May 3, 2017 | Author: Patricio Tamayo | Category: N/A
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Operator’s & Maintenance Manual
Doc. No. S 223.857.en
Tank unit
SANDVIK CTHS430:02
This document is valid for:
Serial No. / Machine No.
Signature
SANDVIK CTHS430:02 Tank unit © Copyright 2012 Sandvik SRP AB. All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints. Document number: S 223.857.en Issue: 20120710 Version: 01 Document type: Operator’s & Maintenance Manual (OMM)
Sandvik Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com
OMM Sandvik CTHS430:02 Tank unit
1. Introduction 1.1 Equipment information........................................................ 1.1.1 Document information............................................ 1.2 Operating principles............................................................ 1.2.1 Main lubrication system ......................................... 1.2.2 Pinionshaft lubrication............................................ 1.2.3 Hydroset system for setting adjustment................. 1.2.4 Description .............................................................
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2. Safety precautions 2.1 Hazard information ............................................................. 2.1.1 Warning signs ....................................................... 2.1.2 Risk levels.............................................................. 2.1.3 Prohibition signs..................................................... 2.1.4 Mandatory signs..................................................... 2.1.5 Personnel............................................................... 2.1.6 Personal protection ................................................ 2.2 General safety precautions................................................. 2.2.1 Machine safety guards........................................... 2.2.2 Machine access ..................................................... 2.2.3 Electrical safety...................................................... 2.2.4 Welding .................................................................. 2.2.5 Hydraulic system.................................................... 2.2.6 Lubrication system ................................................. 2.2.7 Lubricants and waste lubricants............................. 2.2.8 Diesel oil, white spirit and other cleaning agents ... 2.2.9 Lifting and moving loads ........................................ 2.3 Emissions ...........................................................................
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3. Lubrication systems 3.1 General ............................................................................... 3.2 Overview ............................................................................. 3.2.1 Tank unit................................................................. 3.2.2 Cabinet................................................................... 3.3 Main lubrication components .............................................. 3.3.1 Main lubrication components - designation ............ 3.4 Hydroset components ......................................................... 3.4.1 Hydroset components - designation....................... 3.4.2 CH-crusher’s accumulator...................................... 3.5 Connections and drainage .................................................. 3.5.1 Connections and drainage - designation................ 3.6 Pinionshaft lubrication......................................................... 3.7 Overpressure components.................................................. 3.7.1 Overpressure fan ................................................... 3.7.2 Overpressure fan components - designation ......... 3.7.3 Overpressure air regulator ..................................... 3.7.4 Overpressure air regulator components designation.............................................................
28 29 29 30 32 33 34 35 36 37 37 38 39 39 39 40 40
4. Starting up the tank 4.1 General ............................................................................... 4.2 Running-in........................................................................... 4.2.1 Starting the main oil pump...................................... 4.2.2 Starting a crusher in extremely low temperatures ..
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OMM Sandvik CTHS430:02 Tank unit
5. Using the tank unit 5.1 Starting and stopping .......................................................... 5.1.1 Start........................................................................ 5.1.2 Normal operation ................................................... 5.1.3 Stop........................................................................ 5.2 Changing oil........................................................................ 5.2.1 Normal operating conditions .................................. 5.2.2 Operation at elevated temperatures ...................... 5.2.3 Operation in low temperatures...............................
46 46 47 47 48 49 50 51
6. Inspection and care 6.1 Routine inspection and care ............................................... 6.1.1 Daily ....................................................................... 6.1.2 Weekly ................................................................... 6.1.3 Monthly .................................................................. 6.1.4 Twice a year........................................................... 6.1.5 Yearly ..................................................................... 6.2 Overpressure dust sealing.................................................. 6.2.1 Overpressure parts ................................................ 6.2.2 Air flow ................................................................... 6.2.3 Fan......................................................................... 6.2.4 Regulator assembly for compressed air ................
54 54 55 55 56 56 57 58 59 59 60
7. Lubricants 7.1 Lubricant requirements ....................................................... 7.1.1 Miscibility................................................................ 7.1.2 Low temperatures .................................................. 7.1.3 High temperatures ................................................. 7.2 Oil for lubrication system .................................................... 7.3 Oil for Hydroset system ...................................................... 7.4 Oil for pinionshaft lubrication ..............................................
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8. Maintenance 8.1 Main lubrication system ...................................................... 70 8.1.1 Cleaning the tank ................................................... 71 8.1.2 Condensation water, draining................................. 71 8.1.3 Dirt trap, main lubrication ....................................... 72 8.1.4 Main lubrication oil filter.......................................... 73 8.1.5 Oil pump................................................................. 74 8.1.6 Pressure indicator .................................................. 75 8.1.7 Pressure switch...................................................... 76 8.1.8 Temperature indicator ............................................ 77 8.1.9 By-pass valves on coolers...................................... 78 8.1.10 Return oil flow switch ............................................. 79 8.1.11 Return oil screen .................................................... 80 8.1.12 Temperature switches ............................................ 81 8.1.13 Oil heating control .................................................. 83 8.2 Main lubrication oil exchange.............................................. 84 8.2.1 Draining the main lubrication system. .................... 84 8.2.2 Tank with air/oil cooler ............................................ 85 8.2.3 Tank with water/oil cooler (option) .......................... 86 8.2.4 Dirt trap cleaning, main lubrication ......................... 87 8.2.5 Filter exchange, main lubrication ........................... 88 8.2.6 Return oil screen and oil tank cleaning ................. 89 8.2.7 Cleaning out oil remnants, air/oil cooler ................. 90 8.2.8 Cleaning out oil remnants, water/oil cooler (option) 91 8.2.9 Refilling the main lubrication system ...................... 92 8.3 Air/oil cooler ...................................................................... 94 8.4 Water/oil cooler (option) ...................................................... 95 8.4.1 Dirt trap water/oil cooler, cleaning .......................... 95 8.4.2 Blocked water channels in water/oil cooler, cleaning and deliming ............................................ 96 8.5 Hydroset system ................................................................. 98 8.5.1 General .................................................................. 98 8.5.2 Hydroset pump..................................................... 100 8.5.3 Hydroset pressure indicator ................................. 100 8.5.4 Pressure relieve - Hydroset.................................. 101 8.5.5 Oil filter ................................................................. 101 8.5.6 Hydroset hydraulic assembly ............................... 102
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9. Troubleshooting 9.1 Faults and suggested corrective actions .......................... 106
10. Technical specifications 10.1 General data ..................................................................... 10.2 Lubrication systems .......................................................... 10.2.1 Main lubrication system ....................................... 10.2.2 Pinionshaft lubrication system ............................. 10.3 Hydroset system ............................................................... 10.4 Oil cooling systems........................................................... 10.4.1 Air/oil cooler ......................................................... 10.4.2 Water/oil cooler (option) ....................................... 10.5 Overpressure dust exclusion system................................ 10.5.1 General ................................................................ 10.5.2 Fan motor............................................................. 10.6 Tightening threaded fasteners .......................................... 10.6.1 Requirements for joints with threaded fasteners..
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1. Introduction To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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1. Introduction
Tank unit Sandvik CTHS430:02 OMM
1.1 Equipment information Purpose The purpose of this Sandvik equipment is to supply the crusher with oil for lubrication and for operating the hydraulic setting system. This tank unit has been exclusively designed for this application. Sandvik SRP AB will not accept any liability for damage to equipment or injury to personnel caused by unauthorized or improper use or modification of this equipment. Manufacturer This equipment has been manufactured by: Sandvik SRP AB SE-233 81 Svedala Sweden www.sandvik.com For maintenance Contact the nearest Sandvik company, agent or representative, or contact the factory directly: Sandvik SRP AB Service department SE-233 81 Svedala Sweden Telephone +46 (0)40 40 90 00 Telefax +46 (0)40 40 92 60 (Continued)
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OMM Sandvik CTHS430:02 Tank unit
1. Introduction
Tank unit identification The figure below shows an example of the tank units’s identification plate. The identification plate contains data needed when contacting Sandvik SRP AB concerning this specific equipment. Please enter the serial number of the associated machine in the intended field on the first page of this manual (the copyright page).
V10
8 1 7
2
3 1 2 3 4
Machine type Serial number/PCR Local manufacturer number Mass (kg)
4 5 6 7 8
5
6
Order number Manufacturer Maximum operating speed Year of manufacture
CE marking This equipment complies with the basic health, environment and safety regulations of the European Union and European Economic Area. Sandvik will not take responsibility for this compliance when customers modify any configuration of the oil tank unit.
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1. Introduction
Tank unit Sandvik CTHS430:02 OMM
1.1.1 Document information Purpose of this Operator’s and Maintenance Manual The purpose of this manual is to provide the operator with information on how to handle and operate this Sandvik equipment and to provide maintenance personnel with: •
information on all scheduled maintenance procedures listed in the checklists • information for unscheduled maintenance such as: – additional maintenance procedures. It is important to: • keep the manual for the lifetime of the equipment • pass the manual on to any subsequent holder or user of the equipment Document Compliance The instructions in this document are in accordance with the design and construction of the equipment at the time it was delivered from the Sandvik SRP AB manufacturing plant. Technical Publications Technical publications related to the installation of this equipment are: • IM - Installation Manual • IMA - Installation Manual Appendix Technical publications related to the operation and maintenance of this equipment are: • OMM - Operator’s and Maintenance Manual • SPC - Spare Part Catalog Read more about the document structure and accompanying work roles in section 2.1.5 Personnel. Feedback If you have comments on this manual or problems connected to the documentation, send an e-mail to:
[email protected]
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OMM Sandvik CTHS430:02 Tank unit
1. Introduction
1.2 Operating principles There are two separate lubrication systems on the crusher – the circulatory main lubrication system connected to the tank unit and the closed pinionshaft oil bath lubrication. The hydraulic setting system for the crusher has most of its vital parts and an oil tank in the tank unit.
1.2.1 Main lubrication system The main lubrication system is connected to the tank unit.
1.2.2 Pinionshaft lubrication The pinionshaft is lubricated by a separate oil bath in the pinionshaft housing and has no connection to the main lubrication system. The pinionshaft lubrication is described in the Operator’s manual for the crusher.
1.2.3 Hydroset system for setting adjustment To control fragment size and to compensate for wear the crusher has a setting control system, called the Hydroset system. It basically consists of a robust hydraulic jack which supports the mainshaft and adjusts its position. Moving the Hydroset piston up and down will change the discharge setting and the size of the crushed material.
1.2.4 Description
3
The following figure shows an overview of the oil tank unit’s components and nomenclature. 1 4 2 5
1 Oil tank unit 2 Overpressure fan 3 Overpressure air regulator (option)
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4 Air/oil cooler 5 Water/oil cooler (option)
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2. Safety precautions To ensure maximum safety, always read this section carefully before operating, carrying out any work on the equipment or making any adjustments.
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2. Safety precautions
Tank unit Sandvik CTHS430:02 OMM
2.1 Hazard information 2.1.1 Warning signs
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General danger
Dangerous voltage
Risk of crushing
Hanging load
Skid risk
Flying fragments
Rotating fan
Irritant
Hot surface
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2. Safety precautions
2.1.2 Risk levels Throughout the manual, risk levels are indicated with “DANGER”, “WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels are accompanied by a warning sign, see section 2.1.1 Warning signs. Failure to observe information marked “DANGER!” can result in lifethreatening injuries! DANGER! Failure to observe information marked “WARNING!” can result in personal injury and/or serious damage to, or destruction of, equipment! WARNING! CAUTION!
Failure to observe information marked “CAUTION!” can result in minor personal injury and/or damage to equipment!
2.1.3 Prohibition signs
Do not remove guards
2.1.4 Mandatory signs
Disconnect current
© 2012 Sandvik SRP AB
Read the manual
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2. Safety precautions
Tank unit Sandvik CTHS430:02 OMM
2.1.5 Personnel All work on the equipment must be carried out by trained personnel. – “Trained” means that the person in question has been given practical instructions by Sandvik SRP AB personnel on how the various tasks are carried out. All expected work tasks on this production equipment have been defined by Sandvik SRP AB as belonging to one of three categories: • Installation • Operation • Maintenance Sandvik SRP AB provides technical documentation appropriate to the categories: • Installation Manual and Installation Manual Appendix • Operator’s and Maintenance Manual • Spare Parts Catalog Adequate training can be provided, contact Sandvik SRP AB for further information. The technical documentation from Sandvik SRP AB only covers work on the production equipment itself – it does not cover work tasks associated with other equipment or routines at the site. It is the responsibility of the plant management to assign responsibility for: • The production equipment and the work area around the equipment • All personnel in the vicinity of the equipment • Compliance with national and local safety regulations • Checking that all safety devices are fully operational Sandvik SRP AB declines all responsibility for injury or damage resulting from non-compliance with the instructions in this manual.
