The eccentric bushing for wear and scratches.

The eccentric for wear and scratches.

The wearing plate for wear.

The bottomshell bushing for wear and scratches.

The thickness of the step bearing assembly. Check for wear and scratches.

The bevel gears for wear.

The Hydroset cylinder bushing for wear and scratches.

The chevron packing for wear.

17.5 Checking manganese wear

See Section 10.1 - Evaluation of liner wear.

17.6 Checks to be made before the topshell is removed

See Section 10.2 - Checks prior to removal.


Symbols to be marked in the squares: Week No. Week No. Week No. Week No.
INSPECTION PROCEDURE X = no remarks O = adjustment carried out.
The figures refer to the numbers on the next page. S M Tu W Th F Sa S M Tu W Th F Sa S M Tu W Th F Sa S M Tu W Th F Sa
t t t t
DAILY INSPECTION:
Before starting crusher check:
Oil level in lubricating tank
Oil level in Hydroset oil tank
After starting lubricating oil pump check:
That oil flows back into the tank
That the oil lines do not leak
After starting crusher check:
Setting (if ASR is fitted, check also calibration)
During crushing check:
Whether abnormal noises can be heard from the oil pump(s)
Whether abnormal noises can be heard from the crusher
Return oil temperature
Oil pressure(s) at normal running temperature (record the pressure(s) )
That no oil leakage has occurred
That no bolts have loosened
Drive motor current / power (record)
Hydroset pressure (record the pressure)
HYDROCONE CRUSHERS

The feed arrangement


INSPECTION RECORD SHEET FOR

After stopping crusher check:


That the oil heaters are connected
Oil strainer
Oil level in pinionshaft housing
Distance between head nut and spider bushing (A-dimension) (record)
WEEKLY INSPECTION: As daily inspection. In addition check:
Oil filter (red button), dirt trap and oil tank. Change/clean if necessary
Oil pump(s) for abnormal noise and wear
Play between mainshaft sleeve and spider bushing (record)
Grease level in spider bearing
Crushing liners for wear and possible damage
Setting simultaneously at 4 points (record)
Dust seal for wear
Gear backlash (record)
1 (2)

V-belts for wear and tension


2001-11-15
S 223.405 en

All bolts for tightness. Retighten if necessary


INSPECTION RECORD SHEET FOR S 223.405 en
HYDROCONE CRUSHERS 2 (2)
2001-11-15

No. Remarks Cost Sign.

10

11

12

13

14

15

16

17

18

19

20

21
1800-Series Hydrocone crushers S 223.369.00 en 1 (11)

18. Fault tracing 2001-11-15

18. Fault tracing

Contents Page
18.1 General 2
18.2 Crusher stops 3
18.3 Crusher will not hold a constant setting 4
18.4 Oil temperature too high 5
18.5 Crusher cannot be started 6
18.6 Points to watch regarding pinionshaft assembly 7
18.7 Abnormal noise in crusher 8
18.8 Crusher's capacity drops 9
18.9 Increasing bearing component wear (contaminated lubricant) 10
18.10 Bearing failure inside crusher 11
1800-Series Hydrocone crushers S 223.369.00 en 2 (11)

18. Fault tracing 2001-11-15

18.1 General

The symptoms and corrective measures described in this section on fault tracing do not cover
all conceivable problems.

Fault tracing diagrams must rather be considered as suggestions for carrying out systematic
checks on basic functions.

To correctly interpret the fault symptoms covered by the diagrams, start at the "fault" field
and check through the "cause" fields. Follow the arrows to the "corrective action"
alternatives.

When correcting identified faults, consult the appropriate section of the instruction manual for
more detailed information and explanations.
1800-Series Hydrocone crushers S 223.369.00 en 3 (11)

18. Fault tracing 2001-11-15

18.2 Crusher stops

Fault Cause Corrective action

Crusher Pinionshaft oil pump not Pinionshaft oil pump is interlocked with crusher Check that 0.7 MPa (102
stops running. drive motor. Check electric circuits and drive psi) safety valve does not
motor starter. leak oil.

Check operation of cooling system.


Check control thermostat (TG2).
Oil too hot. Protective
Check fan motor and starter.
thermostat TG1 activated.
Check radiator matrix. Clean inside and outside.

Bearing failure. Check operation of protective Strip down crusher to


Crusher seized. thermostat (TG1). inspect and replace
componenets.

Low oil pump capacity. Clean dirt trap.


If necessary, change filter(s).

Check pump capacity. Check operation of return oil


If necessary, change pump. flow switch.

Check oil lines. Check that oil does not


overflow over dust collar.

V-belts slipping Check belt tension and adjust as Restart Check


necessary. crusher. operation of
feed system.

Tramp metal or blockage Clear out crushing Check Reset drive motor Inspect return
in crushing chamber. chamber. condition overload protector. oil strainer.
of liners.
1800-Series Hydrocone crushers S 223.369.00 en 4 (11)

18. Fault tracing 2001-11-15

18.3 Crusher will not hold a constant setting

Fault Cause Corrective action

Crusher will Oil leak in Hydroset Check oil lines Seal or replace
not hold a system the relevant
constant components
setting
No Change safety valve.

Safety valve leaks Check if setting increase Do pressure peaks


has raised oil level in occur? Modify feed
Hyrdoset tank arrangement. Choke
feed! No
Yes segregation.

Control valve leaks Check if setting increase Clean or replace


has raised oil tank level control valve.
in Hydroset tank.

Chevron packing Check if oil level has Replace chevron packing.


leaks risen in lubrication oil Inspect Hydroset cylinder bushing –
tank. replace if necessary.

Air in Hydroset Setting increases during Bleed air from system.


system crushing but returns to
normal when idling.

Check accumulator gas pressure.


Accumulator gas Replace gas bladder or complete
pressure too low accumulator if necessary.

Check if mainshaft
"climbs" to metal-to-
metal position when
crusher is idling.
Accumulator bladder Replace gas bladder Bleed air
damaged. or complete from system.
Inspect Hydroset oil. accumulator.
Nitrogen in oil gives
milky white colour.
1800-Series Hydrocone crushers S 223.369.00 en 5 (11)

18. Fault tracing 2001-11-15

18.4 Oil temperature too high

Fault Cause Corrective action

Oil temperature too Protective thermostat Check operation of cooling fan.


high (TG1) activated Check fan motor and starter.

Oil cooler running Check cooling control thermostat


continuously. (TG2). Inspect radiator matrix –
clean inside and outside.
Check that
thermostatic valve on
cooler operates
correctly (if fitted)

Check that pressure relief valve


("by-pass") closes.
For more
information, see
Section 22: Operating
in low temperatures.
Clean dirt trap. If necessary,
change oil filter(s).

Low oil flow rate. Inspect oil lines.

Check pump capacity. If necessary


change pump.

Wrong oil viscosity. Change to oil with correct viscosity, as


described in Section 6: Lubrication system, to
provide correct operation conditions.