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2. Safety precautions
2.1.6 Personal protection Sandvik SRP AB strongly recommends that personal protective equipment is always worn when working in the vicinity of the equipment. Sandvik SRP AB strongly recommends to use a safety harness when working above, inside or under the equipment. The Sandvik SRP AB recommendation for personal protective equipment includes:
© 2012 Sandvik SRP AB
Ear protection
Safety helmet
Eye protection
Protective gloves
Safety boots
Mask or respirator
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2. Safety precautions
Tank unit Sandvik CTHS430:02 OMM
2.2 General safety precautions
WARNING!
Falling stones Clear the feed arrangement and the crusher thoroughly from process material before any maintenance work is carried out inside or below the crusher, to prevent stones from falling down.
Always switch the power off and lock out the equipment (so that it cannot inadvertently be switched on) before any maintenance work is started. Also ensure that it is not possible for anyone else to switch the power on while maintenance work is carried out. Avoid staying on the equipment, unless necessary for maintenance work. CAUTION!
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Sharp edges can appear on the equipment due to wear, please consider sharp edges when handling worn parts. Remove any sharp edges.
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2. Safety precautions
2.2.1 Machine safety guards Do not remove guards Make sure that all guards are in place and functioning, to prevent exposure to rotating parts. Only operate the equipment when all PROHIBITION! guards are mounted. Rotating parts Exposure to rotating parts (pumps, fans etc.) must be prevented by guards. Always attach the guards after maintenance work. WARNING!
WARNING!
Flying fragments Ejected fragments can fall down in the vicinity of the equipment. Provide adequate guards and warning signs at appropriate places around the danger zone. Sandvik SRP AB also recommends additional protection.
Make sure all defective guards are checked, repaired and replaced before starting the equipment.
2.2.2 Machine access Every machine requires access for personnel who carry out inspections and/ or maintenance work. Suitable access platforms and guard rails must be installed. Walkways, stairs and ladders must be designed in accordance with applicable regulations. These parts are not included in the tank unit’s standard specification. For advice, contact Sandvik SRP AB.
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Tank unit Sandvik CTHS430:02 OMM
2.2.3 Electrical safety CAUTION!
Only personnel working according to European Standard EN 50110 or equivalent are permitted to perform electrical operations on the equipment. Dangerous voltage Personnel must regard all electrical equipment as live until it is proven dead by proper testing procedures.
DANGER!
Make sure all broken or damaged electrical cables and connectors are checked, repaired and replaced before starting the equipment. Control cabinets must be lockable.
2.2.4 Welding
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CAUTION!
Never weld the tank unit or parts attached to it.
DANGER!
Risk of fire and explosion Due to the risk of leakage, open flames and hot surfaces (>200 °C/ >390 °F) must be kept at a safe distance from the tank unit and the lubrication pipe work.
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2. Safety precautions
2.2.5 Hydraulic system CAUTION!
Only personnel certified in hydraulics are permitted to perform maintenance on the hydraulic system (except bleeding air from the Hydroset system).
WARNING!
Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system.
CAUTION!
Never adjust pressure relief valves beyond the recommended values. Hot oil Hydraulic oil can become very hot during operation. Allow the oil to cool before working on the hydraulic system.
WARNING! Hot surface Equipment and hoses/pipes containing hydraulic oil can have hot surfaces. Always wear protective gloves. WARNING!
WARNING! CAUTION!
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Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk. Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.
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Tank unit Sandvik CTHS430:02 OMM
2.2.6 Lubrication system When changing from mineral oil to synthetic oil, or if the oil has coked, the tank unit must be thoroughly cleaned. Contact Sandvik SRP AB for further instructions.
WARNING!
Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the lubrication system. Hot oil Lubrication oil can become very hot during operation. Allow the oil to cool before working on the lubrication system.
WARNING! Hot surface Equipment and hoses/pipes containing lubrication oil can have hot surfaces. Always wear protective gloves. WARNING!
WARNING! CAUTION!
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Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk. Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.
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2. Safety precautions
2.2.7 Lubricants and waste lubricants CAUTION!
Handle all lubricants and waste lubricants with care and according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Collect waste lubricants in suitable containers and dispose as recommended in the MSDS and according to local regulations.
WARNING!
Toxic substances Read the supplier’s Material Safety Data Sheet (MSDS). Used and contaminated oil can be a health hazard. Use protective gloves and goggles.
WARNING!
Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.
2.2.8 Diesel oil, white spirit and other cleaning agents It is recommended to clean the tank and the tank unit’s parts with diesel oil. Use white spirit only if it is necessary. CAUTION!
WARNING!
CAUTION!
© 2012 Sandvik SRP AB
If white spirit is used for cleaning, wipe it off carefully and allow it to evaporate before pouring oil into the cleaned compartments. Health hazard Before you use a cleaning agent, read the supplier’s Material Safety Data Sheet (MSDS) and follow the instructions carefully. Risk of serious injuries to eyes, skin, respiratory system etc. Use personal protection and other safety measures as recommended in the MSDS. Handle all cleaning agents and their waste with care and according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Collect the waste in suitable containers and dispose as recommended in the MSDS and according to local regulations.
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Tank unit Sandvik CTHS430:02 OMM
2.2.9 Lifting and moving loads CAUTION!
Only personnel with adequate lifting training are permitted to perform lifting operations. Hanging load Never work or stand underneath a crane that is lifting material. Keep a safe distance to hanging loads.
DANGER!
Make sure that the capacity of the lifting equipment (Working Load Limit, WLL) is adequate and that the lifting equipment is in good working order. If lifting tackle has to be made up by joining separate components, make sure that the joints are secure and have the same lifting capacity (Working Load Limit, WLL) as the rest of the tackle. NOTE!
Always use lifting tackle certified in accordance with local conditions. Always engage the safety clips on lifting hooks to prevent the tackle from slipping off. Use ropes or poles to steady and maneuver loads. Never use hands or feet. Make sure that the route and the destination are free from obstacles before moving a suspended load. It must be possible to quickly and safely lower the load to the ground in case of an emergency. When depositing loads, keep the lifting equipment in place until it has been made sure that the load is stable.
2.3 Emissions For emissions such as dust, noise and radioactivity in the tank units environment, see section 2. Safety precautions in the crusher’s manuals.
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3. Lubrication systems To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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3. Lubrication systems
Tank unit Sandvik CTHS430:02 OMM
3.1 General The lubrication tank unit is supplied as a complete module with the oil tank and the various components mounted in a cabinet. The tank is equipped with an oil cooler. Two versions are available either the standard version an air/oil cooler or the optional version a water/oil heat exchanger, in this set of manuals are both called coolers. To prevent dust from entering the main lubrication tank and the crusher an overpressure blower is connected to the tank unit and the crusher. The standard version is an overpressure fan and the optional version is a regulator with filter connected to the sites compressed air system.
The tank components designation (bold) used in the text that follows are those that are used in the Installation manual and on the Piping and Instrumentation Diagram (PID) in the Installation Manual Appendix for the tank unit.
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3. Lubrication systems
3.2 Overview 3.2.1 Tank unit The tank unit consists of a cabinet (4) with two tanks, one for the main lubrication and one for the Hydroset oil, both protected with covers (1 and 5) on the cabinet’s top. The covers are used for inspection, cleaning and to pour oil into the tanks. Two pair of outlets are placed underneath the cabinet, one pair for the main lubrication tank and one for the Hydroset tank. Each pair has one outlet for oil and one for condensation water. An electrical cabinet (3) is placed on the same side as the connections to and from the crusher as well as from the overpressure system. 1 2 3 4 5
Main lubrication tank cover Lifting eye Electrical cabinet Cabinet Hydroset tank cover
5
1
4
2
3
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Tank unit Sandvik CTHS430:02 OMM
3.2.2 Cabinet The cabinet contains components of the main lubrication system and Hydroset system such as pumps, filters, valves, indicators etc. In the figures below, the tank unit and the interior of the cabinet is divided into different views: Main lubrication system with air/oil cooler (standard)
Hydroset system
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3. Lubrication systems
Heaters, temperature switches and level indicators
For further information about the pinionshaft oil bath lubrication, see the Operator’s or the Maintenance Manual for the crusher.
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Tank unit Sandvik CTHS430:02 OMM
3.3 Main lubrication components A
M2
TS4
TI1 PI2 H10 PS2 FU1
B
V10
FU1
HA1
A TS1 TS2 TI1
FS1
FU4
LV1
V1
A-A
B
TS1 TS2 TS3
HA1
E7.1
E7.2
LI1 E7.3 TS3 V1 E7.4 B-B FU7 TS4 CV4 M3
CV5
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3. Lubrication systems
3.3.1 Main lubrication components - designation The tank component’s designations on the drawing above and in the table below are those that are used in the Installation manual and on the Piping and Instrumentation Diagram (PID) in the Installation Manual Appendix for the tank unit.
© 2012 Sandvik SRP AB
Component designation, alphabetical order
Description
Note
CV4
By-pass valve
Check valve on air/oil cooler
CV5
By-pass valve
Check valve on water/oil cooler (option)
E7.1
Oil heater element
Oil in tank, cold climate option
E7.2
Oil heater element
Oil in tank
E7.3
Oil heater element
Oil in tank
E7.4
Oil heater element
Oil in tank, cold climate option
FS1
Flow switch
Monitoring the return oil flow (not shown)
FU1
Filter unit with cartridge
Oil, main lubrication
FU4
Filter unit with dirt trap
Oil, main lubrication
FU7
Filter unit with dirt trap
Water to water/oil cooler, option
H10
Warning lamp, red
Too high oil pressure across filter FU1
LI1
Level indicator
Oil level in main lubrication tank
LV1
Logic element valve with drain
Main lubrication system Main lubrication system
M2
Pump and motor
M3
Fan motor
Air/oil cooler
OS1
Return oil screen
In return oil chamber (not shown)
PI2
Pressure indicator
Shows oil pressure across filter FU1 Oil pressure across filter FU1
PS2
Pressure switch
TI1
Temperature indicator
Oil temperature in return oil chamber
TS1
Temperature switch
Return oil chamber. Stops the crusher if the temperature exceeds the limit of the setting
TS2
Temperature switch
Oil in main lubrication tank. Starts the air/oil cooler when return oil temperature exceeds the limit of the setting
TS3
Temperature switch
Controls the heater elements in the main lubrication tank
TS4
Temperature switch
Controls the inlet water to the water/oil cooler (option), adjustable
V1
Ball valve
Main lubrication system NOTE! Must be open during operation
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Tank unit Sandvik CTHS430:02 OMM
3.4 Hydroset components A
V10
PI1 B
C
B
C
V10
FU3 M6 A-A
A
V10
PI1
HA1 LI2 V4 B-B
C-C
V5
HA1
L1
FV8 RV2 RV3 RV4 CV3”1B” CV3”1A” R CV1 MP2 MP1 C MP3 B
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T
A
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3. Lubrication systems
3.4.1 Hydroset components - designation The tank component’s designation on the drawing above and in the table below are those that are used in the Installation manual and on the Piping and Instrumentation Diagram (PID) in the Installation Manual Appendix. Component designation, alphabetical order
Description
Note
A, B, C, R and T
Ports
See VB1 below
CV1
Check valve
Pilot operated
CV3”1A”
Check valve
Mainshaft raising
CV3”1B”
Check valve
Mainshaft lowering
FU3
Filter unit with cartridge
Return oil filter
FV8
Needle flow valve
Relieves system pressure
HA1
Hydraulic assembly
See below
L1
Push button box
ASRi-L1, for Close Side Setting (CSS)
LI2
Level indicator
Oil level in Hydroset tank, min.-max.
M6
Pump and motor
Hydroset
MP1
Measuring nipple
Pressure in port B Pressure in port A
MP2
Measuring nipple
MP3
Measuring nipple
Pressure in port C
PI1
Manometer
Activated by V5
RV2
Pressure relief valve
Raises the pressure to open CV1 Pressure limit for pump
RV3
Pressure relief valve
RV4
Pressure relief valve
Pressure limit for system
V4
Ball valve
Pump drainage line, closed position on drawing
V5
Ball valve
Valve block VB1 suction line, closed position on drawing
V10
Shut-off valve
Activates and protects pressure indicator PI1
HA1 Raising the mainshaft to increase the setting. The pump sucks the oil via port T through check valve CV3”1A” and port A. The oil is pumped via port B to the pilot operated check valve CV1 and then to the crusher via port C. When the pump stops, the pilot operated check valve CV1 will close to prevent oil from draining to the tank. Lowering the mainshaft to decrease the setting. The pump works in reversed direction and sucks the oil from port T via check valve CV3”1B” and port B to port A. From port A the oil is pumped via the pressure relief valve RV3 and further on to port R to raise the pressure until the pilot operated check valve CV1 opens. By then it is possible to suck the oil via port C.
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Tank unit Sandvik CTHS430:02 OMM
3.4.2 CH-crusher’s accumulator The CH-crushers has an accumulator connected to the Hydroset and mounted on the crusher. Accumulator components
AC
MP5 CV6
Accumulator components - designation Component designation, alphabetical order
Description
Note
AC
Accumulator
On CH-crusher
CV6
Check valve
On CH-crusher
MP5
Measuring point (nipple)
On CH-crusher
For further information, see the Operator’s and Maintenance Manuals for the crusher.
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3. Lubrication systems
3.5 Connections and drainage P
L
N
D U
D
J
V U
O
1
2
3
4
V
U
3.5.1 Connections and drainage - designation Connections Description and drainage
© 2012 Sandvik SRP AB
Note
1
Water drain plug
Condensation water from main lubrication tank
2
Oil drain plug
Oil from main lubrication tank
3
Oil drain plug
Oil from Hydroset tank
4
Water drain plug
Condensation water from Hydroset tank
J
Water to cooler
Water/oil cooler option
L
Oil from crusher
Main lubrication tank
M
Oil pipe/hose to crusher
From connection V
N
Oil to and from crusher
Hydroset tank
O
Water from cooler
Water/oil cooler option
P
Overpressure air
To tank via T-connection on pinionshaft housing
U
Oil from tank
Air/oil cooler and water/oil cooler option
V
Oil to crusher
Air/oil cooler and water/oil cooler option
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Tank unit Sandvik CTHS430:02 OMM
3.6 Pinionshaft lubrication The pinionshaft is lubricated in an oil bath in the pinionshaft housing. For main part of the information about checking and changing the oil in the pinionshaft housing: See Maintenance Manual for the crusher. For information about lubricants for the pinionshaft, see section 7.4 Oil for pinionshaft lubrication in this manual.
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3. Lubrication systems
3.7 Overpressure components 3.7.1 Overpressure fan FU5 PF M8
C
P
3.7.2 Overpressure fan components - designation
© 2012 Sandvik SRP AB
Component designation, alphabetical order
Description
Note
C
Coupling to the pinionshaft housing
Overpressure fan/compressed air regulator Overpressure fan
FU5
Air filter
M8
Motor to fan
Overpressure fan
P
Coupling to the main lubrication tank
Overpressure fan/compressed air regulator
PF
Fan
Overpressure fan
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Tank unit Sandvik CTHS430:02 OMM
3.7.3 Overpressure air regulator FV6 FU6
C PI4
P
3.7.4 Overpressure air regulator components designation
40
Component designation, alphabetical order
Description
Note
C
Coupling to the pinionshaft housing
Overpressure fan/compressed air regulator
FU6
Air filter unit
Compressed air regulator
P
Coupling to the main lubrication tank
Overpressure fan/compressed air regulator
PI4
Pressure indicator, manometer
Compressed air regulator
FV6
Flow valve pressure regulator
Compressed air regulator
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4. Starting up the tank The complete instruction for running-in the crusher and the tank unit is collected in the Operator’s Manual for the crusher. This section is mainly a list of references for more information about measures to be taken on the tank unit during running-in of the crusher. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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4. Starting up the tank
Tank unit Sandvik CTHS430:02 OMM
4.1 General Each tank unit delivered by Sandvik SRP AB has been assembled, test run and checked in our factory before shipping. The test run is carried out without connection to the crusher to discover any mechanical faults.
4.2 Running-in For complete step-by step instructions for running-in the crusher and the tank unit, see the Operator’s Manual for the crusher. List of references for more information • Valves V1, V4 and V5 are open, see drawing in section 5.1.1 Start • Level indicator LI1 for oil in the main lubrication tank, see drawing in section 4.2.1 Starting the main oil pump. • Temperature indicator TI1 in the return oil chamber, see section 8.1.8 Temperature indicator. • Temperature switch TS2 for oil cooling control, see section 8.1.12 Temperature switches and section 8.1.13 Oil heating control. • Return oil screen OS1 in the return oil chamber, see section 8.2.6 Return oil screen and oil tank cleaning. •
•
42
Hydroset push button V10 and pressure indicator PI1, see drawing in section 3.4 Hydroset components. For pressure limits, see section 10. Technical specifications. Pressure indicator PI2 for pressure drop across filter FU1, see section 8.1.6 Pressure indicator.
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4. Starting up the tank
4.2.1 Starting the main oil pump LI1
Before the main oil pump is started check the oil level LI1 (for main lubrication tank’s volume, see section 10.2.1 Main lubrication system). When the pump is started, the oil tank must be full (MAX. or a little less) of oil so that the pump does not operate dry. When the pump is operating the oil level should be slightly above the holder (1) on the level indicator LI1. For more information about the oil requirements, see section 7.2 Oil for lubrication system.
4.2.2 Starting a crusher in extremely low temperatures In extremely low temperatures it may be found that lubrication oil overflows over the dust collar when the main lubrication pump is started before normal operating temperature is reached. a) Start and stop the oil pump repeatedly at 10 second intervals until the “Ready for start” signal is obtained. Then start the crusher and allow it to run idle. Check that the oil flow is normal, see section 8.1.10 Return oil flow switch. • For more information about avoiding problems when operating in low temperature, see the Installation Manual for the tank unit.
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Tank unit Sandvik CTHS430:02 OMM
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5. Using the tank unit This section describes basic procedures when using the tank. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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5. Using the tank unit
Tank unit Sandvik CTHS430:02 OMM
5.1 Starting and stopping The crusher and the tank unit are normally controlled by a control system which restricts the ways in which it can be started. Read complementary information from the manufacturer of the control system. Nevertheless, follow or check that the control system follows the start and stop procedures below. For further information about running-in, after repair work or fitting of new parts, see the Operator’s Manual for the crusher. Follow the routine inspection and care procedures described in section 6.1 Routine inspection and care, e.g. daily check the items under section 6.1.1 Daily. For starting the tank unit and the crusher in extremely low temperatures, see section 4.2.2 Starting a crusher in extremely low temperatures and the Installation Manual for the tank unit.
5.1.1 Start M2
H10
PS2 TS3
M6
V4 V1 NOTE!
V5
The oil heating should run for 24 hours a day. The heating elements are automatically controlled by the oil heating temperature switch TS3. a) Start the main lubrication oil pump M2. b) When the signal “Ready for start” lights up, start the crusher’s drive motor M1. (Continued)
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5. Using the tank unit
Hot surface Equipment and hoses/pipes containing oil can have hot surfaces. Always wear protective gloves. WARNING!
c) When the oil has reached operating temperature reset the red pop up button on the pressure switch PS2. If the button pop up immediately or the red warning lamp H10 is lit, stop the crusher and the pump to exchange the filter cartridge at once. See section 8.2.5 Filter exchange, main lubrication. For starting the crusher, see the Operator’s Manual for the crusher.
5.1.2 Normal operation During normal operation: • • • NOTE!
The pump M2 is active. The pump M6 is active when the crusher’s setting is being adjusted. The valves V1, V4 and V5 are open.
Never close any of the valves before the pumps have stopped. If the oil flow is inconsistent or too low check the pumps, see section 6. Inspection and care and section 9. Troubleshooting.
5.1.3 Stop a) Stop the feeder, but let the crusher run until the crushing chamber is free of process material. b) Stop the crusher’s drive motor M1. c) Stop the main lubrication oil pump M2. If any service or maintenance is to be performed during the stop: Wait a few minutes to let oil from the crusher and hoses return to the tank. Hot oil Lubrication and hydraulic oil can become very hot during operation. Allow the oil to cool before working on the systems. WARNING! NOTE!
© 2012 Sandvik SRP AB
The oil heating should run for 24 hours a day. The heating elements are automatically controlled by the oil heating temperature switch TS3.
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Tank unit Sandvik CTHS430:02 OMM
5.2 Changing oil
WARNING!
NOTE!
Risk of fire and toxic gases Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow the instructions and safety directions in the Material Safety Data Sheet (MSDS) from the lubricant supplier when handling oils and greases.
Never mix different brands or types of lubricants. A bad mixture may cause precipitation and loss of its lubricating characteristics. Consult the lubricant supplier. Normally the old lubricant must be flushed out very carefully before a change is made, see section 8.2 Main lubrication oil exchange. The lubricant manufacturer(s) can provide information on whether mixing can take place or not .
TS1 TS2
TS1 TS2 TS3
(E7.1) E7.2
E7.3
TS3
TS1, TS2, TS3
(E7.4)
Designation
Description
Note
(E7.1)
Oil heater element
Oil in main lubrication tank, cold climate option
E7.2
Oil heater element
Oil in main lubrication tank, standard installation
E7.3
Oil heater element
Oil in main lubrication tank, standard installation
(E7.4)
Oil heater element
Oil in main lubrication tank, cold climate option
TS1
Temperature switch
Return oil to main lubrication tank Stops the crusher if the temperature exceeds the maximum limit. This to avoid damage to the crusher parts
TS2
Temperature switch
Starts the air/oil cooler when return oil temperature exceeds the settings
TS3
Temperature switch
Controls the temperature of the oil in the main lubrication tank
(Continued)
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5. Using the tank unit
5.2.1 Normal operating conditions Normal operating conditions Ambient air temperature
±0 to +32 °C (+32 to +90 °F)
a) Choose a main lubrication oil for normal operating conditions according to section 7.2 Oil for lubrication system.
FU1
FU3
TS1 TS2 TS1
FU4
TS2 TS3
TS3
b) Exchange the main lubrication oil according to section 8.2 Main lubrication oil exchange. Also change the filter cartridge FU1 and clean the dirt trap FU4, return oil screen OS1, tank and cooler. See from section 8.2.4 Dirt trap cleaning, main lubrication to section 8.2.8 Cleaning out oil remnants, water/oil cooler (option). c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system and exchange oil in the Hydroset system. Also change the filter cartridge FU3, see section 8.5.5 Oil filter. d) Exchange the oil in the pinionshaft housing. Always use the same oil as in the main lubrication system, see section 7.2 Oil for lubrication system e) If temperature switches TS1, TS2 and TS3 are not already set for normal operating conditions, reset them according to section 8.1.12 Temperature switches and section 8.1.13 Oil heating control.
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5. Using the tank unit
Tank unit Sandvik CTHS430:02 OMM
5.2.2 Operation at elevated temperatures Operation at elevated temperatures Ambient air temperature
+32 to +40 °C (+90 to +104 °F)
If the ambient temperature is so high that the cooling system cannot keep the return oil temperature below 50 °C (122 °F), it may be necessary to permit operation at an elevated temperature. In such a case, contact Sandvik SRP AB. At the same time, a change must be made to a lubricating oil with higher viscosity: a) Choose a main lubrication oil for operation at elevated temperatures according to section 7.2 Oil for lubrication system.
FU1
FU3
FU4
TS1 TS2 TS1
TS2 TS3
TS3
b) Exchange the main lubrication oil according to section 8.2 Main lubrication oil exchange. Also change the filter cartridge FU1 and clean the dirt trap FU4, return oil screen OS1, tank and cooler. See from section 8.2.4 Dirt trap cleaning, main lubrication to section 8.2.8 Cleaning out oil remnants, water/oil cooler (option). c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system and exchange oil in the Hydroset system. Also change the filter cartridge FU3, see section 8.5.5 Oil filter. d) Exchange the oil in the pinionshaft housing. Always use the same oil as in the main lubrication system, see section 7.2 Oil for lubrication system e) If temperature switches TS1, TS2 and TS3 are not already set for normal operating conditions, reset them according to section 8.1.12 Temperature switches and section 8.1.13 Oil heating control.
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5. Using the tank unit
5.2.3 Operation in low temperatures Operation in low temperatures Ambient air temperature
-30 to ±0 °C (-22 to +32 °F)
The oils viscosity increases at low temperatures, but normally it’s not necessary to change to a thinner oil during the winter as the oil tank is equipped with heating elements. Furthermore, there are several other ways to reduce the risk for freezing including e.g. insulation and extra heating. See the Installation manual for the tank unit and consult Sandvik SRP AB. Nevertheless, in extremely low temperatures it can sometimes be advisable to change to a less viscous oil: a) Choose a main lubrication oil for operation in low temperatures according to section 7.2 Oil for lubrication system.
FU1
FU3
TS1 TS2 TS1
FU4
TS2 TS3
TS3
b) Exchange the main lubrication oil according to section 8.2 Main lubrication oil exchange. Also change the filter cartridge FU1 and clean the dirt trap FU4, the return oil screen OS1, tank and air/oil or water/oil heat cooler. See from section 8.2.4 Dirt trap cleaning, main lubrication to section 8.2.8 Cleaning out oil remnants, water/oil cooler (option). c) Choose a Hydroset oil according to section 7.3 Oil for Hydroset system and exchange oil in the Hydroset system. Also change the filter cartridge FU3, see section 8.5.5 Oil filter. It is normally unnecessary to change to a different grade of Hydroset oil. However, if conditions are so extreme that a less viscous oil or a heater in the Hydroset tank is needed, consult Sandvik SRP AB. (Continued)
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5. Using the tank unit
Tank unit Sandvik CTHS430:02 OMM d) Exchange the oil in the pinionshaft housing. Always use the same oil as in the main lubrication system, see section 7.2 Oil for lubrication system. e) For operation under extreme ambient temperatures, consult the lubricant supplier regarding grease for spider bearing lubrication, see the Operator’s Manual for the crusher. f) If temperature switches TS1, TS2 and TS3 are not already set for operation in low temperatures, reset them according to section 8.1.12 Temperature switches and section 8.1.13 Oil heating control.