Incipient bearing If measures described above do Strip down crusher for


failure. not result in a drop in mechanical inspection.
temperature: Check return oil
strainer.
1800-Series Hydrocone crushers S 223.369.00 en 6 (11)

18. Fault tracing 2001-11-15

18.5 Crusher cannot be started

Fault Cause Corrective action

Crusher Oil pump not running. Check electric circuits and


cannot be starter of pump motor.
started.

Check that oil does not overflow Check oil lines.


over dust collar.

Low oil pump


capacity. No "Crusher Clean dirt trap. If necessary, change
ready for start" signal. filter(s).

Check pump capacity. If necessary, Check operation of


change pump. return oil flow switch.

Oil pump running but no TG1 cuts out crusher


"Crusher ready for start" drive motor. Check
Check pinionshaft oil pump operation of
signal is obtained.
(which is interlocked with crusher thermostat.
drive motor).

Check pinionshaft oil


pump motor protector
Oil pump running and Check crusher drive motor's starting and the other electrical
"Crusher ready for start" equipment and the other electrical circuits.
signal is obtained. circuits.

Oil does not return to the Start the oil pump. Let it run approx. 30 seconds.
tank (in cold weather). Bridge over return oil switch so that "Crusher ready for start" signal is
obtained. Start crusher.
Let it run approx. 20 seconds. Remove bridge over return oil switch
For more information, see after approx. 40 seconds.
Section 22: Operating in Crusher will continue to run if sufficient oil is returning to the tank.
low temperatures. If not, return oil switch will cut out crusher drive motor again.
Repeat the sequence again after a couple of minutes.
1800-Series Hydrocone crushers S 223.369.00 en 7 (11)

18. Fault tracing 2001-11-15

18.6 Point to watch regarding pinionshaft assembly

Fault Cause Corrective action

Points to watch
regarding Check oil level. If the oil level keeps
pinionshaft Fill to correct level. dropping, this can indicate
assembly. a damaged inner seal.
Recheck oil level.
High temperature inside Check that pinionshaft oil
and outside pinionshaft pump is running and oil
housing. reaches pinionshaft
housing. Stop the crusher.
Remove the pinionshaft
assembly for inspection
Oil leaking from outer Outer seal or spacer worn or and, if necessary, replace
bearing cover. O-ring damaged. bearing components.

Abnormal noise from Incipient bearing failure.


Change oil in the
pinionshaft assembly.
pinionshaft housing (oil
bath lubrication) or
change oil in the tank
(circulatory lubrication).

Vibration in crusher or Check V-belt pulleys. Clean Check V-belt tension. Are
pinionshaft housing. off any collected dust. V-belts flapping?

Indicates heavy wear on


rollers and races. Check
Large axial bearing play. Schedule removal and
frequently for increasing
bearing replacement for a
noise or rising temperature
convenient time.
in pinionshaft assembly.
1800-Series Hydrocone crushers S 223.369.00 en 8 (11)

18. Fault tracing 2001-11-15

18.7 Abnormal noise in crusher

Fault Cause Corrective action

Abnormal noise Incorrectly fitted bevel gears. Incorrect gear meshing or insufficient backlash can cause noise
in crusher. from gears.
Remove pinionshaft assembly. Measure correct gasket
thickness. Adjust backlash.

Heavy wear on eccentric Wear on eccentric wearing plate leads to reduced backlash.
wearing plate. Insufficient backlash can cause noise from gears. Strip down
crusher and replace eccentric wearing plate.
Readjust backlash.

Crushing liner(s) loose. Check and tighten concave Check if there is play
ring bolts. between mantle and
headcenter.

"Grating" step bearing. Reduce crusher’s operating Inspect return oil


load. Extend running-in strainer. Check for
period. liner ovality.

Packing in crushing chamber Check operating conditions


Increase CSS.
or liners "metal to metal". and CSS. Check for liner
ovality.

If there is still move-


ment between topshell
Movement between flanges of Check with a feeler gauge if and bottomshell
topshell and bottomshell. there is a play between the flanges, the tapered
flanges. Tighten bolts. joint needs
remachining. Contact
Sandvik Rock
Processing.
1800-Series Hydrocone crushers S 223.369.00 en 9 (11)

18. Fault tracing 2001-11-15

18.8 Crusher's capacity drops

Fault Cause Corrective action

Crusher's "Ski-slope" formed on Check the feed Check the top size separation
capacity liners. arrangement. Make sure ahead of the crusher. Is there a
drops. the crusher is choke fed. large proportion of material
smaller than the CSS?

Extremely large play in Check the play in the If there is exceptionally large
spider bearing. spider bushing. See play in the spider bushing,
Section 11 – Spider check the condition of the
bearing. eccentric bushing.

V-belts slipping. Check the V-belt tension – Change V-belts. Inspect the
tighten if necessary. grooves of the crusher pulleys.

Feed material has been Altered material composition, fraction length and
changed. material hardness can lead to changes in capacity.

Bridging in the feed Check the material level in the feed hopper. If
opening. possible, limit the top size of the feed or change
crushing chamber.
1800-Series Hydrocone crushers S 223.369.00 en 10 (11)

18. Fault tracing 2001-11-15

18.9 Increasing bearing component wear

Fault Cause Corrective action

Increasing bearing Contaminated oil. Check the oil condition Change oil regularly
component wear. regularly during the first year of according to results of
operation. oil condition
monitoring.

Oil filter blocked. Replace filter elements.

Dust seal ring worn or Check play between dust collar Replace dust seal ring
damaged. and dust seal ring. if play exceeds the
values given in Table
12.9.1.

Over-pressure dust sealing Inspect entire over-pressure dust sealing system


system is not working. and check operation. See Section 21.
1800-Series Hydrocone crushers S 223.369.00 en 11 (11)

18. Fault tracing 2001-11-15

18.10 Bearing failure inside crusher

Fault Symptom Cause Corrective action

Bearing failure Mainshaft assembly Seizure or incipient seizure Stop the crusher.
inside crusher. rotates very fast or at same between mainshaft and Strip down to inspect the
speed as eccentric. eccentric bushing. bearing components.

Pinionshaft cannot be Seizure between eccentric and If possible, take out


turned. bottomshell bushing. screws holding dust
collar. Remove mainshaft
assembly and complete
eccentric assembly.
Bearing failure in pinionshaft
assembly.
Remove step bearing
components. De-burr
Increased amount of swarf Seizure in step bearing or in edges of oil grooves,
on return oil strainer. bronze bushings. polish bearing surfaces of
bushings or step bearing
components. Inspect
bearing surfaces of
bushings.
Needle-like particles on Seizure or wear on gears.
return oil strainer.