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6. Inspection and care This section describes the routine inspection and care instructions for the tank. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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6. Inspection and care
Tank unit Sandvik CTHS430:02 OMM
6.1 Routine inspection and care Every tank unit must be subjected to regular systematic checks. This will result in fewer and smaller repairs, less downtime and thus lower overall running costs. NOTE!
A new tank unit must be inspected often during the initial operating period. The intervals between inspections can then be increased until a suitable frequency is found. Keep a written log including the tank unit’s operating conditions and pressure, important data and details of adjustments made and any repairs carried out. An example of such a record sheet can be found behind the tab Inspection list in the binder. Since crushers and tank units operate under widely differing conditions, it is impossible to recommend an inspection and care schedule applicable to all crushers. However, regular inspections are necessary. The following table describes an example.
6.1.1 Daily The operator is responsible for these inspections daily or after every 8 hours of operation. Action
When
See section
Check the oil level in the lubrication tank.
Before starting the crusher
8.2
Check the oil level in the Hydroset tank.
Before starting the crusher
8.5
Check that the shut-off valves between the tanks and pumps are fully open.
Before starting the pumps and crusher
5.1.1
Check that lubricating oil returns to the tank and that the oil is clean.
After starting the lubrication pump
8.1.11
Check that the oil lines do not leak.
After starting the pumps
–
Listen for abnormal noises in the lubrication pump.
While crushing and before
–
Check the return oil temperature.
While crushing
8.1.8
Check the Hydroset pressure.
While crushing
8.5.3
Check the oil pressure of the main lubrication system at normal operating temperature.
While crushing
8.1.6
Check that there is no oil leakage.
While crushing
–
Check that the oil heaters are working.
With crusher stopped
8.1.13
Check that there is no contamination increase or change on the return oil screen, e.g. an abnormal amount of metal particles.
With crusher and lubrication pump stopped
8.1.11
(Continued)
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6. Inspection and care
6.1.2 Weekly The operator is responsible for these inspections weekly or after every 40 hours of operation. Action
When
See section
Inspect the oil filter (check if the red button on the pressure switch PS2 protrudes).
With crusher and lubrication pump stopped
8.1.4, 8.2.5
Clean the dirt trap and inspect the oil tank of the main lubrication system.
With crusher and lubrication pump stopped
8.1.1, 8.1.3, 8.2
Check the pumps for abnormal noise and wear.
While crushing.
8.1.5, 8.5.2
Check the oil level in the pinionshaft housing.
With crusher stopped
Operator’s manual for the crusher
Check the cooler core of the air/oil cooler.
With crusher and lubrication pump stopped
8.3
Check the air pressure (fan running or regulator working) of the overpressure dust sealing.
Running idle
6.2.1
Check the hose and filter of the overpressure dust sealing and that the covers on the tank unit are air tight.
With crusher stopped
6.2.1
6.1.3 Monthly The operator is responsible for these inspections that should be carried out monthly or after every 160 hours of operation. The crusher must be stopped. Action
See section
Clean the air vent nipple on the pinionshaft housing.
Operator’s manual for the crusher
Check the tightness of all bolts.
–
Check the quality of the lubrication oil.
7.2
Check the function of the return oil flow switch.
8.1.10
(Continued)
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6. Inspection and care
Tank unit Sandvik CTHS430:02 OMM
6.1.4 Twice a year The operator is responsible for these inspections that should be carried out twice a year or after every 1000 hours of operation. The crusher must be stopped. Action
See section
Clean out the oil tank.
8.1.1, 8.2
Change the oil filter cartridge of the Hydroset system.
8.5.5,
6.1.5 Yearly The operator is responsible for these inspections that should be carried out yearly or after every 2000 hours of operation. The crusher must be stopped. Action
See section
Change oil in the pinionshaft housing.
Operator’s manual for the crusher
Check the function of the temperature indicator.
8.1.8
Check the function of the protective temperature switch TS1 and the temperature switch for the cooler TS2
8.1.12
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6. Inspection and care
6.2 Overpressure dust sealing The crusher and the tank shares a system to keep out dust. Air is introduced into the main lubrication oil tank and the crusher at a small overpressure. A slight negative pressure may otherwise occur when the lubricating oil is circulating. The resultant negative pressure will draw dust into the tank and the crusher and contaminate the oil. Dirt and dust in the lubricant will result in rapid blockage of the filters, accelerated wear of the step bearing components and sedimentation in the oil tank. Other components inside the crusher will also be subjected to unnecessarily heavy wear.
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Tank unit Sandvik CTHS430:02 OMM
6.2.1 Overpressure parts 1 2 P C
FU5 PF M8 1 2 1
C
2
2
FU6 FV6 F5 PF M8 FV6 FU6 P14
Air supply coupling Hoses Coupling to the oil tank unit Coupling to the pinionshaft housing
P14
Filter to overpressure fan Fan Fan motor Compressed air regulator Filter unit to air regulator Manometer
P 2
The overpressure air can be provided by an fan PF as described in section 6.2.3 Fan or from a compressed air system with regulator FV6 as described in section 6.2.4 Regulator assembly for compressed air. Hoses are connected from the overpressure unit to the crusher and the tank unit to accomplish pressure equalization. One hose is connected from the overpressure fan or the compressed air regulator to the T-connector C mounted on the crusher, above the pinionshaft housing. The other hose is connected from C to the sleeve P welded on the tank unit shell and placed above the oil level in the main lubrication tank. NOTE!
The covers on the tank unit must be airtight. Adjust or replace the sealing strips if necessary. When the crusher and the tank are operating, measure the air pressure at the entry to the crusher and check that it is within the limits shown in the table below. Unit
Pa
Air pressure in the tank during operation
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600-1000
psi
0.087-0.145
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6. Inspection and care
6.2.2 Air flow Minimum capacity for air flow at 600 Pa (0.087 psi) pressure
m3/min
foot3/min
0.3
10.6
6.2.3 Fan FU5 PF M8
C FU5 PF M8 P
C
Coupling to the pinionshaft housing Filter Fan Fan motor Coupling to the tank unit
P Check The fan PF has an air filter FU5 with a replaceable pleated paper element. Inspect the filter element at regular intervals and change it when necessary.
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Tank unit Sandvik CTHS430:02 OMM
6.2.4 Regulator assembly for compressed air The regulator assembly includes pressure indicator PI4, a manometer showing the overpressure measured at the entry to the crusher. FV6
FU6
C FU6 FV6 P PI4
C PI4
Coupling to the pinionshaft housing Filter Pressure regulator Coupling to the tank unit Manometer
P
Check The overpressure regulator has an air filter FU6 with a replaceable element. Inspect the filter element at regular intervals and change it when necessary.
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7. Lubricants This section describes the requirements that must be put on the lubricants used in the crusher and the tank unit. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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7. Lubricants
Tank unit Sandvik CTHS430:02 OMM
7.1 Lubricant requirements If the crusher is to be utilized optimally, stringent demands must be made on the lubricants that are used. NOTE!
WARNING!
NOTE!
Lubricants which do not meet Sandvik SRP AB’s requirements must not be used during the warranty period. Risk of fire and toxic gases Oil products present environmental and fire risks and can cause injury if inhaled or brought into contact with the skin. Follow your lubricant supplier’s Material Safety Data Sheet (MSDS) instructions and safety directions when handling oils and greases.
Changing the oil is described in section 5.2 Changing oil. Check A change in oil color may indicate the presence of water or dirt. Change the oil.
7.1.1 Miscibility NOTE!
Never mix different brands or types of lubricants, unless mixing is known to be appropriate. A bad mixture may cause precipitation and a loss of the lubricant’s characteristics. Normally, old lubricants must be flushed out very carefully before replacing with new lubricants, see section 8.2 Main lubrication oil exchange. The lubricant manufacturer(s) can provide information on whether mixing is appropriate.
7.1.2 Low temperatures The oils viscosity increases at low temperatures, but normally it’s not necessary to change to a thinner oil during the winter as the oil tank is equipped with heating elements. Furthermore, there are several other ways to reduce the risk for freezing including e.g. insulation and heaters. See the Installation Manual for the tank unit and consult Sandvik SRP AB. Nevertheless, in extremely low temperatures it can sometimes be advisable to change to a less viscous oil. See section 5.2.3 Operation in low temperatures. (Continued)
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7. Lubricants
7.1.3 High temperatures If the ambient temperature is so high that the cooling system cannot keep the return oil temperature below 50 °C (122 °F), it may be necessary to permit operation at an elevated temperature. In such a case, contact Sandvik SRP AB. At the same time, a change must be made to a lubricating oil with higher viscosity. See section 5.2.2 Operation at elevated temperatures.
7.2 Oil for lubrication system The oil Sandvik SRP AB recommends must have mild EP additives and must comply with the requirements specified in the table below. Requirement specification The oil shall meet the requirements in the table below. Furthermore, it shall contain anti-wear additives as well as additives to prevent oxidation and foaming. The oil must be harmless to copper alloys, as these are used in the crusher’s bearings. Oil requirements for different operating conditions Characteristics
Operating conditions
Testing method
Operation in low temperatures
Normal
Operation at elevated temperatures
Operation at extreme temperatures
Ambient air temperature
–30 to 0 °C (–22 to 32 °F)
–10 to 32 °C (14 to 90 °F)
25 to 40 °C (77 to 104 °F)
35 to 50 °Ca (95 to 122 °F)
Tank temperature (oil to crusher)
From 25 °C (From 77 °F)
From 35 °C (From 95 °F)
From 42 °C (From 131 °F)
From 49 °C (From 131 °F)
Base oil viscosity at (cSt) at 40 °C(104 °F)
100
150
220
320
Base oil type
mineral or PAO ≥ 95
Viscosity index base oil natural Base oil specified weight kgm3 at 15 °C (59 °F)
≥ 870
≥ 870
Lowest pour point
Copper corrosion Rust test Oxidation resistance TOST, hours
≥ 870
ASTM D-2270, DIN ISO 2909 ≥ 880
≥ 200 °C (392 °F)
Flash point COC
Greasability FZG, step
ASTM D-445, DIN EN ISO 3104
≤ –20 °C (-4 °F)
≤ –15 °C (5 °F)
≤ –10 °C (14 °F) ≤ 12 1A
ASTM D-1298 DIN 51 376 ASTM D-92, DIN ISO 3016
≤ –5 °C (23 °F)
ASTM D-97 DIN 51 354 ASTM D-130, DIN 51 811
Approved
ASTM D-665
≤ 1 500
ASTM D-943
a. With oil that meets these specifications, the crusher may be run in ambient temperatures from +40 to +50 °C, if these temperatures are temporary and exceptional. Also refer to section 5.2.2 Operation at elevated temperatures
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7. Lubricants
Tank unit Sandvik CTHS430:02 OMM Examples of lubricants The examples listed below are lubricants which – according to the respective manufacturer – comply with Sandvik SRP AB’s requirements. Local variations can occur in different countries. For safety’s sake, check with your supplier that the selected lubricant complies with the requirements in question. In addition to the lubricants listed, a number of other brands and qualities meet Sandvik Rock Processing’s requirements and are accordingly also usable. Mineral oils For operation under normal conditions: BP Energol GR-XP 150 ESSO Spartan EP 150 Klüber Klüberoil GEM 1-150 Mobil Mobilgear 600XP 150
Molub-Alloy Tribol 1100/150 Shell Omala 150 Statoil LoadWay EP 150 Texaco Meropa 150
For operation at elevated temperatures: BP Energol GR-XP 220 ESSO Spartan EP 220 Klüber Klüberoil GEM 1-220 Mobil Mobilgear 600XP 220
Molub-Alloy Tribol 1100/220 Shell Omala 220 Statoil LoadWay EP 220 Texaco Meropa 220
For operation in low temperatures: BP Energol GR-XP 100 ESSO Spartan EP 100 Klüber Klüberoil GEM 1-100 Mobil Mobilgear 600XP 100
Molub-Alloy Tribol 1100/100 Shell Omala 100 Statoil LoadWay EP 100 Texaco Meropa 100
Biologically degradable oil If a biologically degradable oil is to be used, Sandvik SRP AB recommends that only a 100 % synthetic oil of ester type is selected. If the ambient air temperature is over 32 °C (90 °F), it may still be necessary to reset temperature switches TS1 and TS2 for “Operation at elevated temperatures” since TS1 could otherwise trip because of excessively high oil temperature and thus stop the crusher, see section 8.1.12 Temperature switches. Example:
Tribol Bio Top 1418/150 (VI > 170) (Continued)
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7. Lubricants
Oil quantity Capacity Lubrication oil tank
150 liters / (40 US gal)
When the crusher is running, the oil level must be above the minimum level mark. See the oil level indicator LI1 in the tank unit. When the crusher stops, a certain amount of oil will remain in the crusher and the oil supply lines. The tank should therefore be topped up after testrunning. To prevent flooding over the screen when oil drains back to the tank after the crusher has been stopped, be very restrictive with topping up if the oil lines between the tank and the crusher are long. CAUTION!
Make sure that the heating element tubes and their temperature switch TS3 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 lead additives to an oil with sulphur/phosphorus additives. The oil which is trapped in the crusher must be drained out by breaking the supply line at a suitable point between the crusher and the lubrication oil tank unit. When this is done, the mainshaft must be raised to its highest position so that the oil in the Hydroset piston runs out.
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7.3 Oil for Hydroset system Requirement specification The oil used in the Hydroset system must be miscible with the lubricating oil and comply with the same requirements. However, the viscosity must be according to ISO VG 68 or DIN 51 517-CLP 68. Requirements for the Hydroset oil Properties
Requirement
Test method
Viscosity grade
68
DIN 51 519
Type of base oil
mineral or PAO
Viscosity - nominal, cSt@ 40 °C
68
DIN EN ISO 3104, ASTM D-445
Viscosity index - natural
≥ 95
DIN ISO 2909, ASTM D-2270
Specific gravity, kg/m3 @ 15 °C
≥ 870
DIN 51 757, ASTM D-1298
Flash point COC, °C
≥ 200
DIN 51 376, ASTM D-92
Pour point, °C
≤ - 25
DIN ISO 3016, ASTM D-97
FZG test, load
≥ 12
DIN 51 354
Oxidation stability TOST, hours
≥ 1 500
DIN EN ISO 4263, ASTM D-943
Corrosion copper
1A
DIN 51 811, ASTM D-130
Rust preventing
Pass
DIN 51 585, ASTM D-665
(Continued)
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7. Lubricants
Examples of oils for Hydroset system The examples listed below are oils which – according to the respective manufacturer – comply with Sandvik SRP AB’s requirements. 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 SRP AB’s requirement and are accordingly also usable. Mineral oils BP Energol GR-XP 68 ESSO Spartan EP 68 Klüber Klüberoil GEM 1-68 Mobil Mobilgear 600XP 68 NOTE!
Molub-Alloy Tribol 1100/68 Shell Omala 68 Statoil LoadWay EP 68 Texaco Meropa 68
Never use oil thicker than ISO VG 68, nor normal hydraulic oils. There can be problems with crushers that operate outdoors in very low temperatures, with the normally recommended oil. If this is the case, contact Sandvik SRP AB for information about changing to an oil with lower viscosity. Biologically degradable oil If a biologically degradable oil is to be used, we recommend that only a 100 % synthetic oil of ester type is selected. Example:
Tribol Bio Top 1448/68
Oil quantity Capacity Hydroset oil tank
40 liters / (10.6 US gal)
When the Hydroset oil tank is filled, the mainshaft must be in its lowest position. If the tank is filled when the mainshaft is in its highest position, there may not be sufficient room in the tank for all of the oil when the mainshaft is lowered. Oil changes The oil in the Hydroset system should be changed when the lubricating oil is changed. See section 5.2 Changing oil and section 7.2 Oil for lubrication system – Oil changes.
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7.4 Oil for pinionshaft lubrication When the crusher is delivered from the factory, the pinionshaft housing is filled with Mobil Mobilgear 600XP 150 oil. The oil used for pinionshaft lubrication must be the same as the oil in the main circulatory lubrication system. See section 7.2 Oil for lubrication system and Operator´s Manual for the crusher.
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8. Maintenance This section describes the maintenance and service procedures for the main lubrication and Hydroset systems of the tank unit. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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8.1 Main lubrication system In the main lubrication circuit, oil is pumped from the tank through the filter FU1 and oil cooler to the crusher’s main lubrication inlet. Oil entering the crusher is pressed through the step bearing, up between the eccentric bushing and the mainshaft, and between the bottomshell bushing and the eccentric to lubricate these bearings. The oil lubricates the wearing plate and the bevel gears before running back to the tank unit by gravity.
A
A M2 TI1 FU1 PS2 PI2 H10
70
M2
TI1 PI2 H10 PS2 FU1 LV1
FU4
V1
Main lubrication pump and motor Temperature indicator, return oil chamber Main lubrication filter with cartridge Pressure switch, filter FU1 Pressure indicator for filter FU1 Warning lamp, high pressure across filter FU1
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A-A LV1 Check valve, main lubrication oil to cooler V1 Ball valve, main lubrication oil from tank (closed position on drawing) FU4 Dirt trap with filter screen L Main lubrication return oil inlet
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OMM Sandvik CTHS430:02 Tank unit
8. Maintenance
8.1.1 Cleaning the tank Contaminants such as stone dust, water etc, which enter the lubricating oil, will, to a certain degree, sink towards the bottom of the tank. This should therefore be cleaned out at least twice a year. This periodical cleaning prevents sludge following the oil withdrawn from just above the tank bottom. See section 8.2.6 Return oil screen and oil tank cleaning.
8.1.2 Condensation water, draining 1 Drain plug for condensation water in main lubrication tank 2 Drain plug for oil in main lubrication tank 3 Drain plug for oil in Hydroset tank 4 Drain plug for condensation water in Hydroset tank
1
2
3
4
Condensation water must be removed regularly to avoid too high a percentage of water in the oil. This can be done by taking out the screw in the condensation water drain plug (1) underneath the lubrication oil tank. Use the same procedure to drain the condensation water from the Hydroset tank. Check that the crusher and the appropriate pump are idle and that the oil in the main lubrication line has returned to the tank. a) Put a suitable container/bucket beneath the condensation water drain plug (1 or 4) to catch the water (and oil) that runs out. b) Unscrew the Allen head condensation water drain plug (1 or 4) slowly. c) When the oil content in the condensation water is increasing, screw back the condensation water drain plug (1 or 4) and tighten carefully. CAUTION!
© 2012 Sandvik SRP AB
Handle the drained condensation water as waste oil and dispose according to the oil supplier’s Material Safety Data Sheet (MSDS) and local regulations.
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8.1.3 Dirt trap, main lubrication The dirt trap FU4 protects the oil pump M2 and is mounted ahead of it. CAUTION! CAUTION! NOTE!
Clean the dirt trap regularly. If it is allowed to clog, cavitation will occur in the pump, which can result in pump breakdown. See section 8.2.4 Dirt trap cleaning, main lubrication. The gauze filter element must not, under any circumstances, be left out or replaced by another with a different mesh.
During the running-in period, and when the tank has been cleaned, check the dirt trap daily.
M2 Main lubrication oil pump FU4 Dirt trap V1 Shut-off valve (closed position on drawing)
FU4 V1
M2
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8. Maintenance
8.1.4 Main lubrication oil filter The type of oil filter used is full-flow, which means that all oil pumped to the crusher is filtered (exception, see below). The filter cartridge is of throwaway type.
M2
PI2 H10
PS2 1 FU1
1 M2 PI2 H10
Red pop-up button Main lubrication pump Pressure indicator Warning lamp, high oil pressure across main lubrication filter F1 PS2 Pressure switch FU1 Filter head with filter cartridge
The filter cartridge must be changed when the pressure drop across the filter exceeds 0.22 MPa (32 psi) at normal operating temperature. A red warning lamp H10 will light up and the pressure is shown on the pressure indicator PI2. On the pressure switch PS2 a red button will protrude. The filter cartridge must be changed immediately, see section 8.2.5 Filter exchange, main lubrication. There is a by-pass valve on the filter. It opens when the pressure drop across the filter exceeds 0.35 MPa (51 psi) for example if the crusher is started at low temperature when the oil is more viscous. When the valve is open, part of the oil flow by-passes the filter and is thus not filtered. NOTE!
© 2012 Sandvik SRP AB
If the filter cartridge has to be changed often, the crusher’s dust sealing system must be checked.
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8.1.5 Oil pump Normally the lubrication oil pump M2 requires no special attention. Wear can, however, be considerable if the oil contains stone dust or similar contaminants. The most usual sign of pump wear is a reduction in oil flow. CAUTION!
When the pump is started, the oil tank must be full of oil so that the pump does not operate dry. Before starting the pump, check that the shut-off valve V1 ahead of the dirt trap FU4 is open.
Exchange The pump’s capacity at normal operating temperature and pressure is shown in the table below. (If the motor is connected to a 60 Hz supply instead of a 50 Hz supply, the pump speed will be 20 % higher and the flow will increase). Exchange the oil pump when the flow has dropped below the minimum value in the table below. Lubricant flow Supply frequency 50 Hz
Supply frequency 60 Hz
Normal capacity
l/min
US gal/min
42
11.1
Min. capacity
32
8.5
Normal capacity
50
13.2
Min. capacity
38
10.0
Check Hot oil Lubrication oil can become very hot during operation. Always wear protective gloves. WARNING!
WARNING!
Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.
Check oil delivery by measuring the return oil flow. Position a bucket with a known volume beneath the opening in the return oil chamber and measure the time taken to fill the bucket. Example: It takes 20 seconds to fill a 10 liter bucket. The oil flow is thus: (10×60)/20 = 30 l/min or it takes 20 seconds to fill a 4 US gallon bucket. The oil flow is thus: (4×60)/20 = 12 US gal/min
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8.1.6 Pressure indicator M2
1 M2 PI2 H10 PS2 FU1 FU4 V1
PI2 H10 PS2 FU1
1
Red pop-up button Main lubrication pump Pressure indicator Warning lamp, high oil pressure across main lubrication filter F1 Pressure switch Filter with filter cartridge Dirt trap Shut-off valve
FU4
V1
The pressure indicator PI2 gives the pressure measured by the pressure switch connection between the oil pump M2 and the filter FU1. Check Check the pressure at regular intervals and keep a record of the readings. At operating temperature, the pressure in the main system is normally 0.15-0.5 MPa (21.8-72.5 psi), depending on tank installation. If the pressure ahead of the oil filter rises, this is a sign that the filter cartridge should be changed, see section 8.2.5 Filter exchange, main lubrication. An abnormally low pressure indicates that the pump is worn, or that the dirt trap is choked. NOTE!
© 2012 Sandvik SRP AB
When the fan of the air/oil cooler is running, the pressure in the oil system generally rises. Avoid reading off the pressure at such times.
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8.1.7 Pressure switch M2
PI2 H10 PS2 FU1
1
1 M2 PI2 H10
Red pop-up button Main lubrication pump Pressure indicator Warning lamp, high oil pressure across main lubrication filter F1 PS2 Pressure switch FU1 Filter with filter cartridge FU4 Dirt trap V1 Shut-off valve
FU4
V1
The pressure switch PS2 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 cartridge should be changed, see section 8.2.5 Filter exchange, main lubrication. The signal is given both electrically – to a warning lamp H10 on the outside of the tank unit – and in the form of a red button (1) which protrudes about 4 mm/0.16" from the top of the sensor. NOTE!
During a cold start, the pressure indicator PI2 and the warning lamp H10 can incorrectly give a signal due to higher oil viscosity. The electrical signal will automatically be reset when working temperature has been reached, but the mechanical signal (the red button) on the pressure switch PS2 must be reset manually. If the red button immediately pops up again, or if the lamp does not go out when working temperature has been reached, the filter cartridge FU1 must be changed, see section 8.2.5 Filter exchange, main lubrication.
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8.1.8 Temperature indicator TI1
TI1 Temperature indicator, oil in return oil chamber.
A temperature indicator TI1 monitors and shows the return oil temperature. The return oil temperature is affected by the load of the crusher and the ambient air temperature. See section 8.1.12 Temperature switches. Check Check the temperature indicator once a year against a reference thermometer to ensure that it reads correctly. Carry out this check at an oil temperature of 40-50 °C (104-122 °F).
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8.1.9 By-pass valves on coolers CV5 CV4
CV4 By-pass valve on air/oil cooler CV5 By-pass valve on water/air cooler (option)
Air/oil cooler A by-pass valve CV4 is fitted between the oil filter FU1 and the air/oil cooler. Its duty is to limit the pressure over the pump M2 and air/oil cooler if the crusher is started at low temperature when the oil is more viscous. The valve is set at 0.8 MPa (116 psi). Water/oil cooler (option) A by-pass valve CV5 is fitted between the oil filter FU1 and the water/oil cooler. Its duty is to limit the pressure over the pump M2 and water/oil cooler if the crusher is started at low temperature when the oil is more viscous. The valve is set at 0.3 MPa (43.5 psi).