See corrective actions


High temperature or localized listed for "oil temperature
Tin or lead shavings on overheating and seizure in
return oil strainer. too high" – (18.4).
bushings or step bearing.
Hydrocone crushers S 223.375.00 en 1 (3)

19. Backing with plastic composition 2001-11-15

19. Backing with plastic composition

Contents Page
19.1 General 2
19.2 Backing procedure 2
19.3 Hygienic aspects 3
19.4 Protective measures 3
Hydrocone crushers S 223.375.00 en 2 (3)

19. Backing with plastic composition 2001-11-15

19.1 General

To back concaves, crushing rings, mantles and concave rings in Hydrocone crushers, use a
plastic composition which meets the requirements set by Sandvik Rock Processing. Two
important requirements - after complete hardening and at 20°C (68°F) - are:

Compressive strength at least 110 MPa (15950 psi)

Shrinkage less than 0.01%.

The backing material used by Sandvik Rock Processing is of the epoxy type and handling
procedures are described below. Sandvik Rock Processing urge the user to follow the
safety rules and handling directions mentioned in this instruction manual and provided by
the manufacturer of the plastic backing composition.

19.2 Backing procedure

Mixing

The plastic used to back liners is a 2-component epoxy-based composition with no solvent.
The two components - the resin (component A) and the hardener (component B) - are
mixed immediately before use. First, thoroughly stir component A (which may have
formed a sediment) so that it is homogeneous and easy to pour. Add the hardener
(component B) and then quickly and carefully mix the two components with a low-speed
electric drill fitted with a mixing attachment. Make sure that no air bubbles are formed.

To make mixing simpler, the two components have different colours. This makes is easy to
see when complete mixing has been achieved. Use the composition immediately after
mixing.

Pouring

The setting time varies between 7 and 24 hours, depending on the ambient temperature.

When backing is carried out in cold weather the cans must be heated to approx.25°C
(77°F) since the plastic will otherwise be too viscous. Do not heat the plastic composition
with an open flame as this can damage the material. The components which are to be
backed can be heated to 40-50°C (104-122°F), which will reduce the setting time. If the
components are very cold the plastic will not set.

In warm weather the cans must be protected from direct sunlight or else the composition
may set too rapidly. In such conditions, keep the cans in the shade.
Hydrocone crushers S 223.375.00 en 3 (3)

19. Backing with plastic composition 2001-11-15

Storage

Unopened cans can be stored in a cool, dry place for about 12 months from the date of
manufacture. If the cans are stored at a temperature below 0°C (32°F) the plastic will
crystallize after a time. Heating to 60-70°C (140-158°F) for approx. 2 hours will restore the
plastic to its original consistency.

19.3 Hygienic aspects

Safe handling of epoxy resins and hardeners - in common with most other chemicals -
requires the observation of certain hygienic rules.

Epoxy plastic which has set is physiologically harmless. Epoxy resin and hardener,
however, can with some people cause skin irritation and allergic contact eczema. By
carefully following the recommendations described in Section 19.4 below, these effects can
be avoided.

19.4 Protective measures

Good ventilation must be provided for the room where the plastic composition is mixed
and in other affected work-places.

The room where the plastic composition is mixed must be kept clean so that any spill is not
spread around.

Soap, water and paper towels must be available at the working place.

Protect hands with P.V.C. gloves. A protective ointment should be rubbed into unprotected
skin which can come into contact with epoxy products. Protective ointment can also be
rubbed into the hands and wrists before the P.V.C. gloves are put on.

Use protective goggles. If any splashes reach the eyes, wash them immediately with water.
If irritation persists contact a doctor.

If epoxy resin or hardener has come into contact with the skin, wash the affected area
immediately with soap and water. Do not use a solvent.

Establish whether there are any applicable National standards covering the handling and
use of epoxy products. If so, follow the prescribed procedures.

When removing plastic-backed components with the help of an oxy-acetylene torch or a


carbon-arc cutter - as always when using a torch - take safety precautions. Work of this
kind requires the use of a mask with an air filter.
S 966.001.00 en

Korrobond 65
Plastic backing material
Plastic backing material S 966.001.00 en 1 (5)

Korrobond 65 2001-11-15

Korrobond 65 plastic backing composition

Contents Page
1. General 2
2. Storage 2
3. Handling 2
4. Scrap 3
5. Common misapprehensions 3
6. Korrobond 65, label (component A) 4
7. Korrobond 65, label (component B) 5

Encl.: Data sheet D 966.001 en


Material Safety Data Sheets for Component A and Component B
Plastic backing material S 966.001.00 en 2 (5)

Korrobond 65 2001-11-15

1. General

Sandvik Rock Processing’s plastic backing composition – now with further reduced
affect on the environment!

Sandvik Rock Processing’s Korrobond 65 plastic backing composition – which is used for
the installation of mantles, concaves, concave rings and filler rings – has been the subject
of improvement and modification over a long period and is now the least environmentally
hazardous backing composition on the market. As part of this modification process the
blue pigment previously used in the hardener has been changed to a more
environmentally friendly black pigment.

• Epoxy resins have been available for 50 years and are used in many applications. The
backing of wearing liners in crushers is only a small part of the field of use of epoxy
resins.
• Epoxy plastic composition has extremely good adhesion to steel and concrete.
• Epoxy plastic composition has three times higher compressive strength and twenty times
higher tensile strength than concrete.
• Korrobond 65 is an epoxy-based backing material.
• Korrobond 65 does not contain the environmentally toxic nonylphenol, which is
commonly used as an additive in other epoxy-based backing materials.
• Korrobond 65 has been developed to provide the correct characteristics for its
application and development continues. As an example, ingredients are replaced – step
by step – by others, to provide unchanged technical characteristics whilst at the same
time reducing the environmental impact of the unhardened product on our environment.

2. Storage
Korrobond 65 must be stored – in the original containers – in a cool place. The shelf-life is
one year from the manufacturing date shown on the container.

3. Handling

A common misapprehension is that a ”space suit” is needed when Korrobond 65 is mixed


and poured. What is needed is a pair of overalls, plus gloves and protective glasses. Avoid
bringing the mixed backing composition or the unmixed components into contact with bare
skin and ensure that there is good ventilation – especially when mixing. When hardened
Korrobond is burnt or ground, dangerous fumes are generated and the grinding dust can
contain unhardened particles. For this reason, a breathing mask with an A2P3 filter must be
used and contact with bare skin must be avoided.
See also the relevant sections in our Information Manuals regarding Backing with plastic
composition.
Plastic backing material S 966.001.00 en 3 (5)

Korrobond 65 2001-11-15

4. Scrap

Hardened Korrobond 65 does not present any significant environmental risk and can be
recycled as a fill material. The hardened product can also be dumped. Unhardened
Korrobond 65 must be treated as environmentally dangerous refuse and must be handled in
accordance with the applicable local regulations.

5. Common misapprehensions

Inflammable? Wrong!
Korrobond 65 can be burnt but it is not inflammable –
neither as unhardened components nor as the fully
hardened product.