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8.1.10 Return oil flow switch 1 2 3 4 5 FS1 OS1
Float Weir Adjustable lower outlet Return oil chamber Return oil screen handle Return oil flow switch Return oil screen
FS1 1 2 5
3
4
OS1
The return oil flow is monitored by an oil flow switch FS1 inside the return oil chamber in the oil tank. The return oil flow switch FS1 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 FS1. In addition, the main lubrication oil pump M2 cannot be started unless the return oil flow switch FS1 is functioning properly. The return oil flow switch is connected to a float (1) in the return oil chamber (4) in the tank and monitors whether the float is up or down. The return oil chamber has an adjustable lower outlet (3) and an overflow weir (2). CAUTION!
The lower outlet (3) has been adjusted at the factory before delivery and must not be altered.
When a sufficient flow of oil is returning to the tank, the oil level in the return oil chamber (4) should be 5 mm (0.20") above the weir. With this oil level in the return oil chamber (4), the float (1) is completely immersed in oil but the oil’s lifting force pushes the float (1) up against its upper stop. If the oil flow decreases, the oil level will drop in the return oil chamber. When the oil level has dropped about 15 mm (0.59"), the float (1) will be floating on the oil about 5 mm (0.20") below the upper stop. In this position the microswitch opens and stops the crusher’s drive motor. Check Check the level monitor by pushing the float down about 5 mm (0.20") from its upper stop. The crusher’s drive motor must then stop. CAUTION!
© 2012 Sandvik SRP AB
To avoid skin irritation and burn injuries, wear protective gloves.
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8.1.11 Return oil screen
5 OS1 5 Return oil screen handle OS1 return oil screen
The return oil screen OS1 separates coarser contaminants from the oil and deaerates the oil. Check The return oil screen requires careful inspection, check daily during the running-in period. An abnormal amount of metal particles can indicate trouble, and the cause should be investigated to forestall possible damage. For further information, see the Operator’s and Maintenance Manuals for the crusher. Clean the oil screen regularly: see section 8.2.6 Return oil screen and oil tank cleaning
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8.1.12 Temperature switches
TS1 Temperature switch, protective TS2 Temperature switch for air/oil or water/oil (option) cooler TS3 Temperature switch, heaters LI1 Level indicator, main lubrication oil tank E7.2 Oil heater E7.3 Oil heater
TS1 TS2 TS3 LI1 E7.2 E7.3
Two temperature switches, TS1 and TS2 have their sensing heads in the return oil chamber in the oil tank. TS1 is a protective temperature switch that shuts down the crusher’s drive motor if the oil temperature is too high. TS2 is a temperature switch for air/oil or water/oil cooler and controls the cooling of the oil pumped to the crusher. It is important that the correct temperature settings are used. Set the temperature switches according to the tables below for different operating conditions. For setting instructions from the manufacturer, see Installation Manual Appendix. TS1 Crusher drive motor shut-down function Operating conditions
Normal operating conditions
Operating at elevated temperature
Operating at low temperatures
Ambient air temperature
±0 to +32 °C (+32 to +90 °F)
+32 to +40 °C (+90 to +104 °F)
-30 to ±0 °C (-22 to +32 °F)
Oil viscosity
ISO VG 150
ISO VG 220
ISO VG 100
65 °C (149 °F) 65 °C (149 °F) 68 °C (154 °F) 1
52 °C (126 °F) 52 °C (126 °F) 55 °C (131 °F) 1
Protective temperature switch TS1 Basic setting Closes at Opens at Differential setting
CAUTION!
60 °C (140 °F) 60 °C (140 °F) 63 °C (145 °F) 1
The protective temperature switch TS1 shuts down the crusher when a serious fault occurs in the lubrication system so that the oil temperature rises excessively, for instance if the cooling system doesn’t work correctly. It is therefore important that none of the components are by-passed. Check the cause of the stoppage and correct it before the crusher is re-started.
(Continued)
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TS1 Temperature switch, protective TS2 Temperature switch for air/oil or water/oil (option) cooler TS3 Temperature switch, heaters LI1 Level indicator, main lubrication oil tank E7.2 Oil heater E7.3 Oil heater
TS1 TS2 TS3 LI1 E7.2 E7.3
TS2 Oil cooling control Operating conditions
Normal operating conditions
Operating at elevated temperature
Operating at low temperatures
Ambient air temperature
±0 to +32 °C (+32 to +90 °F)
+32 to +40 °C (+90 to +104 °F)
-30 to ±0 °C (-22 to +32 °F)
Oil viscosity
ISO VG 150
ISO VG 220
ISO VG 100
47 °C (117 °F) 51 °C (124 °F) 47 °C (117 °F) 3
33 °C (91 °F) 37 °C (99 °F) 33 °C (91 °F) 3
Temperature switch for cooler TS2 Basic setting Closes at Opens at Differential setting
40 °C (104 °F) 45 °C (113 °F) 40 °C (104 °F) 4
Check Check the protective temperature switch TS1 by immersing the sensing head in a slowly warmed oil bath together with a thermometer. Note the temperature at which the contacts break and then allow the oil to cool and note the temperature at which the contacts close. Check the temperature switch TS2 for the air/oil or water/oil coolers by holding a thermometer near the sensing head and note the temperatures at which the cooling fan or water pump starts and stops or at which the water valve opens and closes.
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8. Maintenance
8.1.13 Oil heating control
TS3 TS3 TS3 Temperature switch, heaters E7.2 Oil heater E7.3 Oil heater
E7.2 E7.3
To prevent oil overflowing the dust collar, the oil should be heated to the temperature given in the table below before the crusher is started. The standard oil tank unit is fitted with two electrical immersion oil heaters E7.2 and E7.3. The heaters are installed in tubes so that the oil is heated indirectly. There is a separate oil heating temperature switch TS3 which controls the heaters. For setting instructions from the manufacturer, see Installation Manual Appendix. TS3 Oil heating control Operating conditions
Normal operating conditions
Operating at elevated temperature
Operating at low temperatures
Ambient air temperature
±0 to +32 °C (+32 to +90 °F)
+32 to +40 °C (+90 to +104 °F)
-30 to ±0 °C (-22 to +32 °F)
Oil viscosity
ISO VG 150
ISO VG 220
ISO VG 100
Suitable temperature before crusher is started
30 °C (86 °F)
37 °C (99 °F)
25 °C (77 °F)
37 °C (99 °F) 37 °C (99 °F) 42 °C (108 °F) 3
20 °C (68 °F) 20 °C (68 °F) 25 °C (77 °F) 3
Oil heating temperature switch TS3 Basic setting Closes at Opens at Differential setting
NOTE!
30 °C (86 °F) 30 °C (86 °F) 35 °C (95 °F) 3
The oil heating should run for 24 hours a day. The heating elements are automatically controlled by the oil heating temperature switch TS3. Check Check that the heating elements and the sensor of the oil heating temperature switch are always covered by oil during operation.
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8.2 Main lubrication oil exchange 8.2.1 Draining the main lubrication system.
WARNING!
Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the lubrication systems. Hot oil Lubrication oil can become very hot during operation. Allow the oil to cool before working on the lubrication system.
WARNING! Hot surface Equipment and hoses/pipes containing lubrication oil can have hot surfaces. Always wear protective gloves. WARNING!
WARNING!
NOTE!
Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.
The following instructions can with advantage be followed in a sequence. (Continued)
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8.2.2 Tank with air/oil cooler CAUTION!
Collect all waste oil, diesel oil and white spirit in suitable containers. Handle with care and dispose according to the supplier’s Material Safety Data Sheet (MSDS) and local regulation.
V Lubrication outlet cooler to crusher U Lubrication inlet tank to cooler L1 Push button box for mainshaft setting 1 Drain plug for condensation water in main lubrication tank 2 Drain plug for oil in main lubrication tank 3 Drain plug for oil in Hydroset tank 4 Drain plug for condensation water in Hydroset tank
V L1
U
V
1
2
3
4
a) Disconnect the oil hose from the lubrication outlet V on the cooler. NOTE!
This must be done at the lowest point – usually at the oil cooler connection. b) Drain all oil from the crusher and the air/oil cooler (1) into a container. For air/oil coolers volume, see section 10.4.1 Air/oil cooler. c) Raise the mainshaft by using the push button box L1, which is located near the cone crusher, and drain the oil from the piston. d) Open the tank cover on the top of the tank unit. This will equalize the pressure and the oil will drain faster. e) Put a container (for tank volume, see section 10.2.1 Main lubrication system) beneath the drain plug for main lubrication oil (2). The plug is placed underneath the tank. f) Slowly unscrew the Allen head drain plug (2). Drain out all oil. g) Screw back the drain plug (2). h) Reconnect the oil line to the lubrication outlet V. i) Dispose the waste oil, see CAUTION! above.
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8.2.3 Tank with water/oil cooler (option) CAUTION!
Collect all waste oil, diesel oil and white spirit in suitable containers. Handle with care and dispose according to the supplier’s Material Safety Data Sheet (MSDS) and local regulation.
V Lubrication outlet cooler to crusher U Lubrication inlet tank to cooler L1 Push button box for mainshaft setting 1 Drain plug for condensation water in main lubrication tank 2 Drain plug for oil in main lubrication tank 3 Drain plug for oil in Hydroset tank 4 Drain plug for condensation water in Hydroset tank
V L1
U
V
1
2
3
4
a) Disconnect the oil line at the lowest point, usually inlet U. NOTE!
The lowest point is usually at the oil cooler connection. b) Drain all oil from the crusher and the water/oil cooler (1) into a container. For water/oil coolers volume, see section 10.4.2 Water/oil cooler (option). c) Raise the mainshaft by using the push button box L1, which is located near the cone crusher, and drain the oil from the piston. d) Open the tank cover on the top of the tank unit. This will equalize the pressure and the oil will drain faster. e) Put a container (for tank volume, see section 10.2.1 Main lubrication system) beneath the drain plug for main lubrication oil (2). The plug is placed underneath the tank. f) g) h) i)
86
Slowly unscrew the Allen head drain plug (2). Drain out all oil. Screw back the drain plug (2). Reconnect the oil line to the lubrication inlet U. Dispose the waste oil, see CAUTION! above.
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8. Maintenance
8.2.4 Dirt trap cleaning, main lubrication Hot surface Equipment and hoses/pipes containing lubrication oil can have hot surfaces. Always wear protective gloves. WARNING! CAUTION!
FU4 V1 1 2
The gauze element (1) must not, under any circumstances, be left out or replaced by another with a different mesh
FU4 V1
Dirt trap Shut-off valve (closed position on drawing) Gauze element Plug
a) b) c) d) e) f)
1 2
Close the shut-off valve V1 ahead of the dirt trap FU4. Have a suitable container ready to collect the oil that runs out. Unscrew the plug (2). Take out and clean the gauze element (1). Install the gauze element (1) and screw back the plug (2). Open the shut-off valve V1.
CAUTION!
Check that the shut-off valve V1 is fully open before the main lubrication pump is started. The pump and the hoses will be seriously damaged if the valve is closed.
NOTE!
During the running-in period, and when the tank has been cleaned, check the dirt trap daily.
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Tank unit Sandvik CTHS430:02 OMM
8.2.5 Filter exchange, main lubrication M2 Main lubrication pump PI2 Pressure indicator H10 Warning lamp, high oil pressure across main lubrication filter F1 PS2 Pressure switch FU1 Filter head with cartridge FU4 Dirt trap V1 Shut-off valve
PI2 H10 PS2 FU1
M2
FU4 V1 Hot surface Equipment and hoses/pipes containing lubrication oil can have hot surfaces. Always wear protective gloves. WARNING!
a) Stop the crusher and the main lubrication pump M2. b) Close the shut-off valve V1 between the tank and the dirt trap FU4. c) Unscrew the filter cartridge FU1 from the filter head and replace with a new one. d) Inspect the old filter cartridge to check for larger particles on the filter material, as this indicates damaged or worn components in the lubrication system. e) Reset the red pop-up button on the pressure switch PS2. f) Open the shut-off valve V1 between the tank and the dirt trap FU4. NOTE!
The filter cartridge contains contaminated oil and must be disposed as oil according to the oil suppliers Material Safety Data Sheet (MSDS) and local regulations.
CAUTION!
Check that the shut-off valve V1 is fully open before the main lubrication pump is started. The pump and the hoses will be seriously damaged if the valve is closed.
Checks Check the pressure drop on PI2 across the filter FU1 regularly so that new filter cartridges can be ordered in good time before the next change. NOTE!
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When the fan of the air/oil cooler is running, the pressure in the oil system generally rises. Avoid reading off the pressure at such times.
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8. Maintenance
8.2.6 Return oil screen and oil tank cleaning 3
4
5 3 4 5 OS1
Main lubrication tank cover Locking handles Return oil screen handle Return oil screen
WARNING!
CAUTION!