Toxic? Wrong!
Korrobond 65 is not toxic.
However, unhardened product can cause allergic reactions
if sensitive skin frequently comes into contact with it.

Contains isocyanates? Wrong!


Unlike polyurethane-based backing composition,
Korrobond 65 does not contain isocyanates.

Contains solvents? Wrong!


Unlike polyester-based backing composition, Korroband 65
does not contain styrene or other solvents.

Dangerous goods? Partly wrong!


Korrobond 65 component A (unhardened plastic
composition) can be transported by road, sea and air
without requiring special packaging.
Korroband 65 component B (hardener) can be transported
”in limited quantities” by road and sea and – as “dangerous
goods” – by air. This means special regulations concerning
the number of cans per package, packing and marking.
See also Data Sheet D 966.001 en with information on
transport requirements.
Plastic backing material S 966.001.00 en 4 (5)

Korrobond 65 2001-11-15

(Actual label size 200x140 mm)


Plastic backing material S 966.001.00 en 5 (5)

Korrobond 65 2001-11-15

(Actual label size 155x60 mm)


Data sheet D 966.001.00 en 1 (4)

Korrobond 65 2001-11-15

Korrobond 65

Korrobond 65 is a 2-component epoxy-based backing material for the installation of


mantles, concaves, concave rings and filler rings in cone and gyratory crushers.

Korrobond 65 Component A consists of a liquid epoxy resin with specially selected


additives as listed in the accompanying “Material Safety Data Sheet – Component A”.

(Epoxy products have been available for about 50 years and form the most versatile group
of technologically advanced polymer materials. No other material has better adhesion to
steel.)

Korrobond 65 Component B acts as a hardener and consists of aliphatic amines, as


described in the accompanying “Material Safety Data Sheet – Component B”.

(The ambient temperature has a major affect on the speed at which the chemical reaction
takes place. As soon as Korrobond 65 has hardened properly, its properties reach their final
values.)

How much is needed?

When the mantle and concave ring or concaves are to be changed at the same time in one
of our crushers, the total quantity of plastic backing required lies in the range 100-500 kg,
depending on the size and type of crusher and the crushing chamber fitted.

The quantity of Korrobond 65 required for a liner change can be shipped by any normal
form of transport, as long as the applicable transport regulations are followed. (See pages
three and four.)

From a weight and volume viewpoint it is Component A which forms the major part of a
shipment and can set the limit for what can be shipped, for example when express delivery
is necessary by air freight.

Handling the unhardened product

Component A: Epoxy resin is slightly to moderately irritating for skin, eyes and
mucous membranes.
The stickiness of the product can extend the time during which it is in
contact with the skin.
The product is mildly sensitizing (allergenic).
The product is very viscous so the risk of inhalation is thus very low.
Data sheet D 966.001.00 en 2 (4)

Korrobond 65 2001-11-15

Component B: Aliphatic amines are strongly alkaline and are thus irritating and
corrosive.
The product can cause damage to skin, eyes and mucous membranes.
The product can cause sensitization when inhaled.

Close fitting clothing, protective plastic gloves and protective glasses or a face mask
must be used. Avoid exposing bare skin. When mixing the product, make sure that
there is good ventilation and use an adjustable fume extractor.

Working with the hardened product

Cutting: Korrobond 65 contains approx. 25% of organic material. When it is


burnt, various residual products are formed, depending on the air
supply and the combustion temperature.
Remnants of unhardened material can be encountered. Fumes from
such material are dangerous and must be avoided.

Grinding: Grinding dust can contain particles of unhardened material. These


present the same risk of sensitization as when the unhardened material
is handled.

Always use protective glasses and a fresh-air mask.


Avoid exposing bare skin when grinding is carried out.

Handling scrapped product

Unhardened product must be treated as environmentally dangerous refuse. The two


Components A and B must be handled separately, in accordance with the applicable
national laws and regulations.

Fully hardened material constitutes an insignificant environmental hazard. The product


can be disposed of in accordance with local regulations or can be recycled by
fragmentation.

Environmental impact

Component A: Epoxy resins are not easily decomposed by biological action.


The product can be accumulated biologically.
The product is slightly toxic to aquatic organisms.

Component B: Aliphatic amines are not easily decomposed by biological action.


The product is not expected to cause biological accumulation due to a
low log Pow value.
Data sheet D 966.001.00 en 3 (4)

Korrobond 65 2001-11-15

Transporting the product

Korrobond Component A is regarded as material which does not require special packing
and quantities.
Component A is delivered in 9.3 kg plate cans (approved by the UN), packed in boxes or
shrink-wrapped, stacked on pallets. The cans are marked with a label, as shown by the
sample on page 4 of Manual S 966.001 en.

Korrobond 65 Component B is regarded as dangerous goods but in accordance with the


applicable regulations for road and sea transport it can be sent ”in limited quantities” – i.e.
as non-hazardous goods (from a documentation viewpoint) – under the conditions
described below. In the case of air freight, the maximum “limited quantity” is 0.5 lit, which
is less than one can and is therefore not a viable alternative for us.
Component B is delivered in 0.7 kg cans (approved by the UN), marked with a label. (See
example on page 5 of Manual S 966.001 en.)

For Korrobond 65 Component B (hardener) the following regulations apply:

Road transport: Packed in boxes containing max. 16 cans (11.2 liters).


No limit on number of boxes per package.
No limit on number of packages per shipment/order.

Each box must be marked on two opposite sides with ¯.


The designation UN 2735 must be written in the diamonds.

(Applies for Europe in accordance with ADR and the Baltic Treaty, with the exception of
Ireland and the United Kingdom.)

Sea transport: Packed in boxes containing max. 37 cans (29.6 kg).


One (1) box per package.
No limit on number of packages per shipment/order.

The box/package must be marked with the text


“Amines, Corrosive Liquid No. UN2735” or
“Dangerous Goods in limited quantities, Class 8”.
The text “Limited Quantity” must be written on the Bill of Lading.

(Applies internationally in accordance with the IMDG code.)

Air freight (passenger aircraft):

Packed in boxes containing max. 7 cans (4.9 liters).


One (1) box per package.
No limit on number of packages per shipment/order.
Data sheet D 966.001.00 en 4 (4)

Korrobond 65 2001-11-15

Air freight (cargo aircraft):

Packed in boxes containing max. 85 cans (59.5 liters).


One (1) box per package.
No limit on number of packages per shipment/order.

In addition, the following applies for both passenger and cargo aircraft:

Packaging alternatives

• Corrugated cardboard 4G
• Plywood 4D
• Timber 4C1 or 4C2.

Marking

The box/package must be marked with:


• The text “Polyamines, Corrosive Liquid No. UN2735”.
• The name and address of the sender and the recipient.
• The warning sticker “Corrosive”.
• “This way up” stickers on two opposite sides.
• The handling sticker “CAO”, placed alongside the warning
stickers (only for transport in cargo aircraft).

Documentation

DGD – “Declaration for Dangerous Goods” – must be produced in


two copies and must contain the following information:

• Number and type of packages (e.g. “One box, fibreboard, 4G”).


• Gross weight of each package.
• The text “Polyamines, Corrosive Liquid, Class 8, No. UN 2735,
PG III”.

The DGD must be signed by the sender.


The declaration can never be signed by a shipping agent, operator or
handling agent.

The AWB (Air Way Bill) must be produced by the shipping agent.

(Applies internationally according to DGR.)


1800-Series Hydrocone crushers S 223.408.00 en 1 (4)

21. Over-pressure dust sealing 2001-11-15

21. Over-pressure dust sealing

Contents Page
21.1 General 2
21.2 Dust sealing principles 2
21.3 Regulator kit for compressed air 4
21.4 Blower kit 4
1800-Series Hydrocone crushers S 223.408.00 en 2 (4)

21. Over-pressure dust sealing 2001-11-15

21.1 General
The crusher should be connected to a low-pressure air supply. This is because a slight under-
pressure can occur inside the crusher when aerated lubricating oil runs back to the tank. The
resultant under-pressure will draw dust into the crusher and a film of dust will collect on the
inside of the dust collar, at the top. See Fig. 21.2.1.

The lubricating oil will transport dirt and dust around the lubrication system. This will result
in rapid blockage of the filter cartridges, accelerated step bearing component wear and
sedimentation in the oil tank.

Of course, other components inside the crusher will also be subjected to unnecessarily heavy
wear.

21.2 Dust sealing principles


The condition of the dust seal ring is of decisive importance for the function of the seal
against the dust collar.

A worn or oval dust seal ring gives a large gap to the dust collar and increases the possibility
of dust and dirt entering the crusher. See Fig. 21.2.1.

Dust

Figure 21.2.1
1800-Series Hydrocone crushers S 223.408.00 en 3 (4)

21. Over-pressure dust sealing 2001-11-15

Measures to prevent dust entering the crusher are taken in two steps – by equalizing the
pressures within the crusher and the tank unit and by creating an over-pressure inside the
crusher.

Pressure equalization between the crusher and the tank unit can be accomplished with a
simple hose connection.

A plastic hose is fitted to the T-piece mounted on the crusher, just above the pinionshaft
housing. See Fig. 21.2.2.

Tank

Figure 21.2.2

The other end of the plastic hose is connected to the sleeve welded to the end wall of the tank,
above the oil level. See Fig. 21.2.2.

It is important that the inspection covers on the tank unit are air
Note! tight. Adjust or replace the sealing strips as necessary.

An over-pressure is created inside the crusher either with the help of a regulator kit for
compressed air or by a blower kit. See Section 21.3 and 21.4 respectively.

The over-pressure prevents dust-laden air entering the crusher.

The air introduced into the crusher must be free from water and dust.

When the crusher is operating, the pressure at the point of entry into the crusher must be
600-1000 Pa.

The over-pressure air is introduced through the same T-piece on the crusher as is used for the
pressure equalization hose to the tank.
1800-Series Hydrocone crushers S 223.408.00 en 4 (4)

21. Over-pressure dust sealing 2001-11-15

21.3 Regulator kit for compressed air


The regulator kit includes two pressure gauge connections – one for installation adjacent to
the crusher and one for mounting next to the regulator. When the equipment is first installed,
fit the pressure gauge to the connection adjacent to the crusher. Adjust the regulator to give
the correct pressure at the entry to the crusher. Move the pressure gauge to the connection at
the regulator. Read off the pressure and note it down. This pressure can then be used as a
reference for future regulator adjustment.
If possible, install the regulator and air filter in a heated place.

21.4 Blower kit


If compressed air is not available, a blower can be used. The capacity at 600 Pa (60 mm w.g.)
must be at least 0.3m3/min (79 cu.ft./min.). Install the blower in a dust-free place.
Install the blower at a level of at least 200 mm (8 ins.) above the inlet on the crusher (See Fig.
21.4.1). This is to prevent foamed oil running out to the blower if the blower stops while the
crusher is running.
When connecting up the blower motor, check that the direction of motion corresponds to the
arrow on the blower housing. If the direction of rotation is incorrect, the output of the blower
will be insufficient.
The blower has an air filter with a replaceable paper element. Inspect the filter element at
regular intervals and change it as necessary.

Level difference Min. 200 mm

1. Pressure gauge (0-1000 Pa) 3. 3/8" BSP plug 5. T-piece


2. 3/4" BSP T-piece 4. 3/4" BSP sleeve 6. Pressure equalization
hose to tank
Figur 21.4.1
1800-Series Hydrocone crushers S 223.410.00 en 1 (11)

22. Operating in low temperatures 2001-11-15

22. Operating in low temperatures

Contents Page
22.1 General 2
22.2 Insulation of the bottom of the component section
of the oil tank unit 4
22.3 Installation of additional oil heaters 4
22.4 Diesel heating system 5
22.5 Heating cables on oil lines 5
22.6 Heater in the component section of the oil tank unit 6
22.7 Synthetic oils 6
22.8 Mineral oil for the winter season 7
22.9 A thermostatic valve to by-pass the oil cooler 7
22.10 Blanking off the oil cooler radiator 9
22.11 2-speed fan motor for oil cooler 9
22.12 Modified return oil flow switch interlock 9
22.13 Insulation of the oil tank 10
22.14 Continuous running of the lubrication oil pump 11
22.15 A heater in the Hydroset tank 11

Attached:

Drg. No.
3.194.0190 en Circuit diagram – modified return oil flow switch interlock
3.194.0191 en Circuit diagram – additional heaters
3.190.3592 en Circuit diagram – heating cables
3.190.3590 en Circuit diagram – heater for Hydroset oil
1800-Series Hydrocone crushers S 223.410.00 en 2 (11)

22. Operating in low temperatures 2001-11-15

22.1 General

In cold weather there can be problems with starting and running the crusher since the
lubricating oil becomes more viscous.

There are a number of measures which can be taken to heat the oil, to conserve heat in the oil
tank, to facilitate flow in the oil lines and through components, etc. These measures are
described in the following sections (see Contents List on page 1).

The measures which are to be taken must be judged in each individual case.