OS1
Health hazard Before you use a cleaning agent, read the supplier’s Material Safety Data Sheet (MSDS) and follow the instructions carefully. Risk of serious injuries to eyes, skin, respiratory system etc. Use personal protection and other safety measures as recommended in the MSDS. Handle all waste oil, diesel oil and white spirit with care according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Collect waste in suitable containers and dispose as recommended in the MSDS and according to local regulations.
a) Unscrew the locking handles and lift off the cover on the main lubrication oil tank. b) Use the handles (5) and lift out the return oil screen OS1. c) Rinse contamination from the return oil screen with diesel oil (or white spirit if necessary) CAUTION!
If white spirit is used for cleaning, wipe it off carefully and allow it to evaporate before pouring oil into the cleaned compartments.
d) Blow the return oil screen clean with compressed air. e) If the return oil screen is damaged, replace it with a new one. f) Check the bottom of the oil tank. If sediment is discovered, clean out contamination from the bottom of the tank with diesel oil (or white spirit). g) Put the return oil screen back into place in the tank.
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8.2.7 Cleaning out oil remnants, air/oil cooler When the lubrication oil is changed, clean the air/oil cooler with diesel oil. U Connection for oil from tank V Connection for oil to crusher
U
V
WARNING!
Health hazard Before you use a cleaning agent, read the supplier’s Material Safety Data Sheet (MSDS) and follow the instructions carefully. Risk of serious injuries to eyes, skin, respiratory system etc. Use personal protection and other safety measures as recommended in the MSDS.
a) Disconnect both oil hoses from the cooler connections U and V. b) Plug connection V and tighten carefully. c) Fill the air/oil cooler with diesel oil through connection U, see section 10.4.1 Air/oil cooler for the cooler’s volume. d) Leave the diesel oil to dissolve the oil in the cooler for a while. e) Put a suitable container beneath connection V. f) Open connection V and collect all diesel that runs out. g) Dispose the diesel oil. CAUTION!
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Handle all waste oil, diesel oil and white spirit with care according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Collect waste in suitable containers and dispose as recommended in the MSDS and according to local regulations.
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8. Maintenance
8.2.8 Cleaning out oil remnants, water/oil cooler (option) When the lubrication oil is changed, clean the air/oil cooler with diesel oil. U Connection for oil from tank V Connection for oil to crusher
V
U
WARNING!
Health hazard Before you use a cleaning agent, read the supplier’s Material Safety Data Sheet (MSDS) and follow the instructions carefully. Risk of serious injuries to eyes, skin, respiratory system etc. Use personal protection and other safety measures as recommended in the MSDS.
a) Disconnect both oil hoses from the cooler connections U and V. b) Plug connection U and tighten carefully. c) Fill the water/oil cooler with diesel oil through connection V, see section 10.4.2 Water/oil cooler (option) for the cooler’s volume. d) Leave the diesel oil to dissolve the oil remnants in the cooler for a while. e) Put a suitable container beneath connection U. f) Open connection U and collect all diesel oil that runs out. g) Dispose the diesel oil. CAUTION!
© 2012 Sandvik SRP AB
Handle all waste oil, diesel oil and white spirit with care according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Collect waste in suitable containers and dispose as recommended in the MSDS and according to local regulations.
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8.2.9 Refilling the main lubrication system NOTE!
WARNING!
Before filling the tank with new oil, carefully drain out the tank, oil lines and cooler to reduce the amount of remaining diesel oil.
Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.
1 Drain plug for condensation water in main lubrication tank 2 Drain plug for oil in main lubrication tank
1
2
a) Refit the main lubrication oil drain plug (2) underneath the tank unit. b) Check that the condensation water drain plug (1) is tightened. 3 Main lubrication tank cover 4 Locking handles
3
4
c) Unscrew the locking handles (4) and lift off the main lubrication tank cover (3). (Continued)
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d) Connect a hose to an oil drum. OS1 Return oil screen
OS1
e) Fill the tank with new oil through the return oil screen OS1. Capacity Lubrication oil tank
150 liters / (40 US gal)
f) Check for possible leaks in connectors and valves. g) Remove the hose from the lubrication tank. h) Refit the main lubrication tank cover (3) over the lubrication oil tank and tighten the locking handles (4).
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8.3 Air/oil cooler Air flow direction
Hot surface Risk of severe burns. The air/oil cooler could become extremely hot during operation. Make sure the air/oil cooler is cool before touching WARNING! Rotating parts Exposure to rotating parts (pumps, fans etc.) must be prevented by guards. Always attach the guards after maintenance work. WARNING!
To provide the maximum cooling effect, the air must be sucked through the coolers core. Keep the cooling efficiency as high as possible by regularly blowing the air/ oil cooler coil clear with compressed air. If vibration occurs in the fan, it should be cleaned or replaced, to avoid damage to the air/oil cooler. Since there is a large oil flow through the cooler, the oil inlet to the radiator coil can be either at the top or the side. It is normally unnecessary to bleed air from the cooler. The fan motor is controlled by the temperature switch for coolers TS2. See section 8.1.12 Temperature switches. Do not remove guards Make sure that all guards are in place and functioning, to prevent exposure to rotating parts. Only operate the equipment when all PROHIBITION! guards are mounted.
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8.4 Water/oil cooler (option) Plate-type coolers normally need very little maintenance. When the lubrication oil is changed – or if the oil channels are blocked – see section 8.2.8 Cleaning out oil remnants, water/oil cooler (option)
8.4.1 Dirt trap water/oil cooler, cleaning
TS4 J J O FU7 TS4 1 2
Water to cooler Water from cooler Dirt trap Temperature switch, adjustable Gauze element Plug
FU7
F7
O
1 2
Clean the dirt trap with filter FU7 regularly. CAUTION!
The gauze element (1) must not, under any circumstances, be left out or replaced by another with a different mesh
a) b) c) d) e)
Turn off the water ahead of the dirt trap FU7. Have a suitable container ready to collect the water that runs out. Unscrew the plug (2). Take out and clean the gauze element (1). If deliming is needed, leave the gauze element in a solution of 45 gr citric acid in 1 l of water (1.5 oz citric acid in 1/4 US gal of water) until the lime can be brushed off. Rinse with clean water. f) Install the gauze element (1) and screw back the plug (2). g) Turn on the water.
CAUTION!
NOTE!
© 2012 Sandvik SRP AB
Check that the water flow is fully open before starting the main lubrication pump. Risk of damage to the crusher due to high oil temperature.
During the running-in period, and when the tank has been cleaned, check the dirt trap daily.
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8.4.2 Blocked water channels in water/oil cooler, cleaning and deliming
WARNING!
CAUTION!
Risk of severe burns Risk of corrosion 15% hydrochloric acid is a corrosive solution. Before use read the supplier’s Material Safety Data Sheet (MSDS) and follow the instructions carefully. Take any precautions recommended in the MSDS. Use maximum 15%hydrochloric acid solution. A stronger solution will destroy the cooler.
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If the water channels are blocked by dirt, flush them out by reversing the water flow direction. If the water channels are blocked by lime, clean them out with a deliming agent, e.g. a 15 % hydrochloric acid (HCl) solution which is then neutralized with a 5 % soda solution and finally flushed out with clean water.
NOTE!
Ventilate the cooler when a deliming agent is used, to provide ventilation for any gas which may be produced.
CAUTION!
Handle all cleaning agents and their waste with care and according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Collect the waste in suitable containers and dispose as recommended in the MSDS and according to local regulations.
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8. Maintenance
8.4.3 Water/oil cooler, temperature control TS1 TS2
TS4
TS1 TS2 TS3
TS1 TS2 TS3
Temperature switch, return oil Temperature switch, oil in tank Temperature switch, heater elements
TS3
For temperature control of the inlet water, the temperature switch TS4 is used. Setting for temperature switch TS4 is done during installation, see Installation Manual for the tank unit. For oil temperature control, the temperature switch TS2 can be used to start and stop a water pump. If instead the supply pipe to connection J is connected via a solenoid water valve, temperature switch TS2 can be used to open and close the valve. The amount of water required depends on the water temperature, etc. NOTE!
If a water/oil cooler is used, set the temperature switches TS1, TS2 and TS3 at the values given for “normal operating conditions”, whatever the ambient air temperature is. See section 8.1.12 Temperature switches and section 8.1.13 Oil heating control. Use clean fresh water. If only contaminated water is available, contact Sandvik SRP AB first!
NOTE!
© 2012 Sandvik SRP AB
Drain all water out of the cooler if the crusher is shut down in a low ambient temperature (below +5 °C/41 °F).
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8.5 Hydroset system 8.5.1 General CAUTION!
Only personnel certified in hydraulics are permitted to perform maintenance on the hydraulic system (except bleeding air from the Hydroset system).
WARNING!
Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system.
CAUTION!
Never adjust pressure relief valves beyond the recommended values. Hot oil Hydraulic oil can become very hot during operation. Allow the oil to cool before working on the hydraulic system.
WARNING! Hot surface Equipment and hoses/pipes containing hydraulic oil can have hot surfaces. Always wear protective gloves. WARNING!
WARNING! CAUTION!
Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk. Handle all lubricants and waste lubricants with care and according to the supplier’s Material Safety Data Sheet (MSDS) and local regulations. Collect waste lubricants in suitable containers and dispose as recommended in the MSDS and according to local regulations.
(Continued)
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8. Maintenance
V10 PI1
N FU3 LI2 M6 HA1 V5 V4
V10 PI1 FU3 LI2 M6
Button to activate the pressure indicator PI1 Hydroset pressure indicator Filter with cartridge Level indicator for oil in the Hydroset tank Hydroset pump and motor
HA1 Hydraulic assembly V5 Ball valve on HA1 suction line (closed position on drawing) V4 Ball valve on pump drainage line N Hydroset connection for oil to and from the crusher
The Hydroset system is designed to increase or decrease the crusher’s Close Side Setting (CSS). The setting of the crusher is changed by raising (setting decrease) or lowering (setting increase) the Hydroset piston and the mainshaft assembly (complete with mantle) which is supported by the Hydroset piston. When the setting is decreased, oil is pumped into the Hydroset cylinder on the crusher. When the setting is increased, oil is pumped back to the Hydroset tank. The tank has a pressure indicator PI1 which indicates the pressure in the Hydroset system and is activated by V10. See also section 3.4 Hydroset components and the Piping and instrumentation diagram in the Installation Manual Appendix for the tank unit.
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8.5.2 Hydroset pump FU3 V10
PI1 1 LI2 M6 HA1 V5 V4
1 FU3 V10 PI1 LI2
Max. sign for level indicator LI2 Filter with cartridge Button to activate the pressure indicator PI1 Hydroset pressure indicator Level indicator for oil in the Hydroset tank
M6 Hydroset pump and motor V5 Ball valve on HA1 suction line (closed position on drawing) V4 Ball valve on pump drainage line
The Hydroset pump M6 is a reversible gear pump. When the pump is started, the Hydroset tank must be filled with oil up to the maximum sign (1) beside the level indicator LI2. CAUTION!
The ball valves V4 and V5 must be fully open when the pump is operating. Closed valves will cause serious damage to the Hydroset system when the pump starts.
8.5.3 Hydroset pressure indicator The pressure indicator PI1 displays the current Hydroset pressure when pushing the button V10. The pressure is measured at the hydraulic assembly HA1.
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8.5.4 Pressure relieve - Hydroset L1 Push button box for raising or lowering the mainshaft in the crusher.
L1
Relieve the pressure in the system by lowering the mainshaft to the bottom position by using the push button box L1 for Close Side Setting (CSS), located near the cone crusher.
8.5.5 Oil filter The type of oil filter FU3 used is full-flow, which means that the oil passing through is filtered. The filter cartridge is of throwaway type. Hot oil Hydraulic oil can become very hot during operation. Allow the oil to cool before working on the hydraulic system. WARNING!
WARNING!
Skid risk When filling, controlling or changing oil there is a risk of spillage that can cause a slippery surface. Always remove oil spillage and stains to avoid skid risk.
Exchanging the filter cartridge Change the filter cartridge every time the Hydroset oil is changed or at least every six months. a) Check that the crusher and the tank unit are switched off and locked out so that they cannot be inadvertently switched on. b) Relieve the pressure in the system, see section 8.5.4 Pressure relieve Hydroset. c) Unscrew the filter cartridge FU3 and replace it with a new one. NOTE!
© 2012 Sandvik SRP AB
The filter cartridge contains contaminated oil and must be disposed as waste oil according to the oil supplier’s Material Safety Data Sheet (MSDS) and local regulations.
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8.5.6 Hydroset hydraulic assembly Between the crusher and the Hydroset pump is the hydraulic assembly HA1, which is a flow-actuated non-return valve. A relief valve is incorporated to protect the pump.