Products which can be ordered from Sandvik Rock Processing:

• Insulation of the bottom of the component section of the oil tank unit
• Installation of additional oil heaters
• Diesel heating system
• A thermostatic valve to ”by-pass” the oil cooler
• 2-speed fan motor for oil cooler
• A heater in the Hydroset oil tank

Other measures:

• Heating cables on the oil lines


• Extra heat in the component section of the tank unit
• Oil with lower viscosity
• Synthetic oils
• Mineral oil for the winter season
• Modified return oil flow switch interlock
• Insulation of the oil tank
• Continuous running of the lubrication oil pump
• Blanking off the oil cooler radiator

A crusher fitted with ”low temperature equipment” will normally be equipped with:

• An insulated bottom in the component section of the oil tank unit


• Extra heating elements
• Modified oil monitor interlocks
1800-Series Hydrocone crushers S 223.410.00 en 3 (11)

22. Operating in low temperatures 2001-11-15

Low Temperature problems- Symptoms and Remedies

Start

Start the oil pump. Does


yes
the “crusher ready for Has the crusher yes
start” signal appear started and continued Start crushing when the
within 40 seconds? to run normally? crusher has warmed up.
Oil returns to the tank but
not in sufficient quantity. no
no The ambient air
Wait 3-5 min. to drain the Stop the oil pump. Has Does the crusher stop yes
yes temperature is too low,
crusher and then make a due to interruptions
oil run back through which makes the oil
new attempt to start up. in the return oil flow?
the return line to the cooler too effective.
yes
return oil flow switch? The oil is slowed down
no During long periods and blocks the passages
There is a blockage in the
yes with very low in the radiator core!
return oil line. Clean out yes
Has oil overflowed over temperatures, the Blank off the radiator
the blockage. If necessary,
the dust collar? crusher should be completely or partially.
install heating cables in the
no heated during the night Start with 50% blanked
return oil line. Does oil
to avoid excessive off.
flow back to the tank?
yes Install a by-pass around yes cooling. Position a fan
the oil cooler with a heater beneath the
thermostatic valve. Does crusher and cover the Alt. – fit a 2-speed
oil flow back to the feed opening. In motor to the cooling
tank? addition, the lubrication fan.
no oil pump can be run
continuously.
Install low temperature
yes
equipment in the tank. Under very low
(Additional heaters, temperatures the
insulated tank bottom, radiator core can be
time delay for oil monitor “thawed out” with a fan
interlocks.) Does oil flow heater.
back to the tank?
no
yes
Change to a synthetic oil. Alt. use an ISO VG 100
Does oil flow back to oil.
the tank?
no
Install heating cables on
yes
the oil lines. Does oil
flow back to the tank?
no
yes Insulate the oil tank.
Does oil flow back to
the tank?
no
Sometimes it can be
advisable to run the
lubrication oil pump
continuously to minimize
starting problems.
1800-Series Hydrocone crushers S 223.410.00 en 4 (11)

22. Operating in low temperatures 2001-11-15

22.2 Insulation of the bottom of the component section of the


oil tank unit

Normally, the component section of the oil tank unit is completely open at the bottom.
This is because – under most conditions – a bottom plate is unnecessary. In fact, it is
usually desirable to provide good ventilation in this area so that the lubrication and
Hydroset oil pump motors are properly cooled. During the winter, however, it can be
desirable to keep filters and dirt traps etc. warm to reduce pressure drop in the lubrication
system. Bottom plates are available for the oil tank units of H/S 2800, H/S3800, H/S 4800
and H/S 6800 crushers:

Crusher Modification kit Tank drawing No.


H/S2800 442.6965-00 1.442.8911
H/S3800 442.6965-00 1.442.8911
H/S4800 442.9014-00 1.442.9017
H/S6800 442.9014-00 1.442.8946

22.3 Installation of additional oil heaters

In order to heat the oil to the correct temperature, it can be necessary to install extra
heaters. Installation is easiest if this equipment is ordered together with a new crusher, but
extra heaters can also be fitted in the tanks of older crushers.

Modification kits can be ordered under the part numbers given below:

H/S2800/3800

Crusher Modification kit Tank Voltage (V) Rating Connection


drawing No. (W) diagram
H/S2800 2 off 984.0607-00 1.442.8911 265/460 2x1640 3.194.0191
240/415 2x1340
220/380 2x1125
H/S3800 2 off 984.0607-00 1.442.8911 265/460 2x1640 3.194.0191
240/415 2x1340
220/380 2x1125
H/S4800 2 off 984.0605-00 1.442.9017 265/460 2x2190 3.194.0191
240/415 2x1785
220/380 2x1500
H/S6800 2 off 984.0605-00 1.442.8946 265/460 2x2190 3.194.0191
240/415 2x1785
220/380 2x1500
1800-Series Hydrocone crushers S 223.410.00 en 5 (11)

22. Operating in low temperatures 2001-11-15

22.4 Diesel heating system

In plants where there is no electric power during the night – e.g. transportable plants with
dieselgenerators – the installation of a diesel heating system can be a useful addition. With
the help of a battery and a timer, the system goes into operation and starts to heat oil up to
three hours before the electrical supply is available.

A diesel heating system can of course be used together with electrical heating. Tank units
for an H/S 2800, 3800, 4800 or 6800 crusher are prepared for diesel heating.

The diesel heating system uses a 12 V DC supply.

Diesel heating systems can be ordered under the part numbers given below. See also
Section 24 – Optional extra equipment, S 223.411 en.

Crusher Modification kit Tank drawing No.


H/S2800 442.9993-00 1.442.8911
H/S3800 442.9993-00 1.442.8911
H/S4800 442.9993-90 1.442.9017
H/S6800 442.9993-90 1.442.8946

22.5 Heating cables on oil lines

At low temperatures, the oil in the lines between the tank unit and the crusher can solidify
and form a “plug” which interferes with the flow of oil during starting. This problem can
be minimized by insulating the oil lines and installing heating cables.

Before heating cables are installed, the slope of the return oil line should be increased, if it
is possible.

The heating cable should have a rating of 8-10 W/m and 40 mm thick insulation should be
used.

Install the heating cable on the underside of the oil line and use insulating tape to keep the
cable in place.

In the case of oil lines larger than 50 mm in diameter and when it is desired to heat the oil
to a temperature 50ºC above the ambient temperature, the heating cable can be led
backwards and forwards on the same line.

Heating cables are in many countries considered as high voltage equipment and must
therefore be installed by an authorized electrician, in compliance with the relevant
regulations.
1800-Series Hydrocone crushers S 223.410.00 en 6 (11)

22. Operating in low temperatures 2001-11-15

Heating cable is normally supplied for 230 V. It is usually most convenient to purchase the
heating cable from a local supplier who can also install it.
It is preferable to use a heating cable of the self-regulating type which needs no thermostat.
The cable should be connected as shown in the enclosed diagram 3.190.3592.

22.6 Heater in the component section of the oil tank unit


To make it easier to start a crusher it can sometimes be advisable to provide additional
heat in the component section of the oil tank unit. This heat is intended to keep oil in
filters, dirt traps, valves, pumps, pipes etc. easy-flowing.
Extra heat can conveniently be provided by a fan heater with a rating of about 600 W and
equipped with a thermostat which prevents overheating. If maximum benefit is to be
obtained from the extra heat, it is advisable also to insulate the bottom of the component
section of the unit oil tank. (See Section 22.2).
Since the manufacturers are always changing the fan heater models available, Sandvik
Rock Processing has not prepared any modification kits with fan heaters. It is easiest for
the crusher owner to select the heater which he finds most suitable.
Position the fan heater so that no oil can drip onto it.

22.7 Synthetic oils


These oils are in all respects superior to mineral-based oils. The characteristics of synthetic
oils can in general be described as:
• Longer life, thanks to high stability which gives lower cost for oil changes.
• Easier starting at low temperatures.
• Lower energy consumption due to lower friction.
• Wider temperature range.
• Elimination of the risk of dangerous oxidation and ”coking”.

In the case of a Hydrocone crusher, it could be said that if starting difficulties are
experienced with mineral-based oil at -10ºC, for instance, the use of suitable synthetic oil
will mean that the temperature can drop about 10ºC – i.e. to about -20ºC – before similar
difficulties are experienced.

The following synthetic oils can be recommended. Other brands can also be used but the
selection of a suitable type must be discussed with the supplier.

Supplier Type Min. pour point °C Viscosity (cSt) at 40°C


Mobil oil SHC 629 - 48 142
Nynäs Mereta 150 - 42 150
1800-Series Hydrocone crushers S 223.410.00 en 7 (11)

22. Operating in low temperatures 2001-11-15

The oils mentioned here can be mixed with mineral-based lubricating oils but the crusher
and oil tank should be carefully emptied so that the synthetic oil is diluted as little as
possible.

If a change is made to synthetic lubricating oil it is also advisable to change over to a


synthetic Hydroset oil. This is in order to reduce the dilution which can occur in the
lubricating oil if there is any leakage past the Hydroset packing. In addition, a synthetic oil
will give smoother operation than a mineral oil in valves and pipes.
The oil normally used in the Hydroset system is a grade with viscosity 68 cSt at 40°C but
when synthetic oil is used, a grade with a viscosity down to 30 cSt at 40°C can be selected.
The following synthetic oils can be used in the Hydroset system:

Supplier Type Min. pour point °C Viscosity (cSt) at 40°C


Mobil oil SHC 626 - 52 66
Mobil oil SHC 624 - 57 31
Nynäs Mereta 68 - 45 68
Nynäs Mereta 32 - 54 32

Other brands can be used but the selection of a suitable type must be discussed with the
supplier. Whatever the type selected, it must be possible to mix the lubricating and
Hydroset oils used in the crusher.

22.8 Mineral oil for the winter season


In low ambient temperatures – below 0ºC – an ISO VG 100 oil can be used (See SA
3067, 110-AB).

It is vital that thermostats TG1 and TG2 are set in accordance with the
recommendations given in Section 6.14 “Operation in low temperatures” with an
ISO VG 100 oil.

22.9 A thermostatic valve to by-pass the oil cooler

Operation of the thermostatic valve

When a crusher is started up with cold oil, the largest single cause of pressure drop is the air/oil
heat exchanger. This pressure drop can be minimized with the help of a thermostatic valve. See
Fig. 22.9.2.

The thermostatic valve is mounted on the oil cooler and operates in such way that as long as
the oil temperature is below 35ºC, the oil goes from port 1 to port 2 inside the valve, and port 3
is closed.
From port 2, the oil flows through an external line to the cooler’s outlet manifold. It passes
1800-Series Hydrocone crushers S 223.410.00 en 8 (11)

22. Operating in low temperatures 2001-11-15

through the manifold and flows to the crusher. When it passes through the cooler’s outlet
manifold, the oil gives up some of its heat energy to the cooler which is thus warmed up. This
results in a lower pressure drop across the cooler when the thermostatic valve gives free
passage from port 1 to port 3, as described below.

When the oil temperature rises above 35ºC, the thermostatic valve starts to allow some of
the oil to go to the cooler through port 3. At an oil temperature of 45ºC the ”by-pass” line
(port 2) is completely closed off and all of the oil goes through the cooler.

Thermostat and mounting kit

Table 22.9.1

Crusher Cooler Mounting kit


Part No. Designation Part. No.
H/S2800/3800 910.0101-00 995011 A0 442.9845-00
H/S4800 910.0102-00 994303 A3 442.9844-00
H/S6800 910.0103-00 995012 A0 442.9842-00

The thermostatic valve is mounted on the cooler as shown in fig. 22.9.2.

Inlet manifold
Outlet manifold

From oil tank

To crusher via tank


Figure 22.9.2
1800-Series Hydrocone crushers S 223.410.00 en 9 (11)

22. Operating in low temperatures 2001-11-15

22.10 Blanking off the oil cooler radiator

When the oil temperature rises so high that the cooling fan starts, it can happen that the
cooling is too effective. The pressure drop across the cooler rises so high that the pressure
relief valve ahead of the cooler opens. If this happens, the oil is not cooled at all – it can be
too hot even though the ambient temperature is low.

The easiest way to avoid stoppages of this kind is to blank off the radiator so that a smaller
mass of air is passed through the radiator core. The degree of blanking must be determined
by trial-and-error in each individual case. At present no blanking kit is available.

22.11 2-speed fan motor for oil cooler

Compared to the method described in Section 22.10 above, a more sophisticated way of
reducing the air flow through the radiator is to use a 2-speed motor on the cooling fan.

The fan starts at low speed at a certain temperature. If this provides sufficient cooling - i.e.
the oil temperature does not rise further - the fan continues to run at low speed as long as
cooling is required. If, on the other hand, the oil temperature rises further, the fan switches
to high speed at a pre-set temperature.

Table 22.11.1 gives examples of suitable switching points if an ISO VG 150 oil is used.

Return oil temperature Cooling fan


Rising oil temperature 43°C The fan starts at low speed
43-46°C Runs at low speed
Over 46°C Runs at high speed
Falling oil temperature Over 43°C Runs at high speed
43-40°C Runs at low speed
40°C The fan stops

For more information, contact Sandvik Rock Processing.

22.12 Modified return oil flow switch interlock

When the crusher is to be started it can sometimes be useful to by-pass the return oil flow
switch interlock for a short period during the starting phase. The crusher motor can then be
started without the return oil flow switch interlock giving a “crusher ready for start” signal.
With the crusher in motion the oil is effectively heated by friction so that it becomes easier
for the oil to pass through the bearings and other restricted passages. This results in higher
oil flow through the crusher.
1800-Series Hydrocone crushers S 223.410.00 en 10 (11)

22. Operating in low temperatures 2001-11-15

Technically this is arranged in such a way that the lubrication oil pump is started and run
for a pre-set time, for example 20 seconds. When this time has elapsed, a new time period
is started. During this second period, the ”crusher ready for start” signal is given and the
return oil flow switch interlock is by-passed. This second period can also be around 20
seconds, for example, and during this time the crusher motor can be started. If oil reaches
the return oil flow switch before this second period has expired, the crusher will continue
to run. If oil has not reached the return oil switch within this time, the crusher motor will
stop.

A new start attempt should not be made until the oil which has been pumped into the
crusher has run back to the tank. If a new start attempt is made prematurely, there is a risk
that the crusher becomes over-filled with oil. Oil will overflow over the dust collar inside
the crusher and drop down onto the discharge conveyor.