2 FV8
1 L1
RV2
RV3
RV4 R
CV1 CV3”1B” CV3”1A”
V10 PI1
MP1 HA1 V5
1 2 CV1 CV3”1B” CV3”1A” FV8 HA1 L1 MP1 MP2
MP2 MP3
Needle valve lock nut Needle valve Allen head screw Check valve Check valve Check valve Needle valve, relieves system pressure Hydraulic assembly Push button box for Close Side Setting Measuring nipple Measuring nipple
MP3 Measuring nipple PI1 Pressure indicator for Hydroset, activated by button V5 RV2 Pressure relief valve RV3 Pressure relief valve RV4 Pressure relief valve V5 Ball valve on HA1 suction line (closed position om drawing) V10 Button
Emergency manual valve actuation The hydraulic assembly HA1 has a manual actuation facility for emergency use if contamination in the oil has blocked a valve or the hydraulic assembly so that normal motorized setting increase is impossible. (Continued)
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Manual operation is carried out as follows: a) b) c) d) e) f) g)
h) i) j) k) l) m) n) o) p) q) r) s) t) u) v) NOTE!
Stop and lock out the crusher so that it cannot be inadvertently started. Stop the Hydroset pump M6. Close the ball valve V5 on the hydraulic assembly HA1 suction line. Loosen the lock nut (1) on needle valve FV8 with a ring wrench. Loosen the Allen head screw (2) on needle valve FV8 with an Allen-key. Press the push button V10 and check the Hydroset pressure on the pressure indicator PI1, see section 8.5.3 Hydroset pressure indicator. Unscrew and perform a visual inspection for any dirt in the six valves CV1, CV3”1A”, CV3”1B”, RV2, RV3 and RV4. Blow clean with compressed air. Screw back and tighten these six valves carefully. Screw back and tighten the Allen head screw (2) on the needle valve FV8. Screw back and tighten the lock nut (1) on the needle valve FV8. IMPORTANT! Open the ball valve V5. Start the Hydroset pump. The crusher must be switched off. Use the push button box L1 to raise the mainshaft a little. Bleed air from the Hydroset system, see Operator´s manual for the crusher. Disconnect the measuring nipple Raise the mainshaft to its uppermost position with L1. Leave it for a few minutes and then check the Hydroset pressure on PI1. Lower the mainshaft to its bottom position with L1. Raise the mainshaft a little. Bleed air from the Hydroset system again, see Operator´s manual for the crusher. Disconnect the measuring nipple. Set the mainshaft to the desired position.
If the hydraulic assembly still does not operate correctly, check for wear and/ or damage and replace the damaged part. Always keep the Hydroset system clean to reduce the risk that contamination interferes with the valve.
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9. Troubleshooting This chapter comprises a guide for correcting various problems that can appear during operation. It is not intended that personnel such as the operator should carry out corrective actions. It is in the operator’s task to identify the fault or error and report to a supervisor. The supervisor decides on the appropriate action. To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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9.1 Faults and suggested corrective actions The following table shows possible causes and suggested corrective actions for a number of different fault conditions. No.
Fault
Check
Corrective action
1
Cone crusher will not start
No “Ready for start” signal and oil pump not running
Check electrical circuits and starter of pump motor. Start the pump.
No “Ready for start” signal and lubrication oil flow low
If the return oil flow is low, wait a few minutes to see if it stabilizes. Check that oil does not overflow over dust collar, see the Operator’s Manual for the crusher. Check oil lines and remove obstacles if return line is blocked. Clean dirt trap, see 8.2.4. If necessary, change filter cartridge, see 8.2.5. Check pump capacity. See No. 8. Low or no oil capacity.
Normal lubrication oil flow, but no “Ready for start” signal. Oil pump running and “Ready for start” signal obtained
Check operation of return oil flow switch, see 8.1.10. If protective temperature switch TS1 shuts down the crusher, check operation of temperature switch, see 8.1.7. Check starter of crusher’s drive motor and other electrical circuits. See Installation Manual for the crusher.
Oil does not return to tank (in low temperature) 2
Crusher stops Oil pump not running when idling or with material in the chamLow lubrication oil flow ber
See 4.2.2 and the cold climate section in the Installation Manual for the tank unit. Check electrical circuits and starter of pump motor. See Installation Manual for the tank unit. Start the pump. Check that oil does not overflow over dust collar see the Operator’s Manual for the crusher. Check oil lines and remove obstacles if return line is blocked. Clean dirt trap, see 8.2.4. If necessary, change filter cartridge, see 8.2.5. Check pump capacity. See 8. Low or no oil capacity.
Normal lubrication oil flow
Check operation of return oil flow switch, see 8.1.10.
Oil too hot
See No. 3. Lubrication oil temperature too high.
See Operator’s and Maintenance Manuals for the V-belts slipping Crusher’s drive motor overloaded crusher Packing in crushing chamber Tramp iron or blockage in crushing chamber.
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No.
Fault
Check
Corrective action
3
Lubrication oil temperature too high
Protective temperature switch TS1 shuts down crusher
Check operation of oil cooling system and temperature switch TS2 for oil coolers, see 8.1.12. For an air/oil cooler, check fan motor and starter. Clean radiator core. Check that there is sufficient cooling air. See 8.3. For a water/oil cooler (option), check that water channels are not blocked, see 8.4. Protect cooler and tank unit from direct sunlight. If there is a contamination increase in return oil screen OS1, see 8.1.11. Check for incipient bearing failure. See Operator’s and Maintenance Manuals for the crusher. Check that the by-pass valve (CV4 or CV5) on the cooler can close so that the cooler isn’t by-passed, see 8.1.9.
Oil cooler cooling continuously.
See “Protective temperature switch TS1 shuts down the crusher” above. If lubrication oil viscosity is incorrect, change oil. See 7.2 and 8.2.
Low lubrication oil flow
Check oil lines and remove obstacles. Clean dirt trap, see 8.2.4. If necessary, change filter cartridge, see 8.2.5. Check pump capacity. See No. 8. Low or no oil capacity.
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No.
Fault
Check
Corrective action
4
Crusher will not hold a constant CSS, or product is oversized
Low Hydroset pressure
Check capacity of Hydroset pump. If necessary, change pump.
Leakage in Hydroset system
Check Hydroset oil lines. If possible – without going below the smallest A-dimension (see the Operator’s Manual for the crusher) – raise mainshaft until liners have metal-to-metal contact. Don’t exceed maximum Hydroset pressure (see the Operator’s Manual for the crusher for further information about maximum load). Check Hydroset pressure indicator PI1 by pressing the button V10 to see if pressure is falling. Seal or replace relevant components.
Pressure relief valve leaking. Set- If there are overload pressure peaks, see the ting increase has caused oil level Installation Manual for the crusher for further to rise in Hydroset tank. information about feed arrangements. If there are no overload pressure peaks, change the damaged pressure relief valve, see 8.5.6. Hydroset hydraulic assembly leaking, see 8.5.6. Setting increase has caused oil level to rise in Hydroset tank.
Clean or replace Hydroset hydraulic assembly, see 8.5.6.
Hydroset packing leaking
Check if oil level has risen in lubrication oil tank. Replace Hydroset packing. Check Hydroset cylinder bushing, replace if necessary. See the Maintenance Manual for the crusher.
Air in Hydroset system or accumulator gas pressure too low.
See the Operators Manual for the crusher for further information about the troubleshooting.
Nitrogen leaking from accumulator bladder gives milky white color in Hydroset oil. Hydroset pump cannot reduce See Installation Manual for the crusher for further CSS because of pressure peaks. information about feed arrangement.
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No.
Fault
Check
Corrective action
5
Abnormal noise in crusher
“Grating” step bearing components
If there is a contamination increase in return oil screen, investigate possible incipient bearing failure. See 8.1.11 and No. 6. Increasing bearing component wear. See the Operators Manual for the crusher for further information about troubleshooting.
6
Increasing bearing component wear
Contaminated oil leading to increased wear on eccentric wearing
Check oil condition regularly. Clean tank. Change oil at regular intervals. See 8.2.
Oil filter blocked
Change filter cartridge FU1, see 8.2.5.
Overpressure dust sealing system not working
Inspect entire overpressure system and check operation. See 6.2.1 and Operator’s Manual for the crusher.
Bronze particles, increased amount of swarf, needle-like particles, tin or lead flakes in return oil screen.
See the Operator’s and Maintenance Manuals for the crusher and No. 3. Lubrication oil temperature too high.
High return oil temperature
See No. 3. Lubrication oil temperature too high
Dirt
See the Operators Manual for the crusher for further information about troubleshooting.
Pump sucks air through a leak
Replace suction lines, if leaking.
7
8
Oil contaminated
Low or no oil capacity
Replace the pump shaft’s seal, if leaking. Pump rotates in wrong direction
Change direction of rotation. Check that the direction of rotation corresponds to the arrow on the motor housing.
High pressure but still low capac- Exchange oil, see 8.2. ity because of wrong type of oil
© 2012 Sandvik SRP AB
Pump is dry
Fill with oil.
Suction line blocked
Remove obstruction.
Broken pump, e.g. cavitation in pump or broken gear teeth.
Replace pump.
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10. Technical specifications To ensure maximum safety, always read section 2. Safety precautions before doing any work on the equipment or making any adjustments.
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10.1 General data The data presented below are typical values. Specific data may vary depending on installation and machine configuration.
10.2 Lubrication systems 10.2.1 Main lubrication system Characteristics System
Pump
Pump motor
Oil filter
Oil heater
112
Type
Closed circuit with gravity return
System pressure
0.15—0.5 MPa (22–72 psi)
Oil tank mass
310 kg (685 lbs)
Oil reservoir capacity
150 liters (40 US gal)
Oil type
Normally ISO VG 150
Type
Gear pump
Capacity
50 Hz - 42 l/min (11.1 US gal/min) 60 Hz - 50 l/min (13.2 US gal/min)
Number of pumps
1
Type
Squirrel cage
Power
50Hz - 1.5 kW 60Hz - 1.5 kW
Speed
50 Hz - 900 rpm 60 Hz - 1080 rpm
Voltage
50 Hz - 400 V / 525 V 60 Hz - 380 V / 460 V / 575 V
Phases
3
Frequency
50/60 Hz
Service factor
1.25
Enclosure
TEFC
Insulation
F
Protection
IP55
Frame
100L
Number of oil filters
1
Blocked filter indicator
Differential pressure indicator
Type
Electrical immersion heaters
Rating
1.1–1.6 kW / heater depending on voltage
Method
Indirect heating
Numbers of heaters
2–4
Voltage
50 Hz - 380 V–1125 W 60 Hz - 575 V / (332V)–1640 W
Phases
3
Frequency
50/60 Hz
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10. Technical specifications
10.2.2 Pinionshaft lubrication system Characteristics System
Type
Oil bath lubrication in the pinionshaft housing
Oil reservoir
Pinionshaft housing
Oil type
Normally ISO VG 150
10.3 Hydroset system Characteristics System
Pump
Pump motor
Oil filter
Oil reservoir capacity
40 liters (10.6 US gal)
Oil type
ISO VG 68
Hydraulic cylinder size
Ø 400 mm (15.8")
Maximum pressure
8 MPa (1161 psi)
Minimum pressure Mainshaft in bottom position When setting is done
0 MPa (0 psi) >0.2 MPa (30 psi)
Type
Reversible gear pump
Capacity
50 Hz - 6.7 l/min (1.77 US gal/min) 60 Hz - 5.1 l/min (1.35 US gal/min)
Type
Squirrel cage
Power
50 Hz - 1.1 kW 60 Hz - 1.3 kW
Speed Note! 4 poles.
50 Hz - 1440 rpm 60 Hz - 1740 rpm
Voltage
50 Hz - 400 V / 525 V 60 Hz - 380 V / 460 V / 575 V
Phases
3
Frequency
50/60 Hz
Service factor
1.00
Enclosure
TEFC
Insulation
F
Protection
IP 55
Frame
IEC 90S
Number of oil filters
1
Blocked filter indicator
No
Corrosion protection Paint is used to protect the tank cabinet, electrical cabinet and other parts made of plate against corrosion.
© 2012 Sandvik SRP AB
S 223.857.en-01
113
10. Technical specifications
Tank unit Sandvik CTHS430:02 OMM
10.4 Oil cooling systems 10.4.1 Air/oil cooler Characteristics Number of oil/air coolers
1
Volume (oil)
12 liters (3.2 US gal)
Material
Aluminum
Oil pressure drop
0.05 MPa (7.25 psi)
Motor power
50 Hz - 2.2 kW 60 Hz - 2.2 kW
Motor speed
50 Hz - 1440 rpm 60 Hz - 1740 rpm
Max air flow
10 764 m3/h (6335 ft3/min)
Sound level
50 Hz - 84 dBa ±3 60 Hz - 88 dBa ±3
By-pass valve, opening pressure
0.8 MPa (116 psi)
10.4.2 Water/oil cooler (option) Characteristics
114
Number of oil/water coolers
1
Volume (oil)
8.034 liters (2.122 US gal)
Material
Stainless steel
Oil temperature detector
Yes
Oil pressure drop
0.05 MPa (7.25 psi)
Oil flow
33 l/min (1.7 ft3/min)
Water flow