The components needed for this interlock by-pass can be obtained from Sandvik Rock
Processing. It is usually most convenient if a local electrician installs the components
although Sandvik Rock Processing can of course do the job if required.

Crusher Connection diagram


H/S2800/3800 3.194.0190
H/S4800/6800 3.194.0190

22.13 Insulation of the oil tank

In order to heat the oil to the correct temperature during the winter, it can be advisable to
insulate the tank. This means that it will be easier to start the crusher after a cold night
since the oil temperature is higher than it would be if the tank were not insulated.

When the ambient temperature rises (i.e. when the winter gives way to spring) it may be
necessary to remove the insulation if the cooling capacity of the system is insufficient.

Sandvik Rock Processing does not have standard off-the-shell insulation kits. Insulation
can easily be installed by the plant personnel.

A suitable material is Rockwool 1330-00, 50 mm thick. The insulation material must be


protected from moisture, as it will otherwise lose its insulating properties.
1800-Series Hydrocone crushers S 223.410.00 en 11 (11)

22. Operating in low temperatures 2001-11-15

22.14 Continuous running of the lubrication oil pump

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

22.15 A heater in the Hydroset tank

In our combined lubrication and Hydroset oil tank units, the Hydroset oil has no heating
element but is instead heated indirectly by the lubricating oil. Under extreme conditions it
can be desirable to install a heating element in the Hydroset oil tank section as well.

Crusher Modification kit Voltage Rating Connection


(V) (W) diagram
H/S2800/3800 442.8462-00 220/380 225 3.190.3590
H/S4800/6800 442.8463-00 220/380 670 3.190.3590

Since there is not much space in the component section of the oil tank, the heating element
in these modification kits has had to be positioned on the back of the tank unit. This means
that space is required behind the tank (approx. 200 mm).

The thermostat, which is mounted in the element itself, is set at 25ºC. This is a sufficiently
high temperature for the oil to pass easily through the control valve etc. In addition, this
reduces the time the element is switched on and reduces “coking”.
1800-Series Hydrocone crushers S 223.366.00 en 1 (1)

24. Extra equipment 2001-11-15

24. Extra equipment

To simplify and improve the operation of our cone and gyratory crushers when they are
used under special conditions, we have developed a range of optional extra equipment.

This equipment is described in a number of Instruction Manuals / Spare Parts Lists /


Drawings, as described below. These publications can be ordered from Sandvik Rock
Processing.

1. Diesel heating system S 223.411 en

2. Level monitor(s) in feed hopper


Type Telco (for one level) 4.190.3874
Type Telco, Triple (for three levels) 3.194.0104

The design of the equipment and its availability can vary between different crusher models.

To order any of this equipment, contact Sandvik Rock Processing.


Försäkran om överensstämmelse S 058.039.01 1 (1)
Declaration of Conformity
2002-08-20

Försäkran om överensstämmelse Declaración de conformidad Forsikring om overensstemmelse


Declaration of Conformity Assicurazione di conformità Atestado de concordância
Konformitätserklärung Verklaring van overeenstemming Yhdenmukaisuusvakuutus
Certificat de conformité Forsikring om overensstemmelse

Kross typ: Tipo de triturador: Knuse-type:


Crusher type: Tipo di frantumatrice: Tipo de trituradora:
Brecher Typ: Breker, type: Murskain tyyppi:
Type de concasseur: Knuseværkstype:
Hydrocone S2800:1 S3800:1 S4800:1, S4800:2 S6800:1
H2800:1 H3800:1 H4800:1, H4800:2 H6800:1

(sv) Vi försäkrar att produkten som (es) Garantizamos que el producto objeto (no) Vi forsikrer at produktet som
omfattas av denna försäkran är i de esta declaración cumple las omfattes av denne forsikring er i
överensstämmelse med följande disposiciones de las directivas y overensstemmelse med følgende
direktiv och harmoniserade normas armonizadas siguientes: direktiver og harmoniserende
standarder: standarder:
(en) We declare that the product to (it) Assicuriamo che il prodotto (pt) Para os devidos efeitos, declaramos
which this declaration relates is in contemplato da questa assicurazione que o produto abrangido por este
conformity with the following è conforme alle direttive seguenti e atestado está de acordo com as
standards and normative alle norme armonizzate. directivas e padrões harmonizados
documents: seguintes:
(de) Wir bescheinigen, dass das Produkt, (nl) Wij garanderen dat het product (fi) Vakuutamme että kone, jota tämä
auf das sich diese Erklärung waarvoor deze verklaring geldt in vakuutus koskee, on
bezieht, mit folgenden Direktiven overeenstemming is met de yhdenmukainen seuraavien
und harmonisierenden Normen volgende richtlijnen en normien ja ohjeellisten asiakirjojen
übereinstimmt: geharmoniseerde normen: kanssa:
(fr) Nous garantissons que le produit (da) Vi forsikrer hermed, at dette
faisant l’objet du présent certificat produkt, som omfattes af denne
est conforme à la directive suivante forsikring, er i overensstemmelse
et aux normes qui lui sont relatives: med følgende direktiver og
harmoniserede standarder:

93/68/EEC Direktivet om CE-märkning Directiva de certificación CE Direktivet om CE-merking


Directive on CE-marking Direttiva sui contrassegni CE Directiva sobre a gravação de CE
Direktive hinsichtlich CE-Kennzeichnung Richtlijn voor CE-merk CE-merkinnän direktiivi
Directive sur le marquage CE Direktivet om CE-mærkning
98/37/EG Maskindirektivet Directiva sobre maquinaria Maskindirektivet
Machinery Directive Direttiva per le macchine Directiva sobre máquinas
Maschinendirektive Machinerichtlijn Konedirektiivi
Directive sur les machines Maskindirektivet
89/336/EEC EMC-direktivet Directiva EMC EMC-direktivet
EN 50081-2 EMC Directive Direttiva EMC Directiva EMC
EN 50082-2 EMC-Direktive EMC-richtlijn EMC direktiivi
EN 60439-1-am11 Directive EMC EMC-direktivet
73/23/EEC Lågspänningsdirektivet Directiva sobre baja tensión Lavspenningsdirektivet
EN 60439-1 Low-voltage Directive Direttiva per la bassa tensione Directiva sobre baixa tensão
EN 60204-1 Niederspannungsdirektive Richtlijn voor Pienjännite direktiivi
Directive sur les basses tensiones laagspanningsinstallaties
Lavspændingsdirektivet

Anders Nilsson
Konstruktionschef Director de diseño Konstruksjonsjef
Engineering Manager Direttore tecnico O chefe de construção Sandvik SRP AB
Konstruktionsleiter Chef constructie Suunnittelupäällikkö
SE-233 81 SVEDALA, Sweden
Directeur de la construction Konstruktionschef

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